Case Study
Preventing Limescale Failure and Improving Hot Water Reliability at a High-Demand Fitness Club
Scale fallen off element to bottom of the tank
Site: Basic-Fit Wemmel, Brussels
Application: Hot water cylinders, showers, taps & downstream pipework
Solution: Integro™ System
The Challenge
Basic-Fit gyms operate under exceptionally demanding hot water conditions. At the Wemmel site in the Brussels region, very hard incoming water combined with high peak shower usage placed extreme stress on the hot water system.
Prior to water treatment, the club experienced:
- Frequent hot water failures
- Heavy limescale accumulation inside electric hot water cylinders
- Reduced heat transfer due to scale-coated heating elements
- Blocked shower heads and taps
- Regular member complaints and high maintenance intervention rates
These issues were not isolated. Multiple Basic-Fit sites across Brussels were affected by severe limescale problems, making Wemmel an ideal early-stage reference site to evaluate long-term performance of the Integro™ system in a challenging environment.
The Solution
An Integro™ system was installed on 14 November 2024 on the cold water feed supplying the hot water cylinders.
Unlike conventional scale prevention methods, the Integro™ operates without salt, chemicals, or sacrificial media. Instead, it alters ionic activity in the water, preventing calcium carbonate from bonding to surfaces while allowing existing hard deposits to gradually detach over time.
Installation Considerations
- Installed 150–200 metres away from the boiler room
- Located in an adjoining garage due to space constraints
- Treats water before it reaches the hot water cylinders
This long pipe run created a robust test of treatment persistence, as any loss of effectiveness would normally occur over distance and through changes in pipework orientation. The site therefore represents a demanding real-world installation scenario.
Evidence of Performance
After one full year of operation, a detailed inspection was carried out using endoscopic imaging, photography, video evidence, and staff testimony.
Cylinder Interior Condition
Endoscopic inspection of the hot water cylinder revealed:
- Clean internal surfaces relative to the extreme hardness of local water
- No evidence of new hard crystalline limescale formation
- Only small amounts of loose, non-adherent scale present
- Heating elements largely free from bonded scale
This level of cleanliness after 12 months in the Brussels region is highly unusual without effective water treatment and strongly indicates ongoing Integro™ performance .
Removal of Historic Limescale
Loose limescale fragments were visible at the base of the cylinder. This material represents historic scale that has naturally detached over time rather than new scale forming.
This behaviour is consistent with Integro™ operation, where existing deposits gradually lose adhesion and fall away instead of continuing to build up on heat-transfer surfaces
Heating Element Protection
Photographic evidence confirmed that:
- The original heavy limescale coating had detached
- Only light, non-bonded residue remained
- No new hard scale was forming on the element
Clean heating elements are critical for maintaining efficient heat transfer, reducing energy consumption, and avoiding premature equipment failure .
Showers, Taps & Filters
Downstream fixtures were also inspected, including shower heads, taps, and filters. Findings included:
- Clear, unobstructed spray nozzles
- No crusted mineral deposits
- Filters free from significant scale accumulation
This demonstrates that Integro™ provides system-wide protection, not just within the cylinder itself .
Operational Feedback
On-site staff who worked at the club both before and after installation provided direct testimony confirming that:
- Hot water failures were frequent before Integro™ installation
- Member complaints were common
- Maintenance demand was high
Since installation:
- No hot water failures have occurred
- Shower availability has remained consistent
- Maintenance requirements have dropped significantly
- The system is far easier to manage day-to-day
This operational feedback aligns fully with the physical inspection evidence .
Results, Benefits & Conclusion
The Integro™ system delivered clear operational and performance benefits at Basic-Fit Wemmel:
- Prevention of new hard limescale formation
- Gradual removal of historic scale
- Improved heat transfer efficiency
- Faster hot water regeneration
- Reduced energy waste
- Fewer maintenance interventions
- Reliable showers during peak usage
- Improved member experience
Importantly, these results were achieved despite the Integro™ being installed at significant distance from the hot water system, confirming long-term treatment durability.
After one year of continuous operation, the Integro™ system has proven highly effective at Basic-Fit Wemmel. In an extremely hard-water environment with heavy daily demand, the system has:
- Resolved persistent limescale-related failures
- Stabilised hot water performance
- Protected critical assets
- Reduced operational strain
Wemmel now serves as a strong reference site demonstrating how the Integro™ can safeguard hot water systems in high-demand commercial environments where limescale would otherwise cause ongoing disruption .