Overview
Induscoat returns worn, eroded or corroded equipment to service instead of replacing it: cold rebuilding with metal- or ceramic-filled epoxy, leak repair and wear-resistant linings. For plants and mine sites in Quebec and Ontario, on site or in the shop, with no hot work and within the window of your planned shutdowns.
Induscoat rehabilitates worn and corroded assets using cold-curing epoxy, polymer and anti-corrosion systems, including our own Induscoat formulations. These engineered repair compounds restore geometry, seal leaks and rebuild eroded surfaces without hot work or extended shutdowns. Typical applications include flange face repair, pump casing rebuild, heat exchanger tube-sheet sealing, concrete basin lining and worn shaft restoration. Our crews mobilize across mining and energy sites with surface preparation, application and QA documented to the selected system specifications.
What cold rehabilitation covers
We rebuild lost metal with a filled epoxy, protect it with a lining matched to whatever destroyed it, and the equipment goes back into service with its original geometry. The method is cold bonding repair: no heat input, so no distortion, no heat-affected zone and no hot work permit for the repair itself.
- Pumps: eroded or cavitated volutes, casings, wear plates and impellers, rebuilt then lined.
- Valves and flanges: wasted valve bodies and pitted gasket faces, restored without heavy machining (valve body repair).
- Heat exchangers: water boxes, tube sheets and channel covers.
- Chutes, hoppers and cyclones: ceramic-filled linings against sliding abrasion.
- Foundations and baseplates: epoxy grout under heavy machinery, cracked or oil-soaked plinths.
- Leaks: containment of low-pressure leaks on piping and tanks, followed by a planned permanent repair.
What stays with other trades: structural welding and metallurgical repairs, precision shop machining, machine balancing and alignment, regulatory inspection. We coordinate with them whenever a repair affects their scope.
Repair or replace: the decision method
A cold repair only makes sense if it lasts until the next planned shutdown, or longer. Every piece of equipment goes through the same questions, in this order:
- Is it regulated pressure equipment or piping? If so, the decision belongs first to engineering and the code, with your inspector, often through a fitness-for-service assessment; we repair only within that framework.
- Is the damage mechanism understood? Cavitation, slurry erosion, crevice or galvanic corrosion each call for a different product, and an untreated cause undoes the repair.
- Is enough sound metal left to carry the loads and provide a bonding surface? If not, the part is replaced or fabricated.
- Do service conditions (temperature, pressure, chemistry, wear type) stay within the limits of the system's technical data sheet?
- Do preparation and cure fit within the outage window? If not, a temporary repair now and a permanent one later.
Replacement lead time, equipment criticality and cost over the service life complete the analysis. The full method, with the decision tree, is in our guide to repair or replace industrial equipment.
How an intervention runs
- On-site assessment: damage survey, remaining wall thickness from your inspection program, service conditions, access, area classification.
- Technical quote: selected system, target preparation grade, application procedure, acceptance criteria, cure conditions and written exclusions.
- Preparation: lockout and isolation by your crew, decontamination, soluble salt check, abrasive blasting or power tools to bare metal, dew point check.
- Execution: geometry rebuilt with templates and forms, then wear or corrosion protection layers, inside a heated enclosure in winter when needed.
- Checks: geometry, cure, coating continuity and adhesion, before return to service.
- Handover: repair report and QA/QC dossier, with a recommended re-inspection interval.
In classified areas we work under your permit system, from the risk analysis to the cure check; our guide to hazardous area repair without hot work explains what cold repair changes, and what it does not.
Quality control and documentation
A cold repair is judged on preparation as much as on the product. Each step is measured and recorded to standard methods:
- ISO 8501-1: visual surface preparation grades.
- ISO 8502-9: soluble salts by conductivity; ISO 8502-4: condensation risk before application.
- ISO 8503: surface profile after abrasive blasting.
- ASTM D2240: durometer hardness to confirm cure.
- NACE SP0188: discontinuity (holiday) testing of coatings on metal.
- ISO 4624 and ASTM D4541: pull-off adhesion, on witness panels or designated areas.
For pressure piping or vessels, the design of a composite repair follows ASME PCC-2 or ISO 24817; acceptance stays with your inspection program.
