Worldwide Mechanical Services & Repairs

Precision engineering on-site/in-situ, incorporating the latest in alignment and CNC machine control technology

www.metalock.co.uk

Metalock Engineering
Global mechanical equipment repair
Metalock Engineering UK Limited is an established mechanical equipment maintenance, bespoke modications and equipment upgrades around the
Were available 24/7 for cost-effective specialist engineering services that keep your operations running under the harshest land or sea conditions. From routine maintenance to in-situ emergency repairs in the remotest locations, you can call on our support anytime with the added reassurance of backing by the global Metalock Group and MIDROC. Since 1947, weve been an acknowledged leader in specialist mechanical repair, ranging from on-site machining and metal stitching repairs, to welding and alignment, metal spraying and electromechanical work. Because we offer all these services in one place, you enjoy peace of mind and a cost-effective one-stop repair and maintenance service. Whether youre in power generation, steel-making, petrochemicals, water, manufacturing, pressing and forging, food processing or another industry, our combination of traditional maintenance skills and modern techniques helps you enjoy improved equipment efciency, extended operating periods, better equipment availability and improved reliability.

Metalock Engineering UK Limited committed to providing a quality service

Head Office Metalock Engineering UK Limited Unit H5 Pilgrims Walk Prologis Park Coventry CV6 4QG ENGLAND UK

UK Limited
repair company with proven expertise in quality repairs, world.

Your Global Mechanical Equipment Repair Service

24/7 response to your engineering emergency
For your complete peace of mind, were on call 24 hours a day, 7 days a week, worldwide. Our engineers and technicians have all the experience and specialist knowledge needed to get your operation back in action as fast as possible. If anyone can save you time and money and protect your hard-earned reputation, they can.

Metalock Engineering UK Limited is a BS EN ISO 9002 registered company; this shows our commitment to a policy of continuous improvement and excellence. Our LRQA certicates: ISO 9001: 2008 for Quality Management. ISO 14001: 2004 for the Environmental Management. OHSAS 18001: 2007 for Safety Management Systems.

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Top: Steel Industry machining bottom backup roll areas on millstand Left: Turbine Casing machining Above: 8 metre internal bore

On-site Machining
The Metalock UK on-site machining division has built an extensive range of precision portable machining equipment and specialist skills. We provide cost-effective workshop-quality machining for the largest and smallest on-site machining projects around the world. Nearly 70 years experience says we can usually solve your machining challenge on-site
Our services
Our machining team consists of highly skilled engineers and technicians, all with years of experience in global mechanical equipment repairs on the largest, most complex equipment. Were good at what we do and often succeed where others fail. From remote power stations to the largest cargo vessels at sea, we focus on providing accurate on-site machining facilities that reduce costly equipment downtime, avoid the need for expensive equipment replacement, increase your productivity and protect your reputation.

The benets
From Dubai to Denver, and Kendal to Kazakhstan, we promise all the usual Metalock benefits when you entrust your on-site machining to us: A proven solution-focused approach. 24/7 global service call us anytime to save time and money. Build and protect your reputation with our support. Workshop-quality on-site. One reliable source for all your on-site machining. Nearly 70 years UK engineering expertise you know you can trust us to complete challenging projects on time, on budget and to the highest quality.

Metalock in action
When precision on-site machining was needed for 6 x 500mw turbines at the UKs largest coal-fired power station, our experience, reputation and purpose-designed boring bar made us the logical choice. The scope of our work at Drax included LP cylinder upgrades, deepening of carrier seats, re-machining exhaust sections to accommodate larger blades, and drilling, tapping and dowelling to allow the fitting of anti-rotation keys.

How can we save you time and money, and build your reputation for getting plant and equipment working again as fast as possible?

Please contact us on +44 (0) 2476 338205 or email sales@metalock.co.uk for more information or scan for your no-obligation quotation.
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On-site CNC Machining

Metalock has always been at the forefront of specialist engineering services that save you time and money and protect your reputation. Now, our new on-site computer numerical control (CNC) machining operation has given us powerful new capability to undertake more complex and intricate machining contracts
With its advanced Siemens CNC control system, our newest CNC machining equipment improves the capability of our experienced site machining team its another example of Metalock constantly improving its services for you.

Fast, convenient on-site machining

In the past, machining had to be done off-site, at central repair facilities hundreds or thousands of miles from operational sites. Huge plant and equipment often had to be removed and transported through the harshest environments. And to minimise downtime, you often had to buy and fit new or reconditioned parts. It all meant unwanted expense and affected your bottom line. Now, we offer fast, convenient, accurate on-site milling at your remotest sites. We achieve massive time and cost savings in marine and land-based industries alike. So, whether you operate offshore or in a processing plant, steel mill or fleet of bulk carriers, you can have workshopquality in-situ repairs and upgrades when you need them.

The benets

Extending plant life too

As an experienced engineering professional you understand the key benefit of completing complex, intricate machining on-site in a fraction of the time it once took. Whats more, the quality of our repairs is so good that we can often extend equipment service life too. And all without having to take equipment off site. Thats Metalock for you.

