Careers Automated Field Welding Services
Extend asset life and safeguard critical infrastructure with IGS’s industry-proven automated field welding services. From weld overlay and weld build-up to complex structural repairs, our solutions are designed to restore pressure boundary integrity and protect assets operating in corrosive and high-temperature environments.
Our expert planning and execution minimizes turnaround time, achieving a 98.6% on-schedule delivery rate across 400+ global turnarounds.
IGS mobilizes globally to deliver automated welding services tailored to the most demanding industrial environments. From corrosion-prone pressure vessels to high-temperature boiler tubes, our advanced automated welding techniques ensure metallurgical integrity, controlled heat input, and long-term reliability.
Why Equipment Fails – and Where Welding Fits
Industrial assets fail due to a combination of corrosion, erosion, thermal fatigue, and wall thinning, often acting simultaneously under demanding operating conditions.
Corrosion & Erosion
Process environments containing H₂S, CO₂, chlorides, or high-velocity flow gradually degrade materials, leading to:
- Uniform wall loss
- Localized attack
- Sulfidation and erosion damage
Thermal Fatigue & Mechanical Stress
High-temperature cycling and constrained geometries introduce:
- Repeated expansion and contraction
- Stress concentration at welds and attachments
- Crack initiation and propagation over time
Loss of Pressure Boundary Integrity
As damage progresses, assets approach or fall below minimum thickness requirements (t-min), increasing risk of failure and unplanned outages.
Where Automated Welding Provides Value
Automated welding solutions are applied when assets require more than surface protection:
- Weld overlay → creates a corrosion-resistant alloy surface
- Weld build-up → restores wall thickness and pressure boundary
- Structural welding repairs → address cracks and fatigue damage
When to Use Weld Overlay vs HVTS® or Replacement
Selecting the right solution depends on the damage mechanism, integrity requirements, and operating conditions.
- Weld Overlay (WOL)
Used when both corrosion resistance and structural integrity are required. Suitable for restoring thickness and upgrading surface metallurgy in pressure-containing equipment. - HVTS® / Thermal Spray
Applied when corrosion protection is needed without structural repair. Ideal for extending life where wall thickness remains adequate. - Replacement
Required when the asset can no longer meet fitness-for-service (FFS) or minimum thickness requirements.
IGS follows an integrity-first approach – ensuring the pressure boundary is restored before applying any corrosion protection solution.
Our Capabilities
- Automated Weld Overlay: Combat corrosion and erosion in process equipment using metallurgically bonded alloys like stainless steel or Inconel. Ideal for high-pressure and high-temperature service exposed to H₂S or CO₂.
- Pressure Vessel Repair: Extend the operational lifespan of reactors, columns, and other pressure-bearing equipment with structural reinforcement and alloy upgrades.
- Boiler Tube Protection: Reduce forced outages in power generation by applying cladding to shield waterwall tubes.
- Specialty Welding: Complex repairs, section replacements or ID nozzle overlay? Our team adapts welding processes to suit the most challenging applications.
- Weld Build-up: Restore thinning wall sections and prepare the surface for long-term protection with weld overlay, HVTS® or other claddings.
- SIMOPS & Engineering Support: Combining FEA for distortion prediction, structural weld overlay as well as FFS capabilities with our weld overlay execution for asset life extension. Our experts ensure safe and flawless project execution and workforce coordination.
Weld Build-up & Surface Preparation
IGS offers weld buildup services to restore wall thickness, re-establish pressure boundaries, and prepare components for protective claddings, includding weld overlay and HVTS®. This automated process creates a metallurgical bond between the deposit and base metal, delivering structural integrity and long-term performance.
Field-Proven Alloys & Processes
We deploy best-in-class materials including Inconel (Alloy 625, C-276) and stainless steels such as 317L, selected through in-house testing and pre-qualification at our Technology Center.
These alloys are engineered to resist:
- Sulfidation
- Chloride-induced corrosion
- High-temperature degradation
- Thermal fatigue
Making them ideal for automated welding in critical components like distillation columns, boilers, and heat exchangers.
Meet Our Welding Experts
IGS brings together a global team of specialists in welding engineering, metallurgy, and field execution.
Each expert contributes to:
- Welding procedure development and qualification
- Metallurgical assessment and alloy selection
- Failure analysis and repair strategy design
- On-site execution and quality assurance
Industries Served
- Refining, Petrochemical & Agrochemical
- Power Generation: Waste-to-Energy, Biomass, Coal Power
- Metals & Mining
- Chemical Processing
- Pulp & Paper
- Agriculture
Our Welding Services
Extend asset life and safeguard critical infrastructure with IGS’s industry-proven automated welding services
Roger Matos
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 technologies, including Welding, Metalspray™, & HVTS® 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 objectives.
50+ Years of Asset Integrity
Since 1978, IGS has helped the world’s largest industrial operators extend asset life, reduce maintenance costs, and ensure safer, more reliable operations.