Manufacturing & General Industry Coating & Repair Services

Equipment wears and loses tolerance long before the casing itself fails. Bearing bores go oval, journals and keyways hammer out. Pump impellers and casings lose their hydraulic profile to erosion-corrosion, and fan blades thin at the leading edge until the rotor unbalances. Welding the lost metal back adds a heat-affected zone, distorts slender rotors, and ties the part to somebody's shop slot. We rebuild those surfaces cold with metal-repair composites and machine them back to the original dimension. No heat distortion, and the part never leaves the plant.

Bearing bores, bushing seats, and bearing housings get rebuilt and re-chocked to alignment, so the bearing seats to spec. Shaft journals and keyways get rebuilt and machined to the specified diameter. On pumps and fans we restore vane and blade geometry and overcoat with an erosion-resistant ceramic layer, and the unit recommissions on its design curve. We cold-bond structural cracks and holes in casings, and we cast replacement components and gasket seals against the actual mating surface. A repair that would have triggered re-stamping or an OEM order is done in place.

Machinery bases lose contact and alignment over time. Voids, distortion, and gaps under machine feet and pump bases feed vibration straight back into the rotating equipment, and steel shims only make it worse by leaving point contact where there should be full bearing. That uneven load shortens coupling and seal life and pulls the machine off line.

We pour a cold-cure chocking compound that spreads across irregular concrete or steel and transfers load evenly across the full footprint, so the equipment holds alignment with no machining of the foundation. Load-bearing and insulating shims get formed to the real mating surface, and alignment then survives physical and thermal cycling both. For heavier service we bed crane rails and wear plates to full contact, so the track and the supporting structure carry the load without fatiguing at a point. The machine reseats true and stays there.

Plant floors crack and wear under traffic. Forklift wheel paths, loading-bay edges, and joint shoulders crater under constant load, breaking the slab up and slowing material handling. Spalled concrete exposes rebar. Expansion joints lose adhesion and open to water and debris. Process areas take acid, alkali, and spill that strip an ordinary topping and let product reach the substrate.

We rebuild and resurface damaged concrete cold, from crack patching to bulk-fill deep repair, and reseal expansion and building joints with a compound that flexes as the joint moves. High-traffic floors and loading bays get resurfaced with a hard-wearing topping that reopens to forklift and pallet traffic inside the shift. Where the floor takes chemical attack, we lay a chemical-resistant system over prepared concrete or steel that holds the worst-case spill underneath and the impact load on top. Acid-retaining walls, drains, and channels get lined so the structure holds the stream with no slab break-out.

Walkways and platforms go slippery as aggregate wears, oil tracks across the deck, and process spills drop the surface below safe slip resistance. That is a fall risk that grows every shift it sits. We apply cold-cure safety-grip coatings to floors, stair treads, ramps, ladder rungs, and platform decks, and the surfaces reopen to foot traffic the same shift. Visible and front-of-house areas get color matched into a finished non-slip surface. Where static is a hazard near electronics or flammable atmospheres, we install static-dissipative flooring that bleeds charge to ground.

The outcome across all of it is uptime. Metal goes back to tolerance, bases hold alignment, floors carry traffic, and walkways stay safe. All of it happens without hot work, weld distortion, or an OEM lead time. BHI Coatings does the prep, the repair, and the surfacing in place and on your turnaround schedule, with crews ready around the clock across the Texas Gulf Coast.