ECRS

Kilns

8ft diameter Kiln Tire Roll

survey of damages
This roll developed a crack at a location just to the inside of the tire contact surface. The cracking was present at over 3/4 of the circumference of the roll. This damage created a serious problem in the structural integrity of this piece. Because this roll is part of the support structure of the enormous kiln, this problem was addressed immediately.

FEA analysis
ECRS engineers performed a finite element study to try to ascertain the cause of the cracking found in the roll. A 3-dimensional model was constructed and subjected to the appropriate loading. The results of this analysis showed a high stress area at the precise location that the cracking was present. This suggested that the crack initiated under normal operating conditions.

repair procedures performed
The entire length of crack was repaired using metalock® and metalace repair components. This restored both tensile and compressive strength back to the plane of cracking. After our repair was complete, the kiln immediately returned to service.

Thrust Roll

survey of damages
Circumferential cracking had developed in this kiln thrust roll. The cracking was just to the outside of the center hub. The crack extended around the entire circumference of the piece.

FEA analysis
Finite element analysis was performed to help determine how high the stresses were that caused this cracking. This helped in our design of the appropriate repair. Notice that the highest location of stress is at the exact location of cracking.

repair procedures performed
The entire length of crack was repaired using metalock® and metalace repair components. There were also masterlocks incorporated into the repair to provide additional strength. The repair restored tensile strength back to the plane of cracking. After our repair was complete, the kiln immediately returned to service.

Kiln Tire Bearing Housing

The kiln which this bearing housing supported suffered a wreck due to the failure of a tire. The wreck caused severe damage to this bearing housing. The housing was broken into pieces. The repair of this housing was the critical path in returning the kiln to service. For this reason, we worked an emergency overtime schedule. Metalock technicians were able to repair the housing and return it to service in less than 20 hours. Below are before and after pictures.