Restoring HVAC function in hours, not weeks.
At a university office building, an air handler supplying the HVAC system suddenly failed, leading to an urgent need for shaft repair. The maintenance team discovered that a bearing failure had severely damaged the shaft, causing the system to shut down. Without a functioning air handler, the building was left without heating or cooling, requiring a rapid in-place shaft repair to restore HVAC operation as quickly as possible.
Replacing the shaft wasn’t an option. The air handler’s location made access difficult, and a traditional shaft repair or replacement would mean taking the unit offline for weeks — something the university couldn’t afford. They needed a fast, reliable in-place shaft repair to restore HVAC function as quickly as possible.
With time and accessibility working against them, the maintenance team turned to Indcon for a solution. The Sylmasta Metal Repair Kit, featuring Titanium Supergrade HT Epoxy Paste, was chosen for its high-strength, heat-resistant properties and ability to restore metal shafts with minimal downtime. This approach allowed the shaft to be rebuilt on-site, avoiding costly part replacements and extended disruptions.
The Shaft Repair Process
The team began by preparing the damaged shaft. Grinding was used to remove debris and roughen the surface, creating the necessary profile for the epoxy to bond securely. A degreaser was applied to eliminate any oil or contaminants that could weaken adhesion.
Next, they created a custom form to match the shaft’s original dimensions. This form ensured that the repair would hold its shape as the epoxy cured. Before applying the repair compound, a release agent was applied to prevent the form from bonding permanently to the shaft.
Once the surface was prepped, Titanium Supergrade HT epoxy was mixed at a precise 3:1 ratio until streak-free for proper curing. The paste was applied inside the form to prevent voids, then spread onto the damaged shaft. Clamping the form tightly in place forced out excess material, ensuring a precise and durable repair.
After curing, the form was removed, and the repaired shaft was polished with emery cloth, restoring a smooth, functional finish. The new surface was strong enough to support the installation of a new bearing, effectively completing the shaft repair and returning the air handler to full operation.
The Results: Shaft Repair Completed in Hours, Not Weeks
Thanks to the Sylmasta Metal Repair Kit, what could have been a weeks-long shaft replacement was completed in just a few hours. The maintenance team restored the HVAC system with minimal downtime, keeping the university’s operations running smoothly.
This case highlights Titanium Supergrade HT as a high-performance solution for in-place shaft repair. When faced with severe shaft damage and no easy replacement, a strong, reliable epoxy system provided the answer — saving time, money, and unnecessary disruption.
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