Challenge
A large cast-iron engine casing developed a branching crack running out from a bolt hole through the block wall. Welding cast iron in place risks distortion and fresh cracking from the heat, and a replacement casing was estimated at roughly $22,000 with a six to ten week lead time — followed by ten or more days of unit downtime to swap it out. The equipment was needed back in service well before any of that could happen.
Belzona Solution
Rumford Industrial Group repaired the casing in place, cold. The crack was traced to its ends and stop-drilled, then a stitching pattern of drilled and tapped holes was laid out along and across the crack path so the load transfers across the damage rather than through it. Locking pins and stitching studs were installed to pull the fracture closed mechanically, the surrounding area was ground back to clean, profiled metal, and Belzona 1111 (Super Metal) was applied to seal and rebuild the wall over the stitched repair. The rebuilt area was then dressed back flush to the original casing contour so gasket and cover faces sat correctly on reassembly.
- Belzona 1111 (Super Metal)
- Belzona 1121 (Super XL-Metal)
Result
The casing was returned to service in about one day of on-site work for an estimated $1,800 — roughly $20,200 less than replacement, and about nine days of downtime avoided. Because no heat was introduced, there was no distortion of the block and no risk of driving the crack further, and the mechanical stitch plus composite rebuild carries the stress across the repair instead of relying on the cracked section.
Project Photos
