DIY cast iron battery repair

In detail: do-it-yourself cast-iron battery repair from a real master for the site my.housecope.com.

Everyone knows what cast-iron radiators look like. They are rightfully considered to be long-livers in the heating market. Invented back in 1855, they are still popular with buyers. Despite the huge selection of imported and domestic radiators of various shapes and designs, many still stop at cast iron models. After serving for some time, the batteries begin to leak, they heat up worse. Is it better to change or repair them? Experts believe that repairing cast iron batteries makes sense. If they are put in order, then the replacement can be postponed for several more years.

The radiators are of a sectional design. In appearance, the sections resemble metal columns, inside which channels for the coolant are provided. These elements are connected to each other using a nipple system. The joints are sealed with paronite or rubber gaskets. The height of the devices is 350-1500 mm, the depth reaches 65-500 mm. The power of the radiators depends on the number of sections and the heat transfer area. In rooms, cast iron batteries are placed under windowsills. Usually wall mounts are brackets, but there are floor models with legs.

Depending on the model, cast iron radiators have a power of 100-300 watts. Approximately 25-35% of heat is transferred using radiation (radiation), part - convectively. Thanks to radiation, heating is of a better quality: the radiator heats objects, and not just air. Warm air layers rise upward, and radiation provides heating to the lower part of the room. This creates the most comfortable temperature regime.

Video (click to play).

Cast iron tolerates the alkaline medium of the coolant well, is weakly corrosive and has high mechanical strength. Heating devices have a simple design and are very durable, so breakdowns due to common wear and tear of metal are a rare occurrence. A striking example of a potentially possible service life is the working pre-revolutionary batteries preserved in the homes of some Petersburgers. But cast-iron batteries also have weak points, it is in them that the "root of evil" lies.

Cast iron batteries are large and heavy, which becomes a problem during installation. The slightest flaws in the installation can lead to operational malfunctions. If you do not take care of a sufficient number of powerful brackets, batteries can warp over time, which will also lead to negative consequences.

Insufficient resistance to high pressure and water hammer

Cast iron has good technical and operational characteristics, but the load that domestic heating networks can create may turn out to be too large. Due to water hammer, leaks are possible at the joints of the sections.

Together with hot water, impurities, small particles of dirt, rust circulate through the pipes, which leads to blockages in the internal channels. Batteries must be washed in a timely manner, otherwise malfunctions in their operation are inevitable.

Wear on split gaskets and threaded nipples

Joints are always a "risk factor". Nipples and gaskets are much less durable than cast iron. They need to be replaced periodically. After that, you can forget about the problems with heating for a long time.

If during the heating season the room temperature is lower than usual, check how the neighbors are doing. If they have no complaints, it's time to start heating. Perhaps a simple canal flush will solve the problem.

A plaque appeared on the radiator

It usually forms at the joints. The reason is the low quality of the coolant.When the gaskets wear out, they allow fluid to pass through. After drying, a scum-like coating remains.

The most obvious sign of malfunctioning is the appearance of leaks. The repair involves sealing and applying a metal clamp. If there are several leaks in the radiator, it is better to replace the device.

The leak is eliminated with a regular bandage or strip of cloth and epoxy glue. The bandage is impregnated with glue and wound tightly over the leak. After the glue dries, the repaired area is painted in the color of the battery. This "ambulance" ensures tightness for 1-2 years.

Applying a temporary clamp to the leak

If the bandage is not suitable for urgent repairs, you can cut a small piece of dense rubber and tighten it over the leak.

Installing a metal clamp

The clamp is a metal ring with sealing plates attached with two bolts. Next, we will take a closer look at this repair method.

It is a plasticine-like sealing compound. The technology of application is simple: the welding is kneaded to a homogeneous mass and glued to the place of damage. Cold welding tolerates high temperatures well, therefore it is suitable for repairing small leaks.

