Worn Drive Shaft Repair: Power Generation.

The Challenge: Worn Drive Shaft. Power Generation. 

A power generation facility identified significant mechanical wear on the end of a critical drive shaft. This degradation compromised the component’s original dimensions, placing equipment performance and operational reliability at risk. If left unresolved, the wear could lead to failure and extended downtime. Due to the long lead times and high capital cost associated with full replacement, the facility required an immediate, high-precision resurfacing solution to restore the shaft’s structural integrity. This worn shaft repair needed to deliver both durability and long-term reliability.

What is the solution for a worn drive shaft repair?

The repair was completed using Resimac 101 Metal Repair Paste, a high-performance, solvent-free epoxy system.
Surface preparation began by mounting the shaft on a lathe and scoring it to a depth of 1.5–2mm, creating an optimal mechanical key for adhesion. A bristle blaster was then used to achieve a consistent surface profile.
During application, the shaft was slowly rotated while the 101 Metal Repair Paste was applied using a plastic applicator. A wet-on-wet technique was used across multiple layers to prevent air entrapment and build the coating to a total thickness of approximately 3mm.
After curing overnight, the shaft was precision machined back to its original specifications. Aluminium-grade cutting tools and controlled machining speeds ensured a smooth, flush finish in line with strict industrial tolerances.

The results & benefits of the Resimac worn drive shaft repair.

Restored the shaft to its original dimensions and structural integrity.
Maintained reliable operation using a repair system trusted in global power generation environments.
Reduced costs significantly by eliminating the need for full component replacement.
Minimized downtime through fast application and curing times.
Extended component lifespan and reduced future maintenance requirements.

101 Metal Repair Paste used in Resimac solution for a worn drive shaft repair. 

A high-performance, solvent-free epoxy repair compound reinforced with metallic fillers, designed to rebuild and protect metal surfaces affected by erosion and corrosion. This two-component system can be applied to mechanically prepared or abrasive blast-cleaned substrates, delivering excellent adhesion and long-term durability. Once cured, the material can be machined to fine tolerances, making it ideal for precision repairs.
The thixotropic formulation allows application in thicknesses of up to 25mm without sagging, enabling high-build repairs in a single process.

Key Features of 101 Metal Repair Paste.

• Solvent-free epoxy technology
• Two-component system
• High build capability (up to 25mm)
• Excellent mechanical adhesion to metal surfaces
• Fully machinable to fine tolerances
• Suitable for application using standard applicator tools

Typical Applications for 101 Metal Repair.

Worn or damaged pump drive shafts.
Cracked pump or valve casings.
Scored hydraulic rams.
Worn bearing housings.
Damaged flange faces.
Leaking tank seams.
Worn keyways.
Cracked engine blocks.
Marine repairs (rudders, hulls, bow thrusters).
Steel plate bonding and cold bonding applications.

Sustainability Through Durability.

Protecting assets is not just about cost control, it is also about reducing environmental waste. Each time a pump housing or pipeline is repaired rather than replaced, the carbon footprint of your operation decreases. Resimac’s ceramic epoxy systems contribute to sustainable maintenance practices, reducing the frequency of component replacement and conserving valuable resources. By extending asset life, you’re also extending environmental responsibility, proof that industrial performance and sustainability can coexist.

Partnering with Resimac SA.

With decades of expertise in polymer engineering, Resimac SA does not just supply coatings, we deliver complete solutions. From on-site evaluations to product selection and application guidance, our team works alongside engineers to ensure that every project achieves the best possible outcome. We believe in protecting your assets, improving your efficiency, and building a more sustainable future. Ceramic epoxy is not just a coating; it is investment in operational resilience. By combining ceramic hardness with polymer flexibility, Resimac SA’s range of repair and protection systems delivers unmatched performance in abrasion, erosion and corrosion control. When downtime isn’t an option, choose Resimac SA; your expert partner in industrial asset protection and repair.