Industrial repair and coating projects
Repair and protection work BHI Coatings has delivered across the Texas Gulf Coast. Each one shows the failure, the method, and what went back into service.
Repair and protection, job by job
Equipment repaired and protected in the plant where it could be, and in our Alvin shop where it could not.
Project case studies
Storage Tank Floor Reclamation
Corroded aboveground tank floor rebuilt and lined back to immersion service without cutting out plate.
Floor returned to service without cutting out or replacing plateView project
Centrifugal Pump Rebuild & Efficiency Restoration
Cold-rebuilding an eroded pump casing and lining it to restore clearances, no new casting required.
Running clearances restored without replacing the casingView project
Live Pipe Leak Seal & Composite Wrap
Live leak sealed and a degraded process line reinforced with an engineered composite wrap, no welding and often no shutdown.
Live leak sealed without hot work or weldingView project
Wastewater Clarifier & Concrete Structure Relining
Spalled, rebar-exposed concrete clarifier rebuilt and relined for continued immersion service.
Structure rebuilt to its original profile without full concrete replacementView project
Heat Exchanger Water Box Protection
Blasting, metal rebuild, and a barrier coating restore a corroded exchanger water box and tube sheet in cooling-water service.
Corroded water box and tube sheet returned to service without metal replacementView project
Chute & Hopper Erosion Lining
Worn chutes, hoppers, and slurry pumps rebuilt and lined with impact- or abrasion-resistant systems matched to the wear.
Worn steel rebuilt in place without replacing the chutes, hoppers, or pump housingView project
Crude Storage Tank Roof Corrosion Coating
Corroded crude tank roof and shell blasted, rebuilt cold, and barrier-coated to stop further atmospheric loss.
Corroded roof and shell returned to service without replacing plateView project
Separator Vessel Internal Lining
Production separator rebuilt internally and lined against sour, sandy service, with no plate replacement.
Internal metal loss rebuilt in place without cutting out or replacing plateView project
Wellhead Flange Face Reforming
Corroded, pitted wellhead flange face reformed cold to a flat sealing profile, restoring the gasket seal without pulling the spool.
Corroded, pitted flange face reformed to a flat sealing profile in placeView project
Furnace Stack High-Temperature Coating
A corroding furnace stack prepared and coated in situ at operating heat, with no shutdown and no cool-down.
Stack protected against further corrosion without a shutdown or a cool-downView projectReactor Vessel Chemical-Resistant Relining
Failed reactor lining stripped back, attacked steel rebuilt cold, and a chemical-resistant immersion lining applied to return the vessel to process service.
Failed lining stripped and the attacked steel rebuilt in place with no hot work and no plate replacementView projectAcid Pump Casing Erosion Rebuild
Eroded acid pump casing rebuilt cold and lined with a chemical- and erosion-resistant system to restore clearances.
Lost metal rebuilt cold and clearances restored without a replacement castingView project
Chemical Bund Secondary Containment Lining
Cracked concrete bund wall around a chemical tank rebuilt and lined chemical-resistant so it can hold a spill again.
Cracked, degraded bund rebuilt back to a sound profile without demolishing the wallView projectCondenser Tube Sheet Galvanic Protection
Eroded tube ends rebuilt and the tube sheet face coated to separate the dissimilar metals from the cooling water and stop galvanic attack.
Eroded tube ends and tube sheet face rebuilt in place without retubing or replacing the sheetView project
Turbine Pedestal Chocking and Grouting
Load-bearing chocks cast in place under a turbine baseplate that had lost foundation contact, restoring full support and alignment.
Full contact between baseplate and foundation restored without machining or recastingView projectShow all 65 projects
Cooling Tower Basin Concrete Relining
Spalled, cracked, rebar-exposed cooling tower basin rebuilt and lined watertight to stop leaks.
Basin rebuilt to its original profile without full concrete replacementView project
Induced Draft Fan Blade Erosion Protection
Eroded ID fan blades and housing rebuilt cold and coated to resist ash-laden gas and extend the run between rebuilds.