Typically, the leak is easily identified. If there are difficulties with diagnostics, the radiator is removed, immersed in a bath of water and monitored for the appearance of air bubbles. The place from which they rise is not airtight. When a leaking area is identified, materials and tools should be prepared:

thin metal cable;
putty;
a piece of cloth;
metal clamp or something that can replace it: electrical tape, wire, etc.

Cover the floor with oilcloth, put a rag on top to absorb excess moisture.
With a thin cable, clean the leaking section of the radiator to metal, degrease with any solvent or gasoline.
Cover the leak. Apply the putty to a strip of fabric and wrap tightly over the damaged area in several layers. If metal powder or epoxy is used as a putty, then 2-3 layers are enough. If zinc white is 4-5. Cold welding is also used as a putty. No fabric is needed for her.
Place a metal clamp on the putty, tighten with bolts and nuts. Make sure the connection is on the opposite side of the leak. If electrical tape is used instead of a clamp, wind it in several layers and secure with wire.

Repairing cast iron batteries is not difficult, does not require special knowledge and skills, but if you have doubts about your abilities or a leak is really serious, it is better to contact a specialist. It makes sense to replace old radiators, which have leaked more than once, otherwise their repair will become a constant activity during each heating season.

Describe your question in as much detail as possible and our expert will answer it

I begin preparations for the new heating season as soon as the previous one ends. First, I examine the radiators for rust and smudges. In the summer, I start repairing, if such is required. Usually I manage on my own, and the work is limited to cold welding and tinting. There was a case when a rubber gasket came out at the connection of two sections of a new battery, then they called the master to replace it. But I consider the clamps to be a temporary measure, which is used when it is impossible to turn off the heating and replace a section or the entire battery. In the summer, I always change the problem area, so as not to inadvertently flood my neighbors for the next heating season.

Thank you very much for the useful site!)

what is the size of the gaskets? (inner and outer diameters? What is the thickness of the gaskets separately from rubber and separately from paranite?Now I have made a die-cut and will try to do it from car cameras.

Weak heat transfer from radiators during the heating season can occur for various reasons. The most popular of these is depressurization or reduced flow capacity in cavities. It is not always possible to get rid of such elements of the system, so you can carry out an independent repair of the heating battery. With its help, in many cases it is possible to restore the functionality of a failed node.

In modern living quarters, there are several types of radiators that effectively cope with their task. The main difference between the two is the material used. It is customary to use the following types:

Cast iron. Affordable, but heavy. They are used more often in apartment buildings.

Aluminum. They are in demand in low pressure systems. They do not tolerate pressure drops and water hammer.

Bimetallic. They have a long service life. They are quite expensive.

Steel. They have good thermal conductivity, but are susceptible to rapid corrosion processes, which reduce the service life.

In most cases, the repair of heating radiators is effective with cast iron sections.

Homeowners usually start to worry when the radiator is leaking, and not when the first problem symptoms appear. To reduce the likelihood of failure of radiators, it is worth paying attention to the behavior of the system as a whole and its individual sections:

repair of cast iron batteries or other material may be necessary with incorrectly selected pipe diameters, with erroneously set pressure or inappropriate choice of the coolant temperature;
with a large amount of undesirable impurities in the composition of the coolant, physicochemical destruction of the material occurs from the inside of the radiator;
heating batteries will require repair when a plaque forms at the joints between the radiator sections, clogging the passage of the coolant through the system;
damage to threaded nipples leads to the repair of heating batteries;
when the heating radiator in the apartment makes noise, this does not always indicate its malfunction, but you can call the repair team to check this process;
radiators are noisy, including from formed air jams, which arise due to pipe leaks.

Leak point in a cast iron radiator

It is impossible to ignore problem radiators, as this can lead to the formation of material or physical damage, because the temperature of the coolant inside the system is very high.

The appearance of leaking spots is usually observed during peak loads on the heating system. If the heating battery leaks, we will tell you what to do next. It is easy to notice the leak by protruding droplets in a hot area or a small wet area under one of the sections.

Self-repair of a cast-iron battery will be effective in a private house or in an apartment with individual heating. In apartment buildings, it is recommended to connect specialists from the management company to the process, since the system has a higher pressure and it is not always possible to independently disconnect from the central heating.