Planning around your shutdowns
In Quebec and Ontario, most plants concentrate major work on the spring shutdown and the holiday shutdown in winter. A successful rehabilitation is prepared while the plant runs: site visit and readings on the operating equipment, system selection, approved procedure and materials on site before lockout.
Winter adds a constraint that can be managed: epoxy cures slowly in the cold, and steel below the dew point condenses. A heated enclosure, tempered steel and humidity monitoring belong in the quote, not in a same-day improvisation (cold weather epoxy application).
Some repairs can come out of the outage window altogether: leak containment on a live line, external protection, grout under a standby machine. Doing them beforehand frees the shutdown for the work that truly needs it.
When this service is not the right answer
We say so when a cold repair is not the right solution:
- A propagating crack, loss of load-bearing section, a primary load path: that is a metallurgical repair, by welding or replacement.
- A regulated pressure boundary without acceptance from the owner, the engineer and the inspector: the decision belongs to engineering and the code, not to the applicator.
- Temperature, pressure or chemistry outside the system's qualified limits: we change the solution.
- A wear part too far gone to rebuild: our custom parts fabrication service makes it new.
- Large areas, a complete tank or new steel to protect: that is the work of our protective coatings service.
Send photos, the fluid, operating conditions and your outage window through the quote request; if welding is the right answer, we will tell you.
Typical Applications
- Flange face and valve repair (epoxy)
- Pump casing and impeller rebuild
- Heat exchanger tube-sheet sealing
- Concrete basin and bund lining
Typical Problems We Solve
- Pitting and crevice corrosion on flange faces and valve seats
- Erosion of pump casings and impellers in slurry and abrasive service
- Concrete basin degradation from chemical attack and thermal cycling
- Worn shafts and bearing journals requiring costly replacement or chrome plating
What You Receive
- Repair report with before/after surface preparation photos and adhesion test results
- QA/QC dossier with WFT/DFT readings, ambient conditions log and product batch records
- Manufacturer warranty registration when available for the selected system
- Recommended re-inspection interval and maintenance plan
Timeline
2–6 weeks depending on scope and site access; emergency interventions within 24 business hours.
Standards & Certifications
- NACE/AMPP SP0178 — fabrication design for corrosion-resistant service
- ISO 8501-1 — surface preparation grades (Sa 2.5 / Sa 3)
- SSPC-SP10 / SSPC-SP11 — near-white and bare metal cleaning
- ISO 4624 — coating adhesion pull-off test
Industries We Serve
- Mining — slurry pumps, flotation cells, thickener mechanisms
- Energy — condenser water boxes, cooling towers, penstocks
- Chemical & Petrochemical — reactors, tank linings, bund areas
- Oil & Gas — separators, heat exchangers, tank floors
Service FAQ
What's the difference between ceramic coatings, polymer coatings and alumina tile solutions?
Ceramic coatings are thin engineered ceramic films applied by spray or trowel to rebuild eroded surfaces and resist moderate abrasion. Epoxy and vinyl ester polymer coatings form thick chemical-resistant barriers against corrosive media. Alumina tile solutions bond high-alumina ceramic tiles to severe-wear areas (chutes, cyclone inlets, elbows) for maximum abrasion life.
Can repairs be done without hot work or extended shutdowns?
Yes. Our cold-curing epoxy and polymer repair systems cure at ambient temperature, eliminating hot-work permits for the repair itself and reducing shutdown windows. We mobilize during planned shutdowns and restarts or on properly isolated equipment, using formulated repair compounds that restore geometry without welding.
How long do your rehabilitation repairs last?
Service life depends on the substrate, preparation, selected system and operating conditions. We define a recommended inspection interval and maintenance plan for each project so performance can be monitored against the documented service conditions.
Technical guides
Related applications
Concrete industrial use cases where this service is applied.
Other Services
Go deeper
Our technical notes on the subject — applicable standards, selection criteria and implementation traps.
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10 minHeavy machinery epoxy grouting: foundation repair and grout design for SAG mills, crushers, compressors and turbines
SAG and ball mills, crushers, reciprocating compressors and turbines load their foundations with weight, cyclic forces, impact and heat. Epoxy grout is the usual link between the machine and the concrete, but most grout failures come from design and pour, not from the product. This guide covers grout design, anchor bolts, concrete preparation, the pour and how to verify the result.
9 min