Eroded leading edges and housing rebuilt in place without replacing the rotorView projectPotable Water Reservoir Tank Lining
Corroded potable water tank rebuilt and relined with an immersion-grade system suited to drinking-water contact.
Corroded interior brought back to a clean, protected condition without replacing the tankView project
Digester Dome Corrosion Relining
Digester dome eaten from the gas side by hydrogen sulfide rebuilt and relined against the headspace environment, no plate replacement.
Dome rebuilt and relined without cutting out or replacing plateView projectLift Station Wet Well Rebuild
Acid-gas and immersion damage in a sewage wet well rebuilt with repair mortar and lined against the corrosive flow.
Walls rebuilt and benching reformed to profile without replacing the structureView projectBallast Tank Pitting Rebuild
Deeply pitted seawater ballast tank cold-filled and lined for immersion service without cutting plate.
Deep pitting cold-filled flush without cutting out or replacing plateView project
Dock Fender Rubber Rebuild
Torn and gouged dock fender rebuilt cold with a flexible elastomer back to a working profile, no fender replacement.
Torn and gouged fender rebuilt in place without pulling and replacing the unitView project
Splash Zone Piling Composite Repair
Wasted splash-zone piling rebuilt and reinforced with an engineered composite wrap, no welding and no pile replacement.
Wasted splash-zone section rebuilt in place without cutting out or replacing the pileView projectBlack Liquor Tank Lining
Corroded and eroded black liquor tank rebuilt and lined against hot, aggressive process fluid without replacing plate.
Tank returned to aggressive process service without cutting out or replacing plateView project
Stock Pump Impeller Efficiency Restoration
Eroded stock pump impeller and casing rebuilt and coated back to a smooth hydraulic surface to recover lost flow.
Eroded impeller and casing rebuilt in place rather than replacedView project
Paper Mill Roof Leak Membrane
Failed roof seams and details sealed and overcoated with a cold liquid membrane, no tear-off.
Leaking seams and details sealed so water no longer reaches the equipment belowView project
Evaporator Vessel Hygienic Lining
Corroded evaporator vessel rebuilt and finished with a smooth, cleanable lining for hygienic product contact.
Corroded interior brought back to a sound, cleanable condition without replacing the vesselView project
Sugar Mill Floor Chemical-Resistant Resurfacing
Broken-down sugar mill process floor repaired and resurfaced with a chemical-resistant, anti-slip system built for washdown.
Broken-down process floor repaired and resurfaced without tearing out and repouring the slabView project
Syrup Tank Base Corrosion Seal
Corroding syrup tank chime rebuilt and the base-to-foundation joint sealed to keep moisture from working back under the floor.
Wasted chime steel rebuilt in place without cutting out plate or hot workView project
Gearbox Housing Bearing Bore Rebuild
Spun, worn-oversize gearbox bearing bore rebuilt cold and reformed back to dimension without machining a new housing.
Bearing bore reformed back to the correct dimension without machining a new seatView project
Plant Floor Anti-Slip Safety Resurfacing
Worn, slick plant walkway repaired and resurfaced with an anti-slip safety floor for dependable footing.
Worn and slick walkway repaired and resurfaced without replacing the floorView project
Compressor Casing Crack and Leak Repair
Cracked, weeping compressor casing sealed and the cracked section rebuilt cold, with no hot work to risk the casting.
Weeping crack stopped and the split line sealed without weldingView project
Apron Feeder Wear Plate Shimming
Uneven wear plates shimmed with cast conforming backing to stop the pounding, then lined for abrasion where the material rides.
Wear plates seated on full, even support so they no longer pound the structureView projectCrusher Pump Volute Abrasion Lining
Worn slurry pump volute rebuilt and lined along the wear path with an abrasion-resistant composite matched to the feed, no new casting required.