The best solution would be to replace the old radiator with a new one.

Before work, it is necessary to reduce the pressure and temperature in the pipes, since it can be problematic to eliminate a leak in a hot cast-iron radiator. Several repair methods are used:

A hole created by corrosion or mechanical damage is better welded than cold welded. For cast iron, separate electrodes are used, and for the convenience of repair, you can remove the section, having previously blocked the riser with water.

Restoration work must be carried out after a complete seasonal heating shutdown.If the sections are built into a niche and are not supposed to be dismantled, then they must be at a sufficient distance from the wall. With dismantled elements, the restoration of cast iron batteries is usually carried out in their horizontal position. The second method is preferred. The remaining coolant is removed from the cavities and plugs or plugs are disposed of.

When unscrewing the radiators, it should be borne in mind that the plugs have a cut left-hand thread, and the cutouts have a right-hand thread.

We combine the working head of the key with the nipple in the section. We install an emphasis under the key so as not to bend it. Next, we begin to disassemble the sections. If the rusted thread does not lend itself, then this place must be warmed up with a burner or autogenous gun, spinning fire around the thread. Replacing the problem section, we return the radiator to its place.

It is advisable to prevent the formation of foci of corrosion on the outside of the radiators. To do this, it is recommended to paint them regularly. Previously, the surface is cleaned with a metal brush or sandpaper.

Separately, a few words must be said about the paint for radiators. You should choose a special non-toxic coating designed for temperature differences, with protection against corrosion and cracking, so that when heated, no toxic substances are released.

More and more often in apartments and houses you can find unconventional design of radiators. Most often we are talking about protective screens - an aesthetically designed panel that covers the radiator, but at the same time it does not interfere with convection. It is much less common for batteries to be painted in different colors. And although this is still rare in our apartments, it always looks very original and fresh.

VIDEO: How to repair a radiator without draining water from the riser

The service life of cast-iron heating radiators is so long that residents take their work for granted, therefore, in the event of a leak or fistula in the wall of the device, they do not know what to do. It is especially unpleasant if a breakdown occurred in the midst of cold weather, but even in the off-season, heating elements cannot be left unattended. As a rule, preventive work carried out by heating network workers can reveal the presence of dirt or leaks in the device.In this case, there are simple ways to eliminate a leak in a cast-iron radiator.This type of heating device consists of sections. Models of the old type even today are produced in the form of "accordions", while the new generation has a flat outer panel that provides better heating of its entire area.During operation, these devices use two types of heat dissipation:

Radiation, or as professionals call it, radiation makes up 25-30% of heat. It not only heats the air, but is transmitted to nearby objects, providing a better heating of the room.

The convection produced by the heating battery ensures the constant movement of air masses around the room, and accounts for about 75% of the heat transfer.

The device of the cast-iron battery, despite all the external changes, remained the same. It consists of sections equipped with:

plugs;

locking devices;

traffic jams;

shank and thermostat;

locknuts;

nipples and gaskets.

As strong as cast iron is, even it has its limits. As a rule, the service life of cast iron radiators is 25-30 years, and with proper care and optimal working conditions, they can work without interruption from 50 to 100 years.The same cannot be said for the parts that hold the sections together, such as the gaskets. With frequent water hammer, they can "wobble" or crack from time to time. In this case, a leak appears between the sections of the cast-iron battery, which, if not eliminated in time, can cause a serious accident and a threat to human health and life.To avoid this, you need to check the condition of the cast iron radiators after the end of the heating season. In this case, completely different malfunctions in the heating system can be detected.Although cast iron perfectly tolerates the imperfection of the central heating coolant, and the batteries from it have channels wide enough so that debris does not accumulate in them, even they may have problems. And this despite the fact that this metal has no wear. The culprit for the fact that the cast-iron battery burst or a fistula has appeared in its walls may be the following factors:As practice shows, most often it becomes known that something is wrong with the heating system when the repair of cast-iron radiators is already required. To know about a problem in advance, you need to listen for "help signals" that indicate the presence of defects.There are a number of factors that indicate that something is wrong with the heating circuit or batteries. These include:

Feeling cool in the room. In this case, it is worth asking the neighbors how warm they are in the apartment. If everything is in order, then you can start looking for problems in yourself. The reason may be elementary contamination of the channels, the skew of the device or the presence of fistulas. In the first case, it is enough to rinse the batteries, in the second - to fix or change the brackets and check the correctness of installation with a building level, and in the third - to provide assistance to the "sick" radiator.