Whether you use our CNC milling service alone, or with our precision laser tracking alignment services as many customers do, you can look forward to the usual range of benefits: Better machining accuracy than ever and well do it on-site. Save time and money. A proven solution-focused approach around the clock. Global responsiveness. Build and protect your reputation. One convenient source for CNC milling and other engineering services. Decades of expertise you can trust us when we do your on-site CNC machining.

You never know when youll need specialist services such as on-site CNC milling. For immediate help or more information, please contact us.

Please contact us on +44 (0) 2476 338205 or email sales@metalock.co.uk for more information or scan for your no-obligation quotation.
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Laser Guided Machining

Metalock UK are constantly developing and improving their on-site machining equipment, incorporating new technologies, such as laser guided machining, that work along side traditional machining methods. These machining techniques can then be adapted and used on-site for a huge variety of in-situ machining activities in all industries.
Utilising the latest Engineering techniques in-situ
Our global reputation for providing precision machining techniques on-site is well documented and our experience is second to none. Following the recent successful testing we can now offer on-site laser guided machining to a global market. Our newly developed LGM - laser guided machine system, in addition to our very successful CNC site machining techniques that use the latest drives and controls are pushing Metalock UK to the forefront of on-site machining development. These new on-site techniques allow us to machine very large fabrications accurately. This latest addition, the LGM, is a laser guided, self levelling machine that allows us to accurately control the machine operations, keeping it level and at when machining very large structures to work shop accuracy. It currently has a 30 meter diameter limit but it could be extended if and when required. This equipment is modular and can be stripped down and packed into one container for safe and easy transportation. Once the Laser guided machine arrives on-site it can be built up very quickly and machining can begin in the shortest possible time.

The benets

Highly accurate & efcient machining Latest on-site machining techniques used Longevity of your equipment after machining Save time & money Global emergency response Decades of experience in the latest on-site machining developments.

Metalock in action
Our company has been machining large structures for many years, the largest being approximately 22 Meters in Diameter for an offshore FPSO mooring turret. We have also machined slew ring seats on large cranes and mooring systems and faces on large offshore fabrications.

How will our laser guided machining equipment save you time and money and help protect your reputation?

Please contact us on +44 (0) 2476 338205 or email sales@metalock.co.uk for more information or scan for your no-obligation quotation.
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Top: Portable laser tracker alignment Left: Alignment using laser tracker Above: Engine alignment using laser equipment

On-site Alignment
Poorly aligned plant causes excessive wear, premature plant failures, lower process efficiencies and reduced plant availability. Why jeopardise the success of your operation and your reputation when precision alignment is so easy to arrange? Wherever your plant is based, around the world and around the clock, Metalock UK is your alignment partner when you need to avoid mechanical trouble.
Metalock UK has always specialised in precision onsite alignment offering a variety of alignment techniques from traditional fixed measurement, Optical Alignment, Laser alignment and the latest Laser Tracker Alignment technology available. The latest laser alignment equipment lets us align your plant and equipment with formerly unattainable accuracy, our Leica Absolute Tracker CMM system saves time and maximizes the accuracy of on-site alignment. Now weve got the ultraportable Leica Geo System Absolute Tracker (reportedly the most accurate laser tracker available) you enjoy even greater precision, flexibility and timesaving on-site.

Surveying large areas faster

As well as doing conventional alignments, the Leicas accuracy and portability means our highly-skilled two-person teams can survey large areas faster than ever then give you an accurate alignment report.

NEW independent surveys

Our alignment department works alongside other Metalock departments, but we also offer a stand-alone on-site alignment service. The choice is yours: whichever meets your needs, you know the service, accuracy and responsiveness will always meet our established standards.

The benets
Wherever and whenever you need the versatility and accuracy of on-site alignment, youll enjoy a range of benefits: Better alignment accuracy than ever. Save production time and money. Extending plant life and availability Global responsiveness. Build and protect your reputation. One convenient source for laser alignment, surveying and other engineering services. Decades of expertise you know you can trust us with your laser alignment or site survey.

Metalock in action
From steel works to the engine rooms of ships at sea, Metalock precision laser alignment keeps all kinds of industrial and transport processes on the straight and narrow, saving time and money for operators around the world.

How will our on-site alignment and surveying equipment save you time and money and help protect your reputation?

Please contact us on +44 (0) 2476 338205 or email sales@metalock.co.uk for more information or scan for your no-obligation quotation.
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Top: Main bearing machining Left: Machining llet radius Above: Machining crankpin diameter

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Crankpin Machining
Wherever you are, Metalock Engineering UK Limited offers a wealth of on-site machining skills and experience of crankpin and main-bearing journals on large and small engines. Based on decades of challenging work for marine propulsion and power, as well as industrial power generation applications, we know we can usually solve your crankpin machining challenge without resorting to costly removal to a remote workshop
Our range of orbital crankpin machines and main-bearing machining attachments has been specially designed to fit all types of engines. Why incur the cost and inconvenience of workshop repairs when we regularly carry out these services in-situ around the world?

