How to Repair a Worn Shaft with a Forming Technique


Shaft Wear and Damage

Shafts are a critical component of rotating equipment. Shafts are used to transmit power from one part to another or from a machine that produces power to a machine that absorbs power. Shafts are usually operated in immersed or semi-immersed conditions and are subject to damage by corrosion or chemical attack. In the mining industry, shafts can become worn or damaged due to vibration, friction and abrasive media. In the marine industry, gland packing and bushing damage to the shaft together with sand abrasion and seawater exposure can lead to erosion-corrosion on shafts. Additionally, oversized keyways, a crucial component that connects the rotating equipment to the shaft, may cause shaft dysfunction. Worn and damaged shafts can shut down the entire machine. Therefore, worn shafts may hamper or halt production and result in revenue loss.

Shaft wear
Worn bearing seat area of blanching machine shaft

Conventional Shaft Repair Methods

Worn and damaged shafts are conventionally repaired using a hot process (welding/machining or hot metal spray/machining). If not carefully controlled, these conventional methods will cause residual damage to the shaft. They also require the disassembly of the machine. There are problems associated with welding and thermal spraying. Welding can create heat stresses that will tamper and distort the metal, lowering its load-bearing capacity. Metal spraying can only be used to repair damage up to a few 1000s of an inch. These problems and limitations can be avoided by using a combination of polymer technology and proven Belzona application techniques.

Worn shaft repair
Shaft repaired using the Belzona Solution

Belzona Shaft Wear Solution

The problems and limitations of conventional methods like metal spray shaft repair can be avoided by using a combination of polymers and proven Belzona application techniquesBelzona 1000 series polymers provide cold-applied repair solutions, which can often be carried out in situ. Thus, downtime and production costs that can be incurred are minimized.

The Belzona solution requires that a surface be prepared to achieve a rough, irregular profile. The product is then easily applied with simple hand tools and allowed to cure. Since Belzona paste grade compounds are heat sensitive, the entire curing process can be accelerated by adding heat to the repaired surface. This helps reduce your repair time and allows the shafts to quickly return to service, thus minimizing downtime.

Illustration of the repair of a Worn shaft
Worn Shaft Repair Using a Former and Belzona 1111

Watch our worn shaft repair

For this repair, we used Belzona 1111 (Super Metal), a pre-fabricated stainless steel former, Belzona 9111 (Cleaner/Degreaser), Belzona 9411 (Release Agent), and a few tools from our machine shop.  First, we cleaned the repair area, applied release agent onto the internal surface of the former and the area surrounding the repair area. Next, Belzona 1111 was thoroughly mixed and applied onto the internal surface of the former and the repair area of the shaft, forming a peak towards the center. Then, the former was clamped around the shaft and secured in place with fasteners. Exuded product was carefully removed.  Once cured, the former was removed and the repair area was smoothed out with an emery cloth to eliminate any sharp edges.



  1. Cleaning The Worn Shaft

    Thoroughly clean the area to remove all the grease, dirt and other surface contaminants.Shaft repair cleaning

  2. Undercut The Shaft

    l grinder fitted with a suitable disk to undercut the shaft by 1/16″ (1.5 mm) around the circumference.Shaft grinding

  3. Degrease The worn Shaft

    Clean the prepared area with Belzona 9111 (Cleaner/Degreaser) to remove all surface contaminants.Shaft cleaning

  4. Apply Release Agent

    Apply Belzona 9411 (Release Agent) to the internal surface of the former.Belzona mold release

  5. Apply Release Agent to the Damaged Shaft

    Apply Belzona 9411 (Release Agent) to the area surrounding the repair areaBelzona release agent

  6. Mix Belzona 1111

    Thoroughly mix Belzona 1111 2-part epoxy paste for metal repair until a uniform color, free of any streakiness, is achieved.
    Mix Belzona 1111

  7. Wet Out Former

    Apply a thin layer of the mixed Belzona 1111 on the internal surface of the former.

  8. Firmly Apply

    Apply a thin layer of the mixed material onto the shaft, pressing down firmly into the roughened profile.Apply Belzona 1111

  9. Form a Peak

    Form a peak towards the center of the application area.

  10. Position Shaft Former

    Position the former around the shaft.
    Belzona shaft former

  11. Clamp Shaft Former

    Secure the former in position with fasteners ensuring that the excess material is extruded from the ends of the former

  12. Remove Excess

    Remove excess material and allow the applied material to cure.Belzona shaft repair

  13. Remove Former

    Once cured, carefully remove the bolts and the former.Belzona shaft former removal

  14. Smooth Down

    Smooth out the surface of the application area with an emery cloth.Sand belzona 1111

Belzona’s epoxy solutions can be used to repair worn shafts. Belzona also offer solutions to an extensive range of engineering problems and repair situations.

