Heat exchanger repair without hot work
Heat exchangers are among the most critical equipment in refineries, chemical plants, power stations and pulp-and-paper mills. Their tube sheets, water boxes, flange faces and end covers suffer galvanic corrosion, cooling-water erosion, chemical attack and scaling. Induscoat rebuilds these geometries and protects them with cold-curing epoxy composites — no welding, no post-weld heat treatment.
The challenge: heat exchanger degradation by galvanic corrosion
Shell-and-tube exchangers combine cupro-nickel, brass, titanium or stainless tubes rolled into a carbon-steel tube sheet. This junction of dissimilar metals, bathed in chloride-rich cooling water, sets up a galvanic couple that gouges the tube sheet and flange face. Over time tubes loosen, leaks appear, and a full re-tubing — let alone exchanger replacement — costs hundreds of thousands of dollars and idles the unit for weeks.
The solution: cold rebuild of tube sheets
Induscoat rebuilds the tube sheet, water box and flange face with a cold-curing metal-rebuild mastic, restores tube-hole sealing, then applies a ceramic-filled epoxy topcoat. The result: an exchanger restored to its original geometry, durably protected against galvanic corrosion, water erosion and chemical attack — with no welding and no heat treatment.
Inspection of tube sheet, water box, flange faces and end covers
Grit blasting to NACE 2 / SSPC-SP10 near-white metal
Geometry rebuild with cold-curing metal-repair mastic
Ceramic-epoxy topcoat + adhesion and thickness testing
Benefits of cold heat-exchanger repair
- Avoids full re-tubing or exchanger replacement
- Stops tube-sheet galvanic corrosion at its source
- No heat — no distortion of tubes or tube sheet
- Restored sealing of tube roll joints
- Broad chemical resistance: seawater, chlorides, acids, hydrocarbons
- Return to service in 24 to 72 hours depending on scope
Systems we apply
Induscoat selects the rebuild mastic and topcoat based on your service fluid (fresh water, seawater, acid, hydrocarbon) and temperature. We apply Chester Molecular, Arcor and our own Induscoat formulations for Canada's most severe services.
Related solutions
These services and products complement the application described above.
Frequently asked questions
Can you repair a tube sheet that is heavily gouged by corrosion?+
Yes. Cold-curing metal-repair mastics can rebuild a gouged tube sheet to several millimetres of depth, restore tube holes and flange faces, then be protected with a ceramic-epoxy coating. A pre-inspection confirms the repair is viable.
Does the exchanger need to be dismantled for repair?+
The shell-side tube sheet and water box can often be repaired with the shell in place, after opening the end cover. Work still requires isolating and draining the exchanger, plus access for grit blasting.
What service temperature do the coatings withstand?+
Standard systems withstand up to 90–120 °C in continuous immersion. High-temperature systems (up to 180 °C and higher in dry contact) are available for steam and process applications. We specify the right system for your actual service.
Which sectors do you serve in Canada?+
Refineries, petrochemical plants, power stations, pulp-and-paper mills, mines and cement plants — in Quebec, Ontario and across Canada.
Tell us about your equipment to repair
Technical recommendation and quote within 24 business hours.
Request a quote