The benets
Wherever in the world your plant or vessel is located (including mid-ocean), you get all the usual Metalock benefits when you entrust your in-situ crankpin machining to us: proven solution-focused approach (in dock or at sea). 24/7 worldwide service call us anytime to save time and money by avoiding costly workshop repairs. Build and protect your professional reputation with our support. Workshop-quality machining on-site. One source for all your on-site machining. Nearly 70 years UK engineering expertise you can trust us to complete the most challenging projects on time, on budget and to the highest quality.

A range of capabilities
Our capabilities include these: NDT. Magnetic particle inspection (MPI). Dye penetrant. Hardness testing. Machining of journal fillet radii. Journal regrinding and superfinishing to manufacturers specifications.

Avoid the cost of off-site repairs

Imagine the time and cost of a conventional workshop repair: Stripping an engine. Removal of the crankshaft. Transport to a machine shop. Regrinding. Return to site. Crankshaft reinstallation. Engine rebuilding. Imagine how long your vessel or other equipment will be out of service and not earning revenue... Now, consider the benefits of our cost-effective in-situ repair including minimisation of downtime and the avoidance of replacement costs.

Metalock in action
Precision on-site crankpin machining saved P&O time and money, and avoided the hassle of costly machinery removal, when the crankpin on one of MS Pride of Bruges two Wrtsil-Sulzer 9ZAL40 engines required repair. Successful completion of the work demonstrated yet again how we tackle the toughest marine and land-based machining challenges anywhere in the world and around the clock.

How can we save you time and money, and get your plant or vessel earning money again as soon as possible?

Please contact us on +44 (0) 2476 338205 or email sales@metalock.co.uk for more information or scan for your no-obligation quotation.
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Top: 36 diameter baring journal Left: 36 diameter baring journal during recovery Above: 36 diameter baring journal recovered

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Shaft Recovery
When industrial bearings are damaged or fail, theres usually shaft damage too. For decades, weve saved operators time and money with cost-effective shaft recovery services. Forget the direct costs and inconvenience of stripping a complete machine or gearbox just to remove the shaft and the lost production, expensive transport and repair costs, and reinstallation. Weve got a proven alternative
As weve shown for decades, in-situ shaft repairs are cost-effective, accurate, fast and help minimise expensive downtime.

Metalock in action
Following a journal failure on a 40-tonne/hour cement ball mill, we orbitally machined the badly scored ball-mill driveshaft. This enabled fitting of a new white metal bearing and return of the mill to production with minimal disruption to operations and none of the direct and indirect costs of removing and replacing the shaft.

Our services
Based on accurate datum points, parent metal specifications and detailed engineering drawings, we deploy specialist orbital machining and related techniques to repair the shaft: Superfinishing (generally used when salvaging crankshafts on large marine diesel engines). Shrink-on sleeves. Orbital welding. Metal spraying. We also repair worn bore-locations using our in-situ boring equipment.

The benets
Removing a shaft and taking it to a workshop, or replacing it with a new shaft, incurs high direct and consequential costs. Our proven skills, experience and specialist equipment mean you save money and enjoy other benefits: A proven solution-focused approach wherever your equipment is located. 24/7 global service around the globe. Build and protect your reputation. Workshop-quality on-site repairs. One reliable source for all your shaft recovery needs. Nearly 70 years UK engineering expertise you know you can trust us to complete the most challenging shaft recovery projects on time, on budget and to workshop quality.

Re-machining tapered bearing diameter on paper drying cylinder

How can we save you time and money, and build your reputation for mending failed or damaged shafts in a fraction of the time of back-to-base repairs or shaft replacement?

Please contact us on +44 (0) 2476 338205 or email sales@metalock.co.uk for more information or scan for your no-obligation quotation.
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Above: Hand-held application Left: Controlled application with robotic arm Right: Hand-held application

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Thermal Spraying
Metalock Engineering UK Limited is a leading specialist in thermal spraying and applying surface treatments to metal components. Continuous development of new surface coating processes means we meet industrys voracious appetite for new products and give engineers ways to repair and protect a wide range of mechanical engineering equipment for longer life, lower manufacturing costs and cost-effective repair instead of expensive replacement...
Thermal spray coating involves heating material (in powder or wire form) until it is molten or semi-molten. Then we propel it with gas or air to deposit a layer on a receiving component. Because we can repeat this many times, we can build several layers to precise specifications. Common applications for thermal spraying and surface treatments include these: Repair & Reconditioning Anti-corrosion coatings Heat shielding Erosion prevention Insulation Depending on your requirements, our highly-trained specialists will work in the workshop or on-site spraying materials such as these anywhere in the world: Steel Tungsten carbide Chrome carbide Ceramics Plastic composite You can count on us for the highest quality thermal spraying and consistently high-specification results on all types of components with a wide range of materials. These may be single elements, but are more usually alloys or composites with unique physical properties that are only achievable with thermal spraying using one of these techniques: High Velocity Oxygen Fuel (HVOF) Flame spraying Arc spraying Plasma spraying

The benets
From large industrial plant in remote locations, to marine engines at sea, removal of worn components, workshop repairs or replacement are expensive. Our specialist thermal spraying experience saves you money and gives you other benefits: A proven solution-focused approach wherever your equipment is. Worldwide 24/7 service. Build and protect your reputation. Workshop-quality repairs on-site. One reliable source for all your thermal spraying. Decades of UK engineering expertise you know you can trust us with the most challenging thermal spraying projects.

