ECRS/Metalock Corp

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Metalock recently performed a mechanical repair on a multi-cylinder press used to produce various wooden sheet products ...
06/03/2026

Metalock recently performed a mechanical repair on a multi-cylinder press used to produce various wooden sheet products in the Northwestern US. One of the cylinders experienced a fatigue crack in the transition radius from the main cylinder section to the packing gland fl**ge. This is a common location for fatigue cracks to initiate and propagate. Cracking resulted in significant leakage of hydraulic fluid during operation. While the cylinder was fabricated from a weldable material, logistics and scheduling made removal of the cylinder and liner to access the cracked region unfeasible. Therefore, Metalock engineers recommended a mechanical repair be implemented to return the cylinder to service.
Sixteen (16) holes were drilled and tapped into the packing gland fl**ge in order to install custom 1-1/4” bolts. Three (3) of the holes used to install packing gland ring studs were drilled and tapped to install custom 1” bolts. Custom step studs were fabricated to replace the OEM packing gland ring studs. The length of these bolts was such that the crack plane is in compression when the bolts are torqued thus sealing the crack. All work was performed in the overhead position.
The work was performed over three (3) days and the press was returned to service.

Metalock recently repaired a low-pressure cast iron turbine casing for a client in the petrochemical industry. While mat...
05/04/2026

Metalock recently repaired a low-pressure cast iron turbine casing for a client in the petrochemical industry. While mating the turbine to the exhaust piping, the exhaust fl**ge experienced an overload failure resulting in a crack in the transition between the casing body and the exhaust fl**ge. The client requested Metalock design and install a repair in order to return the turbine casing to service.
The attempted installation resulted in plastic deformation of the plane of exhaust fl**ge face becoming conical. Metalock engineers and technicians designed a repair that would be a combination of Metalocks, Metalace, and Tielocks. The Tielocks were installed at an angle through the outboard face of the exhaust fl**ge and anchored into the casing body. The ID side of the crack was repaired with Metalock and Metalace. All components were coated in high temperature sealant before installation. The outside of the casing in the vicinity of the repair was also coated in high temperature sealant. Upon completion of the repair, the fl**ge face was then machined flat.
The casing was return to the client for testing and installation without issue.

Metalock recently repaired the generator pedestal in the nacelle of a wind turbine in the Midwest. The turbine experienc...
04/06/2026

Metalock recently repaired the generator pedestal in the nacelle of a wind turbine in the Midwest. The turbine experienced a catastrophic coupling failure which suddenly unloaded the generator and caused the generator to displace rearward and coupling material to imbed itself into the nacelle housing. This displacement led to an overload failure of the cast iron generator pedestal. The client requested Metalock design a repair to return the turbine to service. Complicating the matter, all tooling and repair components would need to travel the approximately 300 feet up the tower using a hoist and the work would need to be completed inside the cramped nacelle.
Metalock designed a custom reinforcement gusset in conjunction with Metalock components, to return the turbine to operation and allow for maintenance to be performed using the existing procedure.
Metalock mobilized a small team to install Metalocks and Metalace along the crack. Once complete, the custom reinforcement gusset was fitted and bolted in place. The repair was completed over two days and the turbine pedestal was able to be reassembled and returned to service.

Metalock has been designated a 2025 Avetta Safety Star! The Avetta Safety Star Award recognizes contractors and supplier...
03/01/2026

Metalock has been designated a 2025 Avetta Safety Star! The Avetta Safety Star Award recognizes contractors and suppliers with exceptional safety records, with fewer than 5% of Avetta’s global partners receiving this distinction. Based on objective data and expert evaluation, it honors companies with perfect safety scores, high compliance, and proactive safety cultures.

Metalock recently repaired forging machinery in the Midwest used to fabricate equipment supporting America’s favorite pa...
02/09/2026

Metalock recently repaired forging machinery in the Midwest used to fabricate equipment supporting America’s favorite pastime. The equipment experienced an upset condition which resulted in cracking in the lower-case half and a catastrophic disruption to production. The client contacted Metalock and requested an emergency, palliative repair be implemented to maintain operations until a new case arrived in a few months.

Metalock mobilized a small team to install Metalocks along the approximately 48” of cracking. Access to the cracking was obstructed, but Metalock technicians implemented various techniques to install Metalocks in confined locations while also ensuring that the cracked oil sump was sealed. The repair was completed over two days and the machinery was able to be reassembled and returned to service ahead of schedule.

Metalock recently performed a mechanical repair on a cracked ball mill trunnion on a cement mill located in the Eastern ...
01/05/2026

Metalock recently performed a mechanical repair on a cracked ball mill trunnion on a cement mill located in the Eastern US. The trunnion operation was impacted by extensive cracking in the bearing surface after a loss in oil pressure leading to overheating and material smearing. Multiple branching axial cracks were reported in the trunnion surface around its circumference. Some of these cracks propagated through the wall thickness of the trunnion. Metalock personnel recommended that Metalocks be installed in the OD of the trunnion along the length of the cracking.
The work began by performing magnetic particle testing to confirm the crack geometry on the OD, then installing Metalocks and Metalace along the crack. The Metalock components were coated in epoxy sealant prior to installation to prevent oil flow through the crack to the ID. Once the Metalock components were installed, they were ground flush with the trunnion surface. Installing the Metalocks require multiple rotations and setups to complete the repair.
The work was completed over 6 days and allowed the client to return the mill to service.

