WA Integra™

Hardfacing and cladding

ACTING GLOBAL
WELDING LOCAL for more resistant parts

Contents
Local service on a global scale
Integra products and solutions
Hand in hand with industry
Integra case studies
2 3
Local service on a global scale
The Welding Alloys Group is the world’s leading manufacturer of cored welding wires, automated
welding equipment and provider of specialist services for repair, rebuilding, cladding and hardfacing
components to restore parts or to improve service life.
WA Integra is an integrated part of the Welding Alloys Group specifically set up to support industries
that require wear control and performance optimisation.
Using the WA Integra hardfacing expertise on components that have been designed, manufactured
or used by its clients, the Welding Alloys Group can draw on its long term commitment to in-house
3 research and development, combining mechanical expertise and metallurgical technology.
4
5 Globally renowned for the quality of service we provide to industry from our workshops and on-site
6 operations, WA Integra provides a reliable and cost-effective engineering partner for local and
7 international companies alike, leading the way in advanced welding technology.
WA Integra
 Integra products and solutions
Specialists for repair, cladding
WA Integra have developed a unique level of expertise in cladding and hardfacing, whether and hardfacing by welding
in-situ or in our own Integra Service Centres. Our teams of highly experienced welding
engineers have mastered the deposition of noble alloys, with tried and tested processes Integra Solutions
using Welding Alloys cored wire and automated equipment. In partnership with the customers and according
to their specifications, Welding Alloys offers a
full range of services and several solutions:
However, Welding Alloys is not only a welding service supplier, our Integra engineers also Assessment and analysis of parts and their
work with our global research and development teams to produce specific products with working conditions; procedure’s development,
unique features and benefits. applications and measures control ensuring
high standard quality throughout the job.
Supply of our own designed long lasting and
reliable hardfaced components.
Integra Products Application of highly efficient cladding or
Composite wear plates hardfacing procedure with the use of
simultaneously operating fully automated
Integra Hardlite®: Abrasion resistant ultra
welding heads.
thin plates designed for applications where
weight or thickness is restricted.
Integra plates: A range of wear plates with Integra Resources
specific characteristics, satisfying most of Welding engineers, certified welders and
the demanding applications in an abrasive experienced teams.
environment. Strategically located fully equipped Integra
Manufactured parts from composite wear Service Centres with all handling facilities.
plates: Components and parts made of Multilingual personnel, able to intervene
Hardlite or Integra plates, cut, bent, rolled, rapidly in any worldwide location. Large
slotted, fabricated, assembled or welded. international teams can be built to cope
with exceptional demand.
3-DCarb™
Equipped with the latest Welding Alloys
A proven technology to substantially increase specialised welding equipment.
the service life of heavily wearing critical parts. Mobile Service Centres: work in-situ with
3-DCarb bulk deposits outlast conventional or without disassembly.
welded protection and castings in resisting Share of "best working practice" within the
against combined wear. Integra Service Centre network.
Integra Mill
Integra Guarantees
Integra Mill welding cored wires are specially
designed for hardfacing and re-profiling of Sole use of Welding Alloys controlled and
grinding components in vertical grinding mills tested consumables.
for raw, clinker, coal, blast furnace slag and Work performed according to procedure
other minerals. specification and qualification established and
controlled by qualified engineers. Application
Integra Mill products combined with Welding carried out by strictly supervised operators.
Alloys application technology are used with Control or non-destructive testing by external
outstanding results on rolls and tables of all certified or independent laboratory upon
types: improving the service life, grinding request.
efficiency and energy consumption. Follow up of results.
Advanced Components
Specially designed and manufactured
Integra Safety
machinery components for better productivity Operators trained and equipped for safety in
and longer service life. Fabricated and various environments.
hardfaced in our Integra Service Centres Training for specific safety certificates feasible.
according to a specified design, these Respect of the environment, elimination of
components incorporate the most advanced welding fumes and residues according to the
corrosion and wear resistance solutions. local legislation.
 version 2.1

Hand in hand with industry

Integra case studies

WA Integra engineers have built up a worldwide reputation in many industries. Manufacturers

of industrial equipment recommend Integra services as a result of the high quality welding
services provided and the superior components’ performance achieved.

Cement and Steelmaking Mining, earthmoving

building materials and metallurgical and construction
Vertical mills Sinter plants Quarry equipment
Roller presses Blast furnaces Crushers
Ventilators Converters Tunnel Boring Machines Pushing the limits in vertical
Ducts and elbows Continuous casters Concrete mixers mill hardfacing:
Chutes Rolling mills Dredging
Crushers Forging plants In cement, power or steel plants, vertical mill
Clay processing Foundries maintenance is associated with production
equipment losses during stoppage and restart of the
production. To reduce the dramatic effect
on downtime, WA Integra has developed
its own strategy: thorough work preparation
Energy and planning, use of multiple welding heads
and simultaneous welding of several
Turbines
components inside the mills. This maximises
Pulverised Coal Mills
the efficiency and the deposition rate,
Hammer mills
dramatically reducing the downtime period.
Ventilators
Boiler tubes
and panels

Other
industries
Oil and Gas
Food industry
Agriculture
Sugar plants
Petrochemicals
Raw chemicals
Pulp and Paper
Waste treatment Substantial reduction in
Glass industry
maintenance costs:

In a steel mill, on a sinter production line,

different components were failing rapidly
at different time intervals. After a thorough
analysis, Integra experts proposed several
actions to increase significantly the service
life of the most critical components and
improve the behaviour of the others. This
new maintenance program, with only one
World leading companies are relying upon stoppage per year, was implemented
resulting in a reduction in parts’ costs,
Integra for weld repair, cladding and hardfacing production downtime, energy consumption
and a gain in production.

6 7 WA Integra
 A perfectly controlled technology

WA Cored Wires™ WA MultiSurfacer™ WA Integra™ Services

Design and manufacture Design and manufacture Innovative hardfacing
of all types of cored of automated welding and rebuilding solutions
welding wires equipment for hardfacing by welding
and rebuilding applications

A worldwide presence
United Kingdom Greece South Africa
(Head office) Welding Alloys Hellas EPE WASA (PTY) Ltd
Welding Alloys Ltd
India South Korea
Argentina Welding Alloys Welding Alloys Korea Ltd
Welding Alloys Argentina S.A. South Asia Pvt Ltd
Spain
Australia (Trading Partner) Iran Welding Alloys España
Specialised Welding Products Pty Ltd Aliaj Joosh Iran
Sweden
Brazil Italy Welding Alloys Sweden
Welding Alloys Brasil Ltda Welding Alloys Italiana s.r.l.
Thailand
China Japan Welding Alloys (Thailand) Co. Ltd
Welding Alloys China Ltd Welding Alloys Japan

Photography by Caroline Hancox and Rémi Hondier

Turkey
Egypt Malaysia Welding Alloys Limited Şirketi
Welding Alloys Egypt Welding Alloys (Far East) Sdn. Bhd.
Ukraine
Finland Mexico Welding Alloys Ukraine
Welding Alloys