Metalock in action
Cost-effective rotary-steriliser shaft recovery kept baked bean production going for a leading European bean processor. On the recommendation of another customer, thermal spraying and precise orbital turning enabled us to recover a shaft for the Belgian food machinery producer OEM at a fraction of the replacement costs and the time required for conventional shaft replacement.

How can we save you time and money, and build your reputation with thermal spraying and surface treatment?

Please contact us on +44 (0) 2476 338205 or email sales@metalock.co.uk for more information or scan for your no-obligation quotation.
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Top: Heat-exchanger bundle repairs Left: Welding pressure vessel Above: General weld repairs

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Electromechanical
With its electromechanical engineering experience, Metalock UK can help you improve equipment availability and reliability through proactive problem identification and costeffective solutions. We do this by combining traditional maintenance skills with modern design and repair techniques and continual innovation
Poor equipment reliability and unscheduled shutdowns cost you time and money, and harm your reputation. Fortunately, our combination of traditional maintenance skills, modern design techniques and innovative repair techniques mean its easy to detect problems and take corrective action before costly plant breakdowns occur. For decades, weve supported industries facing similar equipment reliability challenges to you: Marine and Offshore Power Steel Petrochemicals Water industry Food & Beverage manufacture Papermaking Process industry They all benefit from improved equipment efficiency and extended operating periods thanks to our equipment upgrades in areas such as the following:

Thermal imaging
We use non-intrusive thermal imaging to detect abnormal temperatures in your electromechanical equipment. By analysing these results, we identify potentially expensive faults before they occur. Our other capabilities include vibration detection and analysis, motor rewinds, gearbox and valve overhauls, compressor repairs, spares supply and manufacture. We can even reverse-engineer repairs by manufacturing and fitting new parts when original spares are no longer available.

The benets
Whatever your electromechanical equipment challenge, our cost-effective services save you money and protect your reputation: A proven, solution-focused approach. Worldwide, 24/7 service. Build and protect your reputation. Workshop-quality work on-site. One reliable source for all your electromechanical needs. Years of UK engineering expertise means you can trust us.

Pump repair and refurbishment

Including realignment on reinstallation to make sure your pumps run efficiently, minimise costly component wear and extend service life.

Metalock in action
For a pump that was no longer a stock item, production and delivery was a long and very costly option so we repaired it instead. The pump was stripped, before damaged wear rings and internal areas of the casing were pre-machined in-situ using a portable boring machine. Next, we grit blasted the internal surface to ensure bonding between the bronze pump and the new high level chemical resistance coating (applied in layers to build up areas of excessive wear). With the pump reassembled, the boring bar was positioned to re-machine the internal seal and bearing areas. Finally, new bearings, seals and an impeller completed an insitu repair that restored the pump to full operation at a fraction of the time and cost of a replacement.

Condition monitoring
Planned monitoring lets us compile detailed reports and monitor changes over time. You can see changes in machine running conditions, so its easier to identify problems early. This reduces the likelihood of breakdowns and lost production.

Flow coatings
We can also upgrade equipment with bespoke coatings to your exact specification. The benefits include improved product flow and better corrosion protection.

How can we save you time and money, and build your reputation with our electromechanical capability?

Please contact us on +44 (0) 2476 338205 or email sales@metalock.co.uk for more information or scan for your no-obligation quotation.
www.metalock.co.uk | 17

Top: Cutting out for master locks Left: Cutting out damaged engine main bearing pocket Above: Transplanted and secured new main bearing pocket ready for re-boring

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Casting Repairs
Every day, around the world, someone in an industry like yours relies on our specialist cold repair techniques for cracked or broken components made of cast iron, steel or aluminium. Why? Because, when you need to get business-critical plant working again as soon as possible, and only a cold repair will do, you can count on the proven Metalock process
Our unique process, developed and refined over several decades, is based on sound engineering principles. It avoids stress problems associated with welding and maintains original alignment, which reduces the need for costly re-machining after repairs.

The benets
From shaft-bearing end covers to long fractures in pressing-line dies and bridge repairs, damaged castings mean inconvenience, cost and delay. Thats when our cold casting repairs get your plant or structure working again as soon as possible: A proven solution-focused approach, worldwide, 24/7. Build and protect your reputation. Workshop-quality on-site repairs. One source for your casting repairs. Nearly 70 years UK engineering expertise means you can trust us.