Metalock recently repaired a 10 cylinder, two stroke engine-compressor used in a natural gas transmission station in the...
12/11/2025

Metalock recently repaired a 10 cylinder, two stroke engine-compressor used in a natural gas transmission station in the Midwest. The engine was cracking near one of the power cylinders and propagating into the air box/crankcase region. This resulted in a loss of structural integrity near the cylinder to the extent that the nearby power cylinder could be observed deflecting during operation.
A third party attempted to repair the cracking by installing screws along the approximately 84” long crack. This sealed the air box and crankcase, but did very little to return structural integrity to the engine. The client contacted Metalock and requested recommendations to provide a palliative repair to last approximately 1 year until the engines are retired.
Metalock recommended the installation of step studs to replace the OEM power cylinder studs that would extend across the crack plane into the crankcase and restrain the top of the airbox/crankcase from deflecting under load. Additionally, custom Tiebolts were installed near the step studs to provide additional restrain to the cracked material. Metalocks were then installed along the cracks to return tensile strength to the impacted material. Custom fabricated reinforcement plates were installed across the two primary crack terminations to prevent crack propagation. Finally, the cracks were coated in a paintable epoxy in order to seal the air box and crankcase from leakage.
The repairs were completed over the course of approximately 5 days and the engine-compressor was returned to service.

Metalock recently performed a weld repair on a cracked kiln tire in cement mill in the Ohio River Valley. The kiln tire ...
11/04/2025

Metalock recently performed a weld repair on a cracked kiln tire in cement mill in the Ohio River Valley. The kiln tire was 18.5’ in diameter, 36” wide and 16” thick. Two subsurface cracks were identified via NDT. The larger crack measured 19” long and 7” deep and intersected the feed side axial face of the kiln tire. The smaller crack was 9” long and 5” deep. These cracks were discovered during a mill outage and the client reached out to Metalock to perform emergency repairs.
Metalock mobilized to perform a weld repair on the kiln tire. A chemical analysis of the kiln tire material indicated it had a carbon equivalence of approximately 0.70. This indicates the material is weldable if proper procedure is implemented. The two cracks were excavated via arc gouging, the weld bevels prepped, preheated, and welded with a technique to ensure a ductile heat affect zone. Once the welding was complete, which required over 400 lbs of filler material, it was stress relieved and allowed to cool. The welds were then ground to match the OD of the kiln tire in preparation of tire grinding by a third party.
The work was completed over the course of approximately two weeks while dealing with unseasonable cold, wintry weather. While on site, Metalock engineers provided additional value to the client by discussing repair options for other plant equipment experiencing fatigue failures.

Metalock recently performed a mechanical repair on a cracked ball mill trunnion at a cement plant in southern Canada. Me...
10/07/2025

Metalock recently performed a mechanical repair on a cracked ball mill trunnion at a cement plant in southern Canada. Metalock repaired this trunnion several years ago and recommended that the trunnion be replaced at the time. The crack had extended in the axial inboard and outboard directions and propagated through the approximately 3.75” wall thickness of the trunnion to the ID. The total length of crack was approximately 20” with branched cracking on the ID side. The client requested Metalock revisit the original repairs and make recommendations for additional repairs. The original repair involved installing Metalocks on the OD of the trunnion. It was recommended that additional Metalocks be installed in the OD of the trunnion and Metalocks, Keylocks, and Mini Keylocks be installed in the ID of the trunnion along the length of the crack.
While reviewing the ultrasonic inspection report, Metalock engineers noticed several of the Metalocks from the original repair had experienced fatigue failures. The work began by performing magnetic particle testing to confirm the crack geometry on the OD, installing Metalocks near the crack terminations, replacing the fatigued components, and installing Metalacing along the crack. The Metalock components were coated in silicone sealant prior to installation to prevent oil flow through the crack to the ID. The bearing cap was reinstalled and the mill was rotated such that the crack was at bottom dead center. The feed scroll and supporting grout on the ID in the vicinity of the repair was removed by a third party. Metalock engineers and technicians then determined the best layout for the repair components along the ID side of the crack. Eight Keylocks were installed in the ID surface with Metalocks being installed between Keylocks.
The work was completed over 4 days and allowed the client to return the mill to service ahead of schedule.

Metalock recently performed a mechanical repair on the cracked bull gear of an approximately 14’ diameter ball mill in t...
09/11/2025

Metalock recently performed a mechanical repair on the cracked bull gear of an approximately 14’ diameter ball mill in the western Canada. The cracking occurred in the fl**ge area associated with the split line between the two gear halves near the circumferential fl**ge that attaches the gear to the mill. The crack appears to have initiated at the inside surface edge of a core window and propagated to a clearance hole for the fl**ge bolts.
Metalock engineers modeled the gear to aid in determining the determine the source of the cracking and the best course of action. A mechanical repair was designed to not only return strength to the fl**ge, but reinforce the fl**ge to prevent future cracking. The repair involved a combination of Metalock components, bolts, and a custom reinforcement plate. This repair was designed to be installed quickly in order to minimize equipment down time.
Metalock and Metalace components were installed across the crack plane on both faces of the fl**ge. These components return tensile and shear strength across the crack plane in addition to aiding in the prevention of crack propagation. A custom reinforcing plate was bolted to the bull gear at the circumferential fl**ge to reinforce the region.
The work was completed over the course of 4 days while appreciating the views of the Rocky Mountains.

Address

2219 Florida Boulevard SW
Denham Springs, LA
70835

Opening Hours

Monday 6:30am - 4:30pm
Tuesday 6:30am - 4:30pm
Wednesday 6:30am - 4:30pm
Thursday 6:30am - 4:30pm
Friday 6:30am - 12pm

Telephone

(225) 334-8291

Website

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