preventive maintenance and repair
MERGER Gearbox Repair - Steel and Mining Industry
The interest of preventive maintenance
The steel industry is a particularly demanding environment for industrial equipment. Between dust, shocks, vibrations, and high temperatures, continuous pickling , cold rolling , continuous annealing , and coating lines must not only be reliable but also capable of withstanding extreme conditions. It was in this context that MERGER , a manufacturer and specialist in the overhaul, drop-in , and retrofitting of industrial gearboxes, was approached by a client to overhaul and repair three gearboxes . The repair work, carried out in Corbas ( 69 ), was completed in three weeks thanks to careful preparation and a precise determination of the necessary maintenance operations , conducted beforehand with the client at their production site.
Discover below these preventive maintenance operations , and how we previously carried out the visit to the customer for an analysis by endoscope , and a pre-identification of the parts to keep and those to change.
Customer context: Anticipate mechanical wear to avoid production line shutdowns
Avoid costly production downtime
Merger 's client operates in the steel industry , a sector where mechanical gearboxes and speed variators are constantly exposed to harsh conditions: pervasive dust, vibrations of varying frequencies, repeated mechanical shocks to the driven rollers, and significant temperature variations all accelerate equipment wear. In such an environment, gearboxes used for rolling mills , conveyors , and roller tables must be particularly robust and reliable. Therefore, their upkeep and preventive maintenance are essential to avoid costly production downtime.
The need: a precise diagnosis on each reducer and a tailor-made revision
On-site visit and endoscopy analysis
Before the intervention, Merger 's technicians conducted an on-site visit. Using endoscope analysis , they were able to precisely inspect the inside of the speed reducers , determine the wear level of each part, and identify potentially damaged mechanical components to establish an initial diagnosis . This analysis made it possible to define which parts should be retained and which should be replaced, ensuring a targeted approach that was both mechanically and financially efficient.
Complete overhaul at MERGER
Trials, tests and finishing
What other operations can merger perform for your reducers?
MERGER maintains production lines equipped with reducers of all sizes, types, brands and eras for its industrial customers.
We also carry out Retro-fit or Drop-in operations on MERGER reducers and reducers from other brands.
What other operation, besides repair, is best suited to your needs?
Repair, but also Retro-Fit and Drop-IN
RETROFIT
Retrofitting involves modifying or improving an existing system. It retains all or part of the original components while integrating technical improvements (e.g. changing gears, reinforcing bearings, adding modern sensors). Aimed at extending the life of the equipment and improving its performance, it often requires engineering studies and custom adjustments.DROP IN
Drop-in involves completely replacing a component or system with a new or equivalent model, designed to fit without major modifications. Often standardized or plug-and-play, it is ready to be installed directly. It does not require complex studies or specific modifications to existing equipment.Cost and complexity
RETROFIT
More complex and often more expensive in initial engineering, because it involves detailed analysis, custom design, and modifications to the existing system.
Ideal when existing equipment is still in good overall condition or difficult to replace completely.
DROP IN
Typically less expensive in terms of engineering, because the component is designed to be directly compatible.
The overall cost, however, can be high if the component being replaced is not standardized or expensive.
What needs or objectives?
RETROFIT
Allows the existing structure to be maintained while adapting it to new technologies or requirements (e.g. compliance with environmental standards such as ATEX).
Ideal for modernizing critical or specific equipment that cannot be easily replaced.
Helps optimize performance and improve energy efficiency or reliability.
DROP IN
Aim for quick and easy replacement.
Preferred solution when the existing system is irreparable, obsolete or when downtime must be minimal.
Does not necessarily change overall performance, but ensures continued operation.
80 years of expertise in installation AND repair of reducers, we work on many brands
Examples of reducer brands for which we work
- Brand of reducers from A to E
- Brand of reducers from F to L
- Brand of reducers from M to P
- Q to Z Reducer Brand
AEI (Associated Electric Industries)
ASEA
Baacke Gearbox
Benoni Engineering Works
Bonfiglioli
Bostock and Bramley
bour
Brevini Gears
BTH (British Thomson Houston)
Catep
CMD – Citroen Messian Durand
DAVID BROWN SANTASALO
Desch
EICKHOFF
ELLI
Falk Gears
Flender Gears
FOC Transmission
GEC Alstom Gears
GUIBE
Hamworthy Transmissions
HANSEN SUMITOMO
Hansen Transmissions
Hygate Transmissions
Jackson Gears
Jahnel Kestermann
John welsh
Kissling
The Stéphanoise
LUFKIN COMELOR
Maag Italy
mergers
Metropolitan Vickers
Metso Drives
Modern Wheel Drive
Motovario
Paramount Gears
PHB – Pohlig Heckel Bleichert
Philadelphia
PIV
Posiva
PUGLIA BROTHERS
Power Plant Gears
Push
Rauma Repola
Sadi Sala
Sauerwald
Sawa
Sonnerdale Richardson
Sumitomo Gears
Thovet
Turbine Gears
Valmet Power Transmissions
Vosgel
WECO
WIKOV
Worm Gears
ZF Gears