Many advantages
Metalock customers value the advantages of our proven cold repair method. These include the following: We usually do the work on-site saving you time and avoiding dismantling. Maintenance of alignment and original surfaces. Dampening and absorption of compression stresses. Spreading of tensile strains. Ensure a good expansion joint on jobs such as cylinder liners. Distribute load away from fatigue points. Maintain relieved condition of inherent internal stresses where these caused the fracture. Provide a low coefficient of expansion in relation to the repaired metal. Because the repair is completely cold, it doesnt need heat application, which could introduce fresh stresses.

Metalock in action
By responding quickly to Toyota UK, we successfully completed metalocking repairs to a fractured cast iron body panel die. Using its experience, specialist skills and around-the-clock working, our team repaired the 4m fracture so the giant car manufacturer could get its pressing-line die working again with minimum downtime.

How can we save you time and money, and help you protect your reputation with our casting repair techniques?

Please contact us on +44 (0) 2476 338205 or email sales@metalock.co.uk for more information or scan for your no-obligation quotation.
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Top: Pump case before and after repair Middle left: Realigning pump and motor Middle right: Remachining pump case Bottom left: Small coupling alignment as standard Bottom right: Reclaimed pump case using controlled welding techniques

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Pump Refurbishment
Professional pump repairs, refurbishment and overhaul by recognised pump specialists are some of the best investments you can make in the longevity of your industrial pumping equipment. With decades of experience behind us, well save you time and money wherever industry moves fluids
Metalock in action
If youre like our other pump customers around the world, were sure youll appreciate the peace of mind and cost savings that come with our industrial pump repair and overhaul service. On-site, or in our well-equipped workshops, we specialise in repairing and refurbishing the industrial pumps used for purposes such as these: Land drainage and irrigation Petrochemical processing Power generation Paper industry Marine pumps To solve the most challenging problems, we can even reverse-engineer pump repairs too. This involves manufacturing and fitting new parts when original spares are hard to find or impossible to get. We can also coat the inside of pumps to suit your particular requirements and specifications. And of course, when your overhaul is complete well reinstall and commission the pump. Well also align it properly using our laser alignment techniques to ensure efficient running, low component wear and longer service life. We successfully overhauled a 25-year-old 12-inch Allen Gwynne mixed-flow bowl pump for Anglian Water Supplies. The pump had become noisy and inefficient as its bearings wore away, causing the impeller to wear a deep groove in the pump shroud. After complete on-site refurbishment (including rebuilding the impellor), we reassembled the pump and re-set all clearances. Compared with the time and costs of installing a new pump, our solution took just 30 days without the need for the electrical and location modifications required for a replacement pump.

The benets
From small agricultural pumps to the massive equipment used in power generation, pump failure means inconvenience, cost and delay. Fortunately, Metalock repairs get your pump working again, revitalise it for years of reliable use and protect your hard-earned reputation: A proven solution-focused approach, worldwide, 24/7. Building and protecting your reputation. Workshop-quality on-site repairs. One source for all your pump repairs. Decades of engineering expertise.

How can we save you time and money with an on-site pump repair?

Please contact us on +44 (0) 2476 338205 or email sales@metalock.co.uk for more information or scan for your no-obligation quotation.
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Top: Vertical boring Left: Vertical lathe Above: Large centre lathe

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Machine Shop Services

For decades, a key benefit of hiring Metalock UK has been the ability to benefit from a wide range of on-site engineering services. However, sometimes the most suitable course of action will be to entrust your engineering work to our fully equipped workshop in Coventry, UK
When a traditional workshop offers the most appropriate solution to your needs, we operate a fully equipped engineering tool room and repair facility at our head office in Coventry in the traditional heartland of British engineering expertise.

The benets
When you entrust work to our machine shop team, you can look forward to enjoying all the benefits that you associate with the Metalock brand: Time and money saving. Proven solution-focused approach. Build and protect your reputation. One source for your machine shop and other engineering services. Nearly 70 years UK engineering expertise if your job is in our machine shop, you know you can trust us.

Traditional values and the latest workshop techniques

The values and attention to detail may be traditional, but the equipment and ongoing staff training at our Prologis Park facility is the latest as befits the demands that you place upon us. When you entrust specialised work to our machine shop, highly skilled engineers work wonders on smaller items of plant and machinery. As with all our services, whether on-site or in the workshop, you can expect accurate machining, the lowest possible lead times and excellent value for money. And of course, with each job you entrust to us comes full access to our unparalleled wealth of engineering skills and experience. In association with the workshop, we also do specialist welding repairs on plant and equipment using all the main welding techniques.

Metalock in action
When the Quainton Railway Society, in Buckinghamshire, UK, needed major repairs on a 1930s steam tank engine, the Metalock machine shop was an obvious choice for precision cylinder reboring, and the manufacture and installation of two new cylinder liners. The work on Thomas the Tank Engine was preceded by our usual thorough survey. We then dismantled the cylinder block, removed and remachined the engines pistons, and fitted new piston rings. Next, we rebored both cylinders and manufactured new cylinder liners before shrink-fitting them into position. Back in action with minimal disruption to the Societys operations, Thomas now has a new lease of life and is set to go on delighting children of all ages for years.