If an incomprehensible plaque appears on the battery, visible to the naked eye, then the reason for this is worn out gaskets. We'll have to turn off the system, dismantle the batteries and install new ones, for example, made of paronite.

The leak is immediately noticeable. If it is small, then you can do with a clamp or cold welding, otherwise you will have to completely change the device.

It should be remembered that even small defects can develop into a big problem if they are not eliminated in time. Do not rely on temporary clamps and patches. Only heating specialists can determine the reliability and tightness of the heating circuit and its elements.For any breakdown, there are a number of reasons accompanying it. Fistulas on the pipes of the heating system or on the radiator are no exception. If a small brown speck appears on the elements of the heating network, you should not think that this is the paint coming off. In fact, this is the beginning of an often irreversible process, but knowing how to seal a fistula in a cast-iron battery, you can stop the destruction and extend its service life. Reasons for the appearance of corrosion:

Taking into account the frequent increases in the cost of utilities, some craftsmen are cunning and, for the sake of saving electricity, connect a zero cable to the heating circuit. The currents that begin their "journey" through the pipes by means of the coolant exactly cause the formation of corrosion. It is possible to identify a dishonest neighbor if there are several fistulas, and they appear with a certain regularity. A call to the appropriate service will help to save the situation in order to identify the offender, and do-it-yourself repair of cast-iron batteries.

Too high acidity of water can harm even corrosion-tolerant cast iron.

The batteries have expired or deposits on the sides have damaged the metal. In this case, even a small fistula or crack under the influence of the pressure of water can cause the battery to burst and a stream of hot water will flow out of it.

Any of the options requires urgent intervention. If the cast-iron battery only leaks slightly, then you can do without disconnecting the circuit and dismantling it. The clamp can save the situation. If the water only drips, then a one-sided pad will do, but if it runs in a thin line, then it is better not to risk it and use a double-sided clip.

In the event that the coolant tore apart the place where the fistula was located, the question immediately arises whether it is possible to brew a cast-iron battery... As a rule, cold welding becomes an emergency aid, but even if it has restored its tightness, it is necessary to call the masters from the heating network to check the condition of the heating system.There are several methods that allow the batteries to hold out not only until the end of the heating season, but also for a couple of years. These include:

If a leak occurs at the junction of the sections, then it can be quickly eliminated with a bandage and epoxy glue. The material is impregnated with glue and wound around the leak. After it grabs, you can paint over this place in the tone of the battery, but the main thing to remember is that such an "operation" is considered temporary, and it is better to buy and install a new section after the end of the cold weather.

If a fistula or crack is found, a clamp will be required. You can buy it at a building materials store, or you can make it yourself from rubber or tin.

Cold welding for cast iron batteries is the best way to quickly fix a defect. This is a special sealant that looks like children's plasticine. It must be thoroughly kneaded and applied to the damaged area. The tool sets quickly, is resistant to temperature extremes and is quite suitable for quick and temporary repair of a cast-iron battery.

Knowing how to weld a cast-iron battery using a welding machine with an inverter circuit, you can save the device from leaks for a long time.Depending on how serious the breakdown is, the actions to eliminate it depend. So, if the leak is small, then you can do without disconnecting the battery from the circuit, and repair will require:

Place a container under the breakage site in case of a breakthrough or an oilcloth with a rag to collect water.

The place of the gap or crack must be cleaned to the base with a cable or emery. It is necessary not only to remove the paint layer, but to expose the metal itself.

