Metal Repair & Rebuilding

Rotating gear always fails at the surfaces carrying the load. Erosion-corrosion and cavitation reshape impeller vanes and casing profiles until the pump is off its head curve and the efficiency is gone. We rebuild the vane geometry and the casing wear areas, then apply a smooth coating that restores the hydraulic profile, and efficiency comes back with no rebalancing for weld heat.

Shafts tell the same story in different words. Keyway hammering and journal scoring leave the press-fit oversized and the journal undersized for its sleeve. Our crew rebuilds journals and keyways cold, then machines back to the specified diameter, with no arc-weld distortion on a slender rotor.

Bearing bores, bushing seats, and vibration-loosened housings shift the rotating axis and shorten coupling and seal life. BHI Coatings rebuilds the bore and retainer surfaces and re-chocks the housing to alignment, so the bearing seats to spec without OEM shop rework.

Compressor, engine, and gearbox housings run the same course at their bearing bores and split lines. Bore wear, split-line distortion, and oil weeping at the gasket faces retire a housing while the internals still have life in them. We rebuild bores and split lines cold and machine them flat, and the housing returns to service inside the same outage rather than the OEM lead time. Supporting Belzona 1000 Series metal composites carry the load through these rebuilds.

Flange faces and vessel walls are where a small defect turns into a leak. Heat cycling, gasket-witness machining, and dropped tools deform the face and corrode the nozzle sleeve, and then the line leaks and stays out of service. We rebuild the face against its own mating flange with a release agent, so the repaired surface mirrors the partner exactly and the spool never leaves the line.

Heat exchangers fail on a different mechanism. Dissimilar tube metals set up galvanic corrosion at the tube sheet and water box, attacking the steel around every tube end. Our crew rebuilds and electrically isolates the joint with ceramic-filled epoxies inside the turnaround window, with no hot work, and the bundle is back in service quickly.

Welding hurts most where there are cracks, holes, and general metal loss on pressure equipment. On separators and code-stamped vessels, BHI Coatings cold-bonds the structural repair and machines it back to dimension, and the fix qualifies as a non-welded repair under the relevant inspection codes such as ASME PCC-2 and ISO 24817.

Where corrosion, erosion, or pitting has wasted a surface down toward a code-trigger thickness, we rebuild with cold-cure metal composites and machine to the original tolerance, and nothing heat-affected is left behind. Valve bodies get the same treatment. Eroded body cavities and bonnet faces come back cold, then take an erosion-resistant overcoat, so the valve is restored without ever being cut out for welding.

Not every repair starts from a known part. A catalog replacement rarely matches the dimension a worn assembly actually needs, and welding to join or fabricate metal brings its own distortion along with it. We bond metal to metal cold and cast replacement parts, gasket seals, and support pads directly against the real mating surface, with no molds and no hot work.

The same approach restores rotating equipment efficiency where flow-induced metal loss has exposed fresh steel for the process chemistry to attack. Our crew rebuilds the worn surface and overcoats it with an erosion-corrosion-resistant layer, so pumps, fans, and turbines recommission on their design curve inside the same outage.

Every repair on this page is built around the same outcome. The unit goes back in service without the cost or the schedule of replacement or welding. No hot-work permit, no stress relief on a code-stamped vessel, no heat distortion on a slender shaft, and no waiting on an OEM casting.

Pumps and rotating gear come back to their rated efficiency, sealing surfaces hold, and pressure boundaries pass inspection as non-welded repairs.

The practical payoff is downtime avoided and asset life extended. A housing, bundle, or spool that would otherwise sit idle through a lead time is back online inside the existing outage, often on the same shift the crew finishes machining.

With 24-hour on-call coverage across the Texas Gulf Coast and a climate-controlled shop for components that come to us, BHI Coatings keeps the repair on your schedule, not the supply chain's. Refiners, petrochemical producers, and marine operators along the Texas Gulf Coast use this to defer capital replacement and keep equipment running well past the point a corroded surface would normally retire it.