How can our UK-based machine shop save you time and money, and help protect your reputation?

Please contact us on +44 (0) 2476 338205 or email sales@metalock.co.uk for more information or scan for your no-obligation quotation.
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Top: Large vessel welding repairs Left: Welding steel ladle Above: Preparing end of vessel for welding

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Specialist Welding
Welding is one of the longest established methods for joining metals. Done correctly, using appropriate techniques and materials, professional welding enables all manner of cost-effective plant and equipment repairs and modifications. Theres lots at stake with every weld including your professional reputation. Thats why it pays to choose the most highly skilled and experienced welding partner for your repairs or fabrication
Metalock UK specialises in repairing metal machine parts using (on-site or workshop-based) the highest quality welding. Experience shows manual arc welding to be the most often used method supplemented, where necessary, by heat treatment. Where arc welding isnt appropriate, our other welding (and welding-related) services, include these: MIG (metal inert gas) welding TIG (tungsten inert gas) welding WIG (wolfram inert gas) welding MAG (metal active gas) welding Submerged arc welding Fusion welding Gas welding E-hand welding Thermal spraying Flame cutting (Oxyacetylene and Plasma)

The benets
From simple fabrication to major plant repairs, when you entrust welding to our team, you can count on all the benefits associated with the Metalock brand: Time and money saving. Complete peace of mind with our coded welders. A proven solution-focused approach around the clock. Global responsiveness. Build and protect your reputation. One convenient source for welding and other engineering services. Decades of expertise when we weld, you know you can trust us.

Metalock in action
Our specialist welding services helped one manufacturer when multiple cracks were found in the 350mm-thick walls of a massive steel extrusion-press cylinder. As ever, time was money as the plant stood idle before our convenient on-site preheating and welding service, complemented by mobile annealing equipment, got the vital machine back in action. Best of all, we did this without the delay and expense of complete plant removal followed by workshop repair or replacement.

Heat treatments
As you expect from your one-stop engineering services partner, we also perform a wide range of heat treatments. We can do this in stationary furnaces or on-site at your location using our mobile annealing equipment. Just tell us what needs to be welded and where. As with all our engineering services, were on call around the world and around the clock.

Fully documented and certied

Nearly 70 years experience in welding is complemented by full certification for the techniques that we use. For your peace of mind, not only can you be sure that we have the required techniques in-house, but that our welding experts have the documentation to prove their capabilities.

How will our specialist welding services save you time and money and help protect your reputation?

Please contact us on +44 (0) 2476 338205 or email sales@metalock.co.uk for more information or scan for your no-obligation quotation.
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Industries Served
Steel
For decades, weve supported businesses like yours in steel industries around the world. Large and small organisations that share the challenge of manufacturing and processing high quality steel and steel products Supporting efcient production and consistent product quality
Are you familiar with the following and their role in maintaining the performance of steel production facilities? Mill housing machining. Modification of housings for roll bending/shifting units. Boring of screw-down bores. Gearbox line boring. Shaft journal machining and grinding, and shaft recovery. Drilling, tapping and screw cutting large holes. BOS vessel trunnions and flange-joint faces. Alignment surveys. From rolling mills to blast furnaces, these are just some of the specialist services that we regularly provide for the steel industry usually in-situ because of the plant sizes involved. Maybe youre improving your steel-strip quality to be more competitive? Or implementing vital productivity improvements after mill refurbishment? Or speeding up bobbin changes? Whatever engineering challenge you face, its reassuring to know that steel giants in the UK, Sweden, India, Canada and elsewhere already trust our skills and experience when they refurbish their mills to ensure efficient production and consistent product quality.

Pressing & Forging

Pressing and forging industries are essential to modern manufacturing with metals and other materials under high temperatures and pressures. But because of the harsh operating regimes, constant vibration and immense pressures, cracks, fretting corrosion and other damage are constant threats to continued operation of your plant and its ancillaries Decades of experience
Metalock skills and expertise, built over decades in specialised engineering, are ideally suited to maintaining, repairing, refurbishing and modifying large and small pressing and forging plant: Press frames Press beds and crowns Rams and con rods Plattens Flywheels Air cushions Press tools and dies Tee-slot repair

One-stop availability for the services you need

Worldwide availability and a full range of services complement our ingenuity and innovation around the clock. From specially developed moveable carriage systems for precision press-bed regrinding, to proprietary repairs for cracked forge-press crossheads, our capability covers most repair or maintenance needs. Indeed, our repairs are so good that they often make installing new parts unnecessary a cost-effective outcome for you. In one case, the quality of our temporary repair meant that a replacement crosshead remained unused before eventually being sold as a spare when the repaired press was sold. Stories like this demonstrate the engineering quality we provide to the pressing and forging industry.

Priceless peace of mind

Our solution-focused approach, 24/7 global responsiveness and nearly 70 years specialist engineering expertise underpins cost-effective repairs and modifications, priceless peace of mind and protection of your reputation in pressing and forging.

