9 8 4 1 2 5 3 6 7 11


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Breakages usually occur because of overloading, accidents, equipment misuse or flaws in the casting.


The illustration of the Metalock repair system, above, is a basic repair to a flat surface. Damage to more complex fractures and castings requires the Metalock Engineer to draw on his skills and knowledge in coping with both the difficulties of the component’s shape, its operation and its environment. This all has to be completed, often with a minimum downtime, frequently involving 24/7 working.


Whilst the tried, tested and unique repair system is a repetitive operation, the application is as varied as the plant and machinery for which it is designed. This extends from ship’s engines to power presses and petro chem refineries to heritage buildings.


Over the 75 years since the inception of the process, Metalock Engineering has developed special tools, jigs, fixtures and materials to facilitate the repair which enables the restoration of machines and structures to their owner’s satisfaction.


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The fracture, after a survey and report has been presented to the customer, is positioned, realigned, and firmly held together by special fixtures and clamps.


By the use of special Jigs, groups of holes are drilled across the line of fracture to the tool depth of the casting.


The Metalock Key is a multi-dumbell shaped section of highly ductile alloy, the size and length being selected to suit the type of fracture.


The holes are then joined by the use of pneumatic chisels to conform to the shape of the Metalock Keys.


Individual layers of Keys are inserted in the apertures and peened into a metal-to-metal condition, which becomes almost integral with the parent metal.


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Holes are then drilled along the line of the fracture, then tapped,


and filled with studs,


each stud biting into it’s predecessor, resulting in a pressure-tight join and restoring a rigidity to the casting.


A Metalock stud is an important aspect of the Metalock process, bearing in mind that pressure repairs are often required.


The studs are then run down till the heads shear, the remaining rough metal being removed by pneumatic chisels.


The whole repair receives treatment from hand grinders prior to it’s final coat of paint


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