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

ECRS/Metalock Corp

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ECRS/Metalock Corp

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11/05/2026

Metalock recently performed field machining services on the pressure ring bore of an aluminum extrusion press on the Northeastern US. The pressure ring bore was worn and two pressure ring retaining bolts had broken off in the face of the pressure ring bore. The client requested Metalock to machine the pressure ring bore and extract the broken studs in order to install a new pressure ring.
Initial bore dimensions were documented and the broken studs were extracted prior to installing the boring equipment. It was discovered that the female threads of one of the stud holes was either damaged in service or otherwise poorly formed likely contributing in failure of the associated stud. It was decided that a threaded insert would be installed as a repair. The remaining stud hole was chased with a tap and completed.
The machining successfully recovered a uniform machined bore surface. Final dimensions of the bore were provided such that the new pressure ring bore could receive final machining in parallel to minimize operational impact. The boring equipment was disassembled and the threaded insert installed.
Once alignment and other maintenance items were addressed, the press was reassembled and successfully returned to service.

10/12/2026

Metalock recently performed weld repairs to an aluminum extrusion press in the Southwest US. NDT inspections revealed cracking under one of the column nut seats in the rear platen near the main cylinder. This is a common location for fatigue cracks to form in extrusion presses. The cracking extended nearly through the entirety of the 4.75” wall thickness and was approximately 18” along the OD. The cracking was propagating toward the ID in the vicinity of the main ram bushing. Metalock was tasked with the repair.
Metalock recommended the cracked material be gouged out and welded using the proper procedure to ensure a sound weld. It was also recommended that the main ram bushing be removed so that the ID could be properly inspected. The repairs were made over the course of approximately 6 days and stress relieved. The bore of the main cylinder was measured in multiple locations to ensure that any distortion resulting from the repair did not impact the installation of the bushing and operation of the press. During welding operations, small cracks in the associated crosshead were ground out and recontoured. The client reassembled the press and successfully returned the press to service.

09/08/2026

Metalock recently performed a mechanical repair on a set of reciprocating compressor heads. The compressor experienced an internal failure that resulted in damage to the heads. The damage resulted in multiple cracks and sections of the head failing. The failed sections intersected the cooling jacket resulting in water entering the process stream. Metalock was contacted in order to repair the heads and return the compressor to service.
Dry magnetic particle testing was performed on the head in order to determine the extent of the cracking. The edges of the perforations in the head were prepared and matching sections machined from cast iron. The sections were hand finished to fit and Metalaced into position. The cracks were Metalocked and Metalaced per procedure.
The heads were successfully hydrotested and returned to the client within a few days.

08/04/2026

Metalock recently performed weld repairs on an extrusion press in a major Midwestern city. The extrusion press was cracked in front platen at the tunnel bore exit at the roughly 10 and 2 o’clock positions. These are common locations for front platen cracks due to the high local operational stresses.
Metalock mobilized on site and routine dry magnetic particle testing revealed an additional 18 smaller cracks, and other surface imperfections in the vicinity of the primary cracks. In order to ensure reliable, long term press operation, all of the cracks were excavated and ground clean. Heating blankets were then installed and the weldment brought to temperature. The primary welding was completed in short order and the weldment was then stress relieved. Once the weldment cooled to an acceptable temperature, the welds were ground smooth and the surfaces peened.
The press was returned to a satisfied client with assurances to call us in the future if need arises.

07/14/2026

Metalock recently performed a bespoke repair on a submersible pump used in a local petrochemical plant. The pump discharge is constructed as a concentric annulus with the center bore serving as the drive shaft housing and the outer ring serving as the flow path for the process fluid. The shaft is supported by a water bearing that resides in the center bore. During operation, the water bearing seized onto the shaft resulting in a catastrophic failure of the bearing housing. The client requested that Metalock design and implement a repair so that the pump could be used as an emergency spare.
Metalock technicians machined the fractured area of bearing housing so the surface was flat and trued the OD to form a male stub section that would receive a repair sleeve. Metalock engineers designed a cast iron repair sleeve to replicate the function and strength of the original bearing housing. The geometry of the OD of the sleeve was optimized to minimize the impact to pumping efficiency. The repair sleeve was machined for a shrink fit over the stub with additional strength provided with industrial adhesive and screws. The opposite end of the sleeve was threaded for the water bearing. A smooth transition between the pump casting and the repair sleeve was achieved with fiberglass reinforced polyester filler. The repair was completed by applying a brushable ceramic coating to the transition region and screw heads.

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.

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.

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.

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

http://www.metalockusa.com/

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