Supporting steel manufacture 24/7

Our convenient one-stop range of services, 24/7 global responsiveness and decades expertise with in-situ machining, cold cast iron repairs, fusion welding and other specialisms support cost-effective repairs and modifications. They also give you priceless peace of mind and help protect your reputation as a steel industry professional. 26

Process
If you operate plant in the processing industries, youll be familiar with the range of machinery and the challenge presented by needing to meet production targets, work within ever-tighter operating budgets and upgrade equipment to stay competitive in cutthroat markets. From food to cement
From food manufacture to mineral processing, our skills and experience have provided an around-the-clock, around-the-globe lifeline to processing for nearly 70 years. Our ever-expanding range of specialist engineering services perfectly matches the diverse equipment repairs, maintenance and modifications in your industry. Heres some of the work we do: Tyre and kiln-support roller grinding. Orbital machining/grinding of shaft journals on crushers, ball mills and drives. Machinery bedplate milling. Gearbox line boring. Flange machining (all sizes). Girth wheel and crusher gear tooth replacement. Welding repairs to kiln tyres, support rollers and associated plant.

Heritage
As a custodian of our rich architectural heritage, do you face the challenge of preserving old structures and monuments with cast iron components? At Metalock UK, weve earned a reputation for our special understanding of heritage building and structure repairs. When a piece of history needs maintenance, you can count on our experience and specialist skills
Weve built our reputation on a complete service for cold mechanical repairs to cast iron and other metals as well as many other specialist engineering services.

Repairing cast iron heritage structures

Customers with needs like yours already rely on Metalock technology that was initially developed to revitalise invaluable (and often irreplaceable) industrial machinery. Now, the Metalock process is an invaluable tool for repairing and restoring cast iron heritage structures and components including these: Columns Balustrades Pilasters Main beams Copings Architectural sections Fixing locations Weve repaired some of Britains most treasured architectural features and structures some so special and sensitive that were not allowed to name them! From a 50-year-old postbox to Londons Albert Memorial or cast iron columns in Darlingtons historic covered market, were often the first call when the UKs architectural heritage needs repairs.

Bespoke solutions save you money

When we tackled in-situ recovery of a rotary steriliser shaft, our combination of orbital machining and thermal spraying halved the cost and duration of conventional shaft replacement. Ingenuity and innovation underpin our position as a leader in specialist engineering services for the process industries. And when Lafarge Cement challenged us to machine a 5.2m diameter base table, we designed a special machining rig. Its examples like these that endear us to demanding customers around the world.

Priceless peace of mind

As well as saving you time and money, our solutionfocused approach, 24/7 global responsiveness and decades of expertise deliver priceless peace of mind and help protect your hard-earned reputation.

Protecting architectural treasures

When centuries of craftsmanship and care have gone into classic structures or monuments, why take chances with their future? As well as saving time and money, our solution-focused approach, 24/7 responsiveness and massive experience gives you priceless peace of mind and helps maintain our rich architectural heritage for future generations.

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Industries Served
Marine & Offshore
What price do you put on time when vessels or offshore production facilities break down? Metalock UK specialises in rapid, high quality, in-situ repairs, preventative maintenance and upgrades that keep ships and offshore plant earning revenue Global service, 24/7
When marine crankshafts fail or engine bedplates need repair, well save you time and money by avoiding the cost and inconvenience of removal and replacement. Whether a vessel is docked or mid-ocean, our specialist service is available 24/7, around the world.

Power
With power generation infrastructure having such strategic importance, even small breakdowns can have massive implications. For decades, Metalock UK has helped operators keep power generation plants online helping them work more efficiently, and getting them back in operation as soon as possible when the worst happens Protecting your reputation in power
Are you facing the challenge of recovering a massive girth ring gearwheel, repairing worn blade slots, or an emergency casing rebore? Or perhaps you need retrofit upgrades to increase the efficiency of low-pressure steam turbines? Whatever specialist engineering services you need, weve probably got a technique to save you time and money, avoid removing plant to remote workshops and protect your reputation in power industry engineering: Line boring turbine casings for diaphragms, glands and seals. Steam inlet and outlet flange machining. Turbine joint faces. Casing stud removal. Tip grinding (rotary and fixed blades). HP and LP valve machining. Coupling-hole machining. Turbine-rotor journal machining. Remote-control machining in nuclear power stations. As well as using existing techniques, we regularly develop bespoke processes to address special challenges. Thats how weve grown and developed over nearly 70 years in business. And youre the one who benefits.

Avoid costly component replacement

Existing customers include QinetiQ, the Royal Navy and other high-profile marine and offshore operators. The common factor? They count on us for the highest quality in-situ workmanship. The repairs that, in one case, avoided a five-month wait for a replacement part and the associated loss of service and revenue. Our capabilities include these and more: Journal machining and grinding for crankpins and main bearings. Line boring for engines, stern tubes and A brackets. Rudder bore refurbishment. Optical and laser alignment. Upper and lower cylinder-liner landing sleeving. Coupling-hole machining. Engine mounting pads. NDT and hardness testing. Entablature and bedplates. Cylinder covers and liners. Turbo casings, generators, pistons, alternators, steering gear, windlasses and capstans.