Worn volute rebuilt and lined rather than replaced with a new casting, avoiding the casting lead timeView project
Ladle Walkway Handrail Rebonding
Loose, corroded handrail stanchions rebonded and anchored to a steel-mill walkway, with anti-slip footing added and no hot work.
Loose stanchions rebonded and anchored fast without rewelding into live structureView project
Mill Stand Roll Housing Bore Reclamation
Worn roll housing bores and liner seats rebuilt cold and shimmed with conforming support to restore the bearing fit, no machining required.
Worn bores and liner seats rebuilt in place without line-boring or replacing the housingView project
Valve Bonnet and Seat Reclamation
Rebuilding a passing gate valve's worn seat and bonnet faces cold to restore shutoff and a tight bonnet seal, with no new casting.
Valve recovered without a new casting and without the lead time of a replacementView projectShell-and-Tube Channel Cover and Tubesheet Repair
Eroded pass-partition rib and gasket land rebuilt, the sealing faces reformed flat, and the process side barrier-coated so the cover pulls up tight.
Pass-partition rib and gasket land rebuilt in place without replacing the cover or tubesheetView project
Agitator and Mixer Shaft Rebuilding
Worn agitator shaft seal area and journals rebuilt cold and the wetted length coated, without scrapping the shaft for a new forging.
Seal area and bearing journals rebuilt cold and machined back to the original diameter, so the shaft runs true and carries the bearings squareView projectConveyor Pulley and Idler Lagging
Worn pulley lagging and grooved idlers rebuilt and relagged so the belt drives without slip, no replacement pulleys.
Pulley shells relagged with a tough, gripping elastomer instead of being replacedView project
Sluice Gate and Penstock Refurbishment
Corroded sluice gate and penstock seats rebuilt and reformed flat so the gate seats square and the leak path closes.
Gate seats square and the leak path closes when fully shutView projectKiln Trunnion and Tire Seal Repair
Worn kiln trunnion roller and bearing seats rebuilt cold and dressed back to the running line, with the hot seal area coated for protection.
Trunnion roller face and bearing seats rebuilt cold and dressed back to the running lineView projectCooling Tower Basin Lining
Spalled, cracking cooling tower basin rebuilt and lined as one watertight barrier without tearing out the slab.
Spalled floor and wall sections rebuilt in place without tearing out and recasting the basinView projectDemister and Mist Eliminator Housing Lining
Pitted mist eliminator housing wall and pad support ledge rebuilt and lined so the demister seats true and the wall stops losing metal.
Pitted housing wall and pad support ledge rebuilt in place without replacing steelView projectKnife-Gate Valve Seat Reclamation
Worn slurry knife-gate valve seat and gate guides rebuilt and lined so the blade shuts off square again, no replacement valve.
Worn seat and gate guides rebuilt in place without a replacement valveView projectID Fan Blade and Housing Erosion Lining
Eroded ID fan blades and scroll rebuilt cold and erosion-lined to bring the rotor back toward balance and restore airflow.
Eroded leading edges and wear faces rebuilt cold, with no welding or heat into the bladesView project
Wet Scrubber and Ductwork Lining
Corroding wet scrubber and ductwork blasted, rebuilt, and lined under one chemical-resistant film so the condensate runs over the lining instead of into the steel.
Scrubber and ductwork returned to service without cutting out or replacing plateView projectBoiler-Feed and Slurry Pump Rebuild
A multistage boiler-feed pump and a slurry pump rebuilt cold to original clearances and lined, so both go back to service without new castings.
Eroded volutes and opened wear-ring areas rebuilt cold back to the original clearancesView project
Transformer Radiator Leak Sealing
Weeping transformer radiator headers and seams sealed and rebuilt with an oil-tolerant composite, then coated to keep the corrosion from spreading.
Weeping oil leak stopped at the corroded headers and seamsView projectSugar Mill Roll and Screen Rebuild
Worn mill roll journal rebuilt cold and the corroded screen plate built back up, then both protected for the grinding season.
