Careers Automated Field Weld Overlay
Extend equipment life and maximize operational reliability with IGS’s automated weld overlay solutions.
IGS delivers high-performance automated field weld overlay services to protect critical equipment in the world’s harshest operating environments. Our automated welding process applies a durable alloy layer that protects pressure vessels, columns, boilers, and other components from erosion, chemical attack, and high-temperature damage.
Comprehensive Overlay Capabilities
Our automated welding services are optimized for precision and efficiency in field environments, enabling the restoration and enhancement of critical assets without costly replacements.
-
Custom weld overlay protection for pressure vessels, towers, reactors, and other process equipment
-
Internal diameter (ID) nozzle overlay from 2″ diameter
-
Boiler waterwall protection for long-term thermal and corrosion resistance
-
Overlay solutions tailored for carbon steel, alloy steel, and other base materials
Technical Advantages
Our weld overlay cladding process offers unmatched reliability and performance in demanding industrial conditions.
Controlled Dilution: Achieve required chemistry as specified by industry codes and service conditions, ensuring overlay integrity and corrosion resistance
Minimal Distortion: Low heat input protects component geometry
Metallurgical Bonding: Superior adherence to the substrate
Process Consistency: Automated process and controlled welding parameters ensure uniform overlay thickness and quality
Versatility: Compatible with various base materials and overlay alloys
– Base materials: carbon and alloy steels, nickel based alloy, monel
– Overlay materials: SS 309L, 316L, 317L, 312, alloy 625, 622, and custom solutions
Field-Proven Applications
Our weld overlay process is designed to meet the corrosion, temperature, and wear challenges in critical equipment across multiple sectors:
-
Waste-to-Energy & Biomass Boilers: Protection against high temperatures, corrosive gases, ash particles, chlorides and sulfates corrosion
-
Refining & Petrochemical: Protection against naphtenics, H2S, CO2, HCl, MIC, and Ammonia, among others
-
Chemical Processing: Acid and erosion resistance
-
Pulp & Paper: Black liquor recovery boiler and continuous digester protection
Key Benefits
- Extended Asset Life: Significantly longer service intervals
- Corrosion Rate Control: Halt or drastically slow corrosion rates
- Reduced Maintenance Costs: Avoid premature equipment replacement and associated downtime costs
- Schedule Control: Field application expertise
- Quality Assurance: 100% inspection with UT, PT, MT, PMI, VT testing
- Global Experience: Projects completed in over 50 countries
- Turnaround Excellence: Specialized project management for critical path turnaround operations
- Accelerated Execution: Our thorough planning and preparations enable faster application with minimal delays
- Specialty Alloy Expertise: In-house laboratory testing and pre-qualification of high-performance alloys ensures optimal performance
WATCH VIDEO: Weld Overlay Technology
Our Welding Services
Extend asset life and safeguard critical infrastructure with IGS’s industry-proven automated welding services
- Automated Field Overlay
- Weld Build-up
- Speciality Welding
I’m here to help
Colin Bateman
IGS Subject Matter Expert
Why Choose IGS?
At IGS, we deliver measurable value through our proprietary technologies, fostering long-lasting partnerships built on efficient execution and excellence.
- Industry-Leading Technology: Proprietary Welding, Metalspray™, & HVTS® technologies ensure consistent quality
- Safety First: Industry-leading safety standards
- Trained Specialists: Full-time specialized workforce with extensive experience
- Proven Track Record: 40+ years’ experience across 500+ annual projects in 105 global locations
- Superior Project Management: Expert planning and execution that minimizes turnaround time
- Comprehensive Preparation: Our detailed planning process means we execute faster with fewer surprises
- Advanced Alloy Expertise: In-house laboratory for testing and pre-qualification of specialty alloys
Contact our team of experts to discuss your specific challenges.