Interested in purchasing Belzona’s epoxy-based composites?

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This Post Has 18 Comments

  1. Tracy

    In-situ repair solutions are cheaper, innovative, and efficient. Well done!

  2. Alexander Murillo

    Dear Mr. Fernando,

    Yes I believe its possible to rebuild and then machine down to size, in a way thats what they have been designed for. We recommend that you contact a local Belzona Distributor for them to assess the conditions of the repair area and make the right recommendation of the solution. You can find a Belzona Distributor in your area by using this link: or let us know where you are located and we will send you contact information.

  3. Lionel Fernando

    Is it possible to repair ductile cast iron SG EN-GJS-400-15? We have to repair bore of butterfly valve stem. Butterfly valve body material of the valve body is ductile cast iron SG EN-GJS-400-15. After repairing the bore it should machined to get the required bore size. Is it possible to machine the repaired surface with Belzona?

    1. Yulia Burova

      Dear Mr. Fernando, thank you for contacting us! One of our engineers will get back to you shortly.
      Best regards,

  4. Randy

    Hello, I have an issue where the Bearing froze on a basket shaft for a washing machine. The part is not longer available. The inner race wore the shaft down approximately .035″ radially. The bearing fit is too loose to put the machine back into service. Since there will be a load in the area of repair, do you think that your product will withstand the pressures exerted in this particular area where the bearing sits? Thanks and much appreciated.

    1. Yulia Burova

      Thank you for your question! We have passed on your inquiry to our Technical Department. Best regards, Belzona

  5. Pete Stan

    howdy from El Paso Tx. We have a Minster 60-ton metal stamping press. On the crankshaft in the area of the flywheel there is 2 roller bearings that has been metal sprayed and is failing. we need to repair that to bearing fitment 3.937″. there isn’t any real abuse happening there, it just needs a good true fit. re; minster cfc 22 clutch

    1. Yulia Burova

      Hello Mr. Stan,
      Thank you for your question!
      We recommend that you contact a local Belzona representative for your area. Here is the company’s contact information:
      Danco Technologies, Inc.
      PO Box 6576
      Abilene, TX, 79608, United States

      Please feel free to let us know if you have any other questions at all.
      Best regards,
      Belzona Team

  6. Alexandre

    Dear Yulia Burova,

    We want to use Belzona product to repair a worn shaft of wind generator, do you have any case off successful application for wind industry?


  7. Peter Pompey

    After repairs can these shafts in the case of a mature run at 5000rpm

  8. rashel

    hi. I have shaft with 2 inches diameter. Material is 410 AISI and 1400 rpm can I use this type of your product? Please help me?

    1. Yulia Burova

      Dear Rashel,
      Thank you for the question and reading our blog!
      We have a few case studies that you can review as they feature the repair you are interested in:

      If you follow the procedure outlined in this post as well as Belzona’s Instructions for Use for Belzona 1111.

      Please feel free to let us know if any further questions.
      Best regards,
      Belzona Team

  9. sathya narayan

    I have a worn out chrome zirconium copper shaft which has got worn out,the area which has worn out is subjected to high current transmission of 12000a and heat,similar to a carbon contact brush,the only difference here being the stationary shoe is silver pad.
    Please let us know if belzona has a solution/product for this repair

    1. Yulia Burova

      Dear Sathya Narayan,

      Thank you for your inquiry!
      We will need to have more details of the operating conditions to give you an answer. Please fill out this form so one of the Belzona representatives in your area can contact you to assist you with the inquiry:
      Best regards,
      Belzona Team

  10. Pingback: Shaft Repair Using Injection with Belzona 1321 and a 3D Former

  11. Luc Brazeau ing

    how can we fix only a zip cut mark on a shaft when remouving a coupling or a trouche nic when flame cutting the coupling hub?

    Any sugestions?

    1. Yulia Burova

      Dear Mr. Brazeau,
      Thank you for your question.

      Belzona has many applications that are repeated on a regular basis. We make these applications in to application system leaflets and they show clients how to complete the work step by step. From your question I think the application system leaflet MPT-03 Repairing a scored shaft / hydraulic ram would be a good starting point.

      Please share with us where you are located or fill out this form so our local office could provide this information to you and any further assistance you may need.

      Belzona Team

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