Worn Shaft Repair: Power Generation Facility, UK

28th November 2024

Industry: Power
Location: UK
Application: Worn Shaft Repair
Products: 101 Metal Repair Paste

The Problem

A power generation facility identified significant mechanical wear on the end of a critical drive shaft. The degradation compromised the component’s original dimensions, threatening equipment performance and operational reliability. Left unaddressed, the wear posed a high risk of failure and prolonged service disruptions. Given the lead times and capital expenditure required for a full replacement, the facility required an immediate, high precision resurfacing solution to restore the asset’s structural integrity. This specific worn shaft repair needed to be durable and reliable.

The Solution

The repair process utilised Resimac 101 Metal Repair Paste, a high performance epoxy system. Preparation began by mounting the shaft on a lathe and scoring the surface to a depth of 1.5–2mm, creating a mechanical profile for maximum adhesion. Technicians then used a bristle blaster to achieve a uniform surface roughness.

During application, the shaft was rotated while the 101 Metal Repair Paste was applied using a plastic applicator. A wet-on-wet technique was employed across multiple layers to eliminate air entrapment and build the coating to a total thickness of 3mm. Following an overnight cure, the shaft was precision machined back to its original specifications. Technicians used aluminium grade cutting tips and specific speed settings to ensure a smooth, flush finish meeting exact industrial tolerances.

The Outcome

Returned the critical shaft to its exact original dimensions and structural integrity
Ensured continued reliable operations using a worn shaft repair system trusted across global power generation facilities
Significantly reduced cost by avoiding full replacement and installing a replacement shaft
Rapid repair and curing times ensured a swift return to service
Increased the component’s lifespan while reducing the frequency of future maintenance