Degrease the prepared area with some kind of solvent.

If special glue or epoxy is used to eliminate the breakage, then strips of thick cloth or bandages will be required. Apply the product to them and wrap them in several layers over the gap.

In the case of cold welding, no fabric is needed.

A clamp is put on and screwed onto the place seized by the sealant, but it is important to make sure that its clamps are on the opposite side of the leak. For example, a crack has formed on the inside of the radiator, which means that the clamps will be on the outside, and vice versa.

If the breakdown is serious and hot water gushes from the battery, then you need to call the emergency team, and not try to stop the leak yourself without the necessary tools.

Even the highest quality repair does not guarantee a long service life of the device. The restored cast-iron radiators will still have to be changed, and the sooner this is done, the safer it will be in the apartment.You can repair cast iron batteries yourself if you have tools and the necessary materials, but only in case of minor defects. Cold welding is the easiest and fastest way to return the heater "in operation", but even it does not guarantee that everything will be in order in the future.To make sure that the heating circuit and all its elements will last a long time and will not be a threat to people's lives, you need to either completely replace the repaired structure after the end of the cold season, or invite specialists to check its reliability.Repairing heating radiators is, in general, a simple matter and does not require much special knowledge. The main thing here is to have a general idea of what this radiator is. Therefore, it would be necessary to first figure out what kind of radiators are, and only then talk about their repair.Repair of radiators is a delicate thingSo, a radiator is a heating device that consists of columnar elements, or sections. All these sections are hollow inside and a coolant circulates through these cavities.In most cases, this is water, but there is also another heat-carrying liquid. For example, mineral oil.Radiators are divided into several types:

Cast iron.

Aluminum.

Steel.

Bimetallic.

Oil.

Cast iron heating radiators are installed in multi-storey buildings. They are quite powerful and compact, do not react to the poor quality of the heating fluid circulating in them and do not corrode, which makes them durable. Due to their heavy weight, these batteries are quite heat-intensive, but the same characteristic complicates their installation and maintenance.Old, but not yet forgotten cast iron radiatorAnother disadvantage is probably the destruction of the nipples and wear of the intersection gaskets, which often leads to the formation of leaks. In addition, plaque forms on the walls of the porous internal channels, which reduces heat transfer.Aluminum radiators have the following subtypes:

cast, in which each section is a one-piece cast product;

extrusion, that is, those in which each section consists of three hermetically connected components.

Heating structures made of aluminum have a high heat transfer. Due to the fact that these batteries hold a small amount of heating fluid, they are quite convenient when there is a need for constant temperature control.Well-known aluminum radiatorThe use of this type of radiator in systems intended for centralized heating is not desirable, since they are easily destroyed by pressure drops. Along with this, they are quite easy to install and weigh relatively little.The main disadvantage of such batteries is that they do not tolerate well the components that make up the heating fluid. In addition, gases accumulate in them, and this causes airing of the heating system.Steel radiators are of the following subspecies:The panel battery consists of two sheets of steel. These sheets have special recesses, which during welding form channels for the circulation of the heating fluid.