Peace of mind at sea

As well as saving you time and money, our solutionfocused approach, 24/7 global responsiveness and decades of expertise deliver priceless peace of mind and help protect your hard-earned maritime reputation.

24/7 service in the UK and worldwide

Our convenient one-stop range of services, 24/7 global responsiveness and unparalleled sector expertise are the key to cost-effective repairs and modifications for strategically important power generation infrastructure. 28

Paper industry
If you operate plant in the paper industry, youll be familiar with the range of machinery repairs and the constant challenge presented by meeting production targets, working to tightly controlled operating budgets and upgrading equipment to stay competitive in competitive markets.
Traditionally, paper industry repairs rely on time-consuming strip-down and repair. Our skills and expertise (gained over several decades in the industry) now make in-situ repairs a cost-effective and reliable alternative when you must save time and money and get plant working again as fast as possible.

Petrochemicals
Metalock and the petrochemical industry have entered the twenty-first century together. From advanced grinding to emergency gearbox repairs in West Africa, all our departments have worked successfully with the petrochemical industry for decades. Thats why you can be sure well understand your special needs and meet your toughest challenges Trained for the worlds harshest industrial environments
From first enquiry to the moment the oil or chemicals flow again, you can count on a team thats trained to the highest levels the standards required to safely and productively deliver services such as these in the worlds toughest industrial environments: On-site machining Crankpin machining Shaft recovery Thermal spraying Electromechanical Casting repairs Precision alignment Machine shop services Thermal spraying

The benets of in-situ working Processes for the paper industry

Heres a selection of the work we can do for you: Grinding of drying cylinders. Grinding and hydrostatic debarking of drum tyres and thrust faces. Sleeving of damaged drying-cylinder journals. Calendar roll and frame machining. Line boring and milling of printing machine frames. Thermal spraying of cylinders. Whether were regrinding drying rolls or repairing your plant with advanced thermal spraying, we regularly complete jobs in a fraction of the time they used to take. The benefits for reduced downtime are obvious and the quality is the best. For complete peace of mind, we also offer related services such as pressure vessel reassessment before your plant re-enters service. Usually, well save you time and money by working on-site. Our in-situ repairs and upgrades regularly save customers time and money and protect hard-earned reputations in the field. Whether were designing and building a bespoke machine to regrind the bores of your extrusion plant, or avoiding the downtime of sourcing a non-stock replacement pump, were on call 24/7 from Coventry to Kazakhstan.

Protecting your reputation in petrochemicals

And of course, when return-to-base is the only option, our fully equipped workshops are strategically located for the highest quality, fast, convenient service. Whatever challenge you throw at us and whatever solution you choose, trust us to save you time and money, and protect your reputation in petrochemicals.

The benets of in-situ repairs

With so much at stake, it makes sense to entrust your repairs to acknowledged specialists. Imagine the time and costs involved in wholesale plant disassembly and transport to a workshop. Then imagine the time and money youll save when we complete your repair in-situ. www.metalock.co.uk | 29

Heritage
Metalock has become synonymous with a complete service for the cold mechanical repair of cast iron and other metals. Initially developed to give new life to invaluable and sometimes irreplaceable industrial machinery, the process proved highly successful.
Further research and refinement of the technique was undertaken which increased the scope of the process, most significantly in the application of repairs and restoration to cast iron structures. Much has been written about Britians industrial and architectural heritage, and in recent years the Metalock process has been used extensively and very successfully in restoring and repairing many famous landmarks and historic buildings, both large and small. We can carry out Metalock repairs on a wide range of items, including the following: Architectural castings Balustrades Beams Bridge columns Columns Copings Gutters and downpipes Gates and posts Pilasters Scan the qr code to view more case studies.

From top: High level Bridge, Newcastle, Ha penny Bridge, Dublin (photograph by infomatique), Metal stitching repairs on cast iron canal bridge. Right: Albert Memorial, London (photographs by Rev Stan, exfordy and Uli Harder).

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Case Study Albert Memorial

The 135-year old Albert Memorial standing opposite The Albert Hall in London has been recently restored to its former glory by English Heritage.
The memorial is constructed from elaborate cast iron sections, up to 75mm thick, clad in lead and decorated with bronze and mosaics. There is also wrought iron, early mild steel, copper and gold. The lead in places is 20mm thick. In the original design there was no provision for the lead to expand, and being constrained it buckled in hot weather.

www.metalock.co.uk | 31

Metalock Engineering UK Limited Unit H5 Pilgrims Walk Prologis Park Coventry CV6 4QG ENGLAND Tel: +44 (0) 2476 338205 Fax: + 44 (0) 2476 360190

sales@metalock.co.uk

www.metalock.co.uk

@metalockuk

Our LRQA certicates ISO 9001: 2008 for Quality Management ISO 14001: 2004 for the Environmental Management OHSAS 18001: 2007 for Safety Management Systems

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