Plant Mechanical Equipment Repairs

Restoring Reliability and Uptime

Industrial processes depend on the performance and reliability of mechanical systems. When critical equipment fails, production stops and downtime costs rise fast. IAC’s Plant Mechanical Equipment Repair Services deliver rapid, expert-driven solutions that return your systems to peak operating condition.

With more than 35 years of field experience across industries such as cement, mining, biomass, steel, and power generation, IAC’s certified field crews and millwrights diagnose, repair, and rebuild essential plant equipment on-site or in our 500,000 sq. ft. fabrication facility. From rotary dryers and furnaces to conveying systems, fans, and dust collectors, we restore performance, extend service life, and ensure operational safety.

As both an OEM and EPC contractor, IAC combines engineering precision with practical field expertise providing a single-source solution for mechanical repairs, equipment optimization, and full-system restoration.

Comprehensive Mechanical Repair Capabilities

IAC’s Field Services team is equipped to handle complex mechanical challenges across the full spectrum of process equipment and systems. Whether restoring a single component or performing large-scale rebuilds, our crews combine OEM manufacturing knowledge with field-tested expertise to ensure performance, safety, and reliability.

Our Capabilities Include:

• Rotary Dryers & Drums: Trunnion alignment, tire resurfacing, shell replacement, and flighting optimization.
• Burners & Furnaces: Mechanical and refractory repairs, burner control tuning, and combustion optimization.
• Baghouses & Dust Collectors: Housing repair, hopper rebuilds, fan replacement, and ductwork modifications.
• Pneumatic & Mechanical Conveyors: Repairs for blowers, screw conveyors, bucket elevators, airlocks, and valves.
• Fans & Blowers: Shaft and bearing replacement, impeller balancing, and motor alignment.
• Structural & Support Systems: Steel fabrication, bracing repair, and integrity reinforcement.
• Custom Fabricated Components: Replacement of hoppers, chutes, and stack sections engineered for fit and performance.

With mobile crews and in-house fabrication resources, IAC performs repairs, replacements, and retrofits with minimal downtime keeping plants across North America running efficiently.

Diagnostic and Preventative Maintenance

Every successful repair begins with an accurate diagnosis. IAC’s field service technicians use advanced diagnostic tools and engineering insight to uncover the root causes of mechanical failures preventing repeat issues and improving long-term reliability.

Our assessment and preventative maintenance services include:

• Alignment and Balancing: Precision measurement of rotary equipment, trunnions, shafts, and fans to prevent premature wear and vibration.
• 3D Laser Scanning: Structural and dimensional analysis of drums, dryers, and ductwork to identify fatigue or misalignment.
• Vibration and Thermal Testing: Early detection of bearing wear, mechanical imbalance, or overheating components.
• Airflow and Pressure Evaluation: Systematic analysis of ducting, baghouses, and fans to confirm performance and efficiency.
• Equipment Performance Benchmarking: Comparing actual results against design criteria to optimize maintenance planning.

By combining data-driven diagnostics with proactive service scheduling, IAC helps plants minimize downtime, extend equipment life, and maintain compliance with safety and emissions standards

Repair, Replacement, and Rebuild Solutions

When critical components fail or equipment performance declines, IAC delivers turnkey mechanical repair and rebuild solutions tailored to your plant’s operating conditions. Our integrated teams combine field expertise, OEM manufacturing precision, and engineering support to restore productivity quickly and safely.

Core services include:

• Emergency Repairs & Rapid Response: 24/7 mobilization for unplanned shutdowns or component failures, minimizing production loss.
• Component Replacement: Fabrication and installation of new housings, shafts, trunnions, bearings, dampers, and valves to OEM or upgraded specifications.
• Equipment Rebuilds: Complete refurbishment of dryers, baghouses, conveyors, and fans for extended operational life.
• System Retrofits & Upgrades: Engineering-driven improvements to increase capacity, improve efficiency, and reduce maintenance frequency.
• On-Site & In-Shop Services: Flexible repair options at your facility or within IAC’s 500,000 sq. ft. fabrication plant for larger rebuilds.

Every repair is executed to industrial quality standards (ASME, AWS, and AISC), ensuring structural integrity and dependable performance under demanding conditions.

OEM-Level Expertise and Quality Control

As both an Original Equipment Manufacturer (OEM) and a full-service EPC contractor, IAC brings unmatched engineering precision and process insight to every mechanical repair project. This dual capability ensures that repairs not only restore equipment function but also return it to optimal performance levels—often exceeding original design standards.

Each repair is backed by rigorous quality assurance and traceable documentation, including:

• Detailed inspection reports and pre-/post-repair evaluations
• Engineering verification of materials, welds, and tolerances
• Conformance to ASME, AWS, and AISC mechanical and structural standards
• In-house fabrication for critical components to ensure exact fit and finish
• Start-up support and operational verification testing after installation

Our clients gain the confidence of knowing every repair meets IAC’s OEM manufacturing and quality benchmarks are the same standards used in our new equipment production and EPC system builds.

Lifecycle Support and Long-Term Reliability

IAC’s service philosophy extends beyond the repair itself. Our goal is to help facilities achieve lasting reliability and predictable performance across the entire equipment lifecycle. Following mechanical repairs, we offer structured support programs that combine maintenance, monitoring, and modernization to prevent future downtime.

Lifecycle services include:

• Preventative Maintenance Programs: Scheduled inspections, lubrication, alignment, and component replacement to maintain system integrity.
• Predictive Monitoring: Integration with IAC Smart Plant™ technology for real-time performance tracking and early warning alerts.
• Parts and Component Supply: Access to more than 55,000 OEM and replacement parts, ensuring fast turnaround for future maintenance.
• System Optimization Reviews: Post-repair audits to identify potential upgrades that improve energy efficiency, throughput, or emissions control.
• Training and Documentation: On-site or virtual instruction for maintenance staff on proper operation, inspection, and reporting practices.

By combining OEM parts, engineering-backed service programs, and data-driven insight, IAC provides a path toward sustained performance and lower total cost of ownership.

Partner with IAC’s Field Service Experts

When unplanned failures put production at risk, you need a partner who can respond quickly and restore equipment performance with precision. IAC’s Field Services team brings the mechanical expertise, troubleshooting capability, and safety-first execution required to keep your plant running reliably. If you need immediate repair support or want to schedule a planned outage, our team is ready to help.

Tell us what you need, and we’ll get your plant back online.

Request More Information