Panel steel radiatorSuch products weigh little, and also have a shallow depth. For their production, steel is used, which is degreased, phosphated and coated with enamel. This subtype of radiators is afraid of corrosion and its service life is very short.Sectional steel batteries are very similar to cast iron ones, but their sections are connected by welding. They are very durable, however, their price negatively affects the popularity.Tubular radiators are welded structures, the joints of which significantly reduce the likelihood of leakage. Their big disadvantage is the small thickness of the steel.Bimetallic radiators, unlike aluminum ones, have steel elements inside the structure. This allows her to take on a fairly high level of pressure. The heating fluid in these radiators is completely isolated from the aluminum that is part of the product. The only drawback of bimetallic batteries is their very high price.Bimetal radiator - durability and efficiencyThere are also oil coolers. Such a heating battery has a sealed casing filled with mineral oil. This housing houses an electric heaterIt is worth saying once again that it is not difficult to repair a radiator on your own. In this case, the most important thing is the availability of the necessary tools. The primary tool for repairing a radiator is a dedicated radiator wrench.The most common malfunction is a radiator leak, which may be caused by a torn gasket. This defect is corrected by replacing the damaged structural element. It happens that a leak occurs as a result of the formation of a small hole in the battery.This hole can be cold welded.Place of leakage of a cast iron batteryHappens when the problem is related to a malfunction of the tap, plug or lug. Then the battery is repaired in the same way - by replacing the worn out part. This is easy to do with your own hands, without resorting to outside help.If any of the above happened, then the radiator repair begins with your own hands by draining the water. It is most convenient to carry out repair work outside the heating season, when the battery is cold, but you do not have to choose. Sometimes, after draining, a certain amount of liquid remains inside the radiator so that it does not fall on the floor, you just need to substitute a basin and the leak will not spoil the floor covering.Tap for draining water from the heating systemVery often, repair work is made difficult by the fact that the plugs and fittings are not unscrewed. This situation occurs as a result of the "gluing" of these parts. In this case, it will be advisable to call a wizard who will solve this problem using an autogen. This, of course, costs money, but the described steps are indispensable.Sometimes the repair of cast-iron radiators is, rather, their restoration, since the defect is damage to the appearance. You can fix this inconvenience with your own hands using paint, so the cost of repairing radiators of this type, in this case, directly depends on what kind of paint you are going to use.Removing old paint from a batteryBatteries are painted only if the surface of the heater is cold. Before applying a new layer of paint, remove the old one, then thoroughly wash the battery and degrease its surface.It happens that the only way to fix a radiator defect is to replace it. The battery must be dismantled when the heating is turned off so that the product is cold. The radiator is separated from the system using special means. Such work is urgent, especially in cold weather, otherwise you can be left without heating at all.Replacing a radiator is easier but expensiveAs for other types of batteries (aluminum, bimetallic, steel), their repair differs little. If the damage is not complicated, you can fix it yourself. A small leak can be sealed with cold welding. It is quite simple to dismantle such structures, although two people are required to complete this task, at least.Repair of oil radiators can also be done by hand, but here it must be borne in mind that the breakdown may concern the electric heater.You can order the services of one of the firms specializing in the repair of radiators today both on the Internet, and by phone, and directly at the office of your chosen company.

Cast iron radiators are considered classics of water heating: since invention in 1857 to the present day, they are used in many houses and apartments.

Corrosion resistance, high heat transfer, low hydraulic resistance, thermal inertness - qualities that ensure the demand for these products.

Cast iron radiators have sectional structure. Equipped with locking devices, plugs, plugs, nipples, gaskets.

The products are heavy, they are mounted on special wall brackets, but there are also floor standing batteries with legs. Heaters provide comfort mode: up to 35% heat transmitted by radiation, the rest - by convection.

Cast iron is characterized by high strength, the service life of heating products - 25-30 years old, under optimal conditions - 50 years and more.

But thick-walled cast-iron batteries have vulnerabilities: most often radiators leak between sections, at the joints with pipes, sometimes fistulas and cracks appear on the cast iron itself.

Main reasonsfor which repairs have to be performed:

Great weight. Depending on the type and manufacturer, the weight of one cast-iron section 4.5-7.1 kg, filling volume 1-4 liters, the standard set consists of 4-10 elements. In case of improper installation and incorrect calculation of the number of brackets, the radiator is skewed. As a result, the connecting elements suffer, and metal fatigue occurs. In places where there is no coolant, corrosion appears, then a fistula.
Instability to water hammer, high pressure. With a sharp elimination of the obstacle, the liquid acquires tremendous speed and rushes into the area of least pressure. The power of the water hammer in the heating circuit exceeds the force of a hammer blow. A sudden change in pressure or its high values threaten the depressurization of the heating system - more often leaks occur at the joints of the radiator parts.
Dirt and debris. The elements of domestic cast-iron batteries are made by casting. The technology is such that the surface remains rough, which is excluded in imported counterparts.