Journal rebuilt cold and dressed back to size so the roll carries its bearings trueView projectButterfly Valve Disc and Seat Restoration
Pitted disc edge and corroded seat rebuilt and recoated so a large butterfly valve shuts off tight again, no replacement valve.
Valve shuts off tight again instead of passing water past the discView projectDigester and Clarifier Mechanism Repair
Corroded digester and clarifier rake arms and drive components rebuilt and coated so the mechanism turns true again, without pulling the basin for new arms.
Rake arms and drive components rebuilt in place without replacing the mechanismView projectLoading-Rack and Bund Concrete Rebuild
Spalled loading-rack deck and bund rebuilt and lined chemical-resistant so containment holds a spill instead of soaking into the slab.
Spalled deck and bund walls rebuilt to profile without tearing out and repouring the slabView projectDock Fender and Bollard Repair
Torn fender faces, corroded mounting steel, and spalled bollard-pocket concrete rebuilt in place without replacing the fender line.
Torn and chunked fender faces rebuilt so they cushion berthing loads againView projectFD Fan Blade Protection and Balance
Worn forced-draft fan blades rebuilt cold and coated to restore balance and the airflow the furnace needs.
Worn blade tips and faces rebuilt cold without replacing the rotorView projectCompressor Cylinder and Casing Restoration
Corroded compressor cylinder and casing rebuilt cold and the gasket land reformed flat so the joint seals, without a new casing.
Weeping joint sealed and the gasket land reformed flat so the casing pulls up tightView projectBlower Housing and Impeller Erosion Lining
Eroded blower impeller and housing rebuilt and lined to restore airflow and stand up to a dust-laden stream.
Impeller vanes and the housing scroll rebuilt back to profile rather than replacedView projectFlue Gas Stack and Breeching Lining
BHI Coatings rebuilt and lined a flue gas stack and breeching that had thinned where acidic condensate attacked the steel below the dew point.
The rebuilt steel and the coating keep the acidic condensate off the wall, so the metal no longer thins at the cold spots.View projectBall Mill and Crusher Liner Rebuild
Worn mill liner backing and crusher transfer points rebuilt so the plates sit on a solid seat and the shell is protected from impact.
Worn liner backing and shell metal rebuilt in place so the wear plates bed on a solid seatView projectPotable Water Standpipe and Riser Lining
Corroding standpipe and riser rebuilt and lined for potable water service without cutting and replacing plate.
Pitted floor and weld seams rebuilt in place without cutting or replacing plateView projectProcess Floor Anti-Slip and Chemical Resurfacing
A worn, spalled process floor chipped out, rebuilt, and resurfaced with a chemical-resistant anti-slip system that drains and sheds washdown.
Failed and spalled concrete chipped out and rebuilt back to profile without replacing the slabView project
Crane Rail and Runway Support Grouting
Re-bedding a crane runway rail on a fresh full-contact grout bed so it stops rocking and pounding the support steel.
Rail re-aligned and seated on a fresh, full-contact grout bed that carries the load evenlyView projectContainment Roof and Membrane Weatherproofing
A leaking plant roof over critical equipment sealed with a continuous liquid membrane, no tear-off.
Leaking seams, flashings, penetrations, and joints sealed and tied into one continuous membraneView projectClarifier Launder and Weir Resurfacing
Spalled concrete launder and weir lip rebuilt, reprofiled to a true edge, and lined for an even overflow.
Spalled launder and weir lip rebuilt to profile without replacing the structureView projectEngine and Gearbox Casing Leak Repair
Oil-weeping engine and gearbox casing sealed and rebuilt with a machinable composite, no machining or housing replacement.
Oil leak stopped at the cracked housing, worn bore, and split-line faceView projectContact BHI Coatings
Have equipment that needs to stay in service?
Tell us what is failing. We respond quickly, and we offer 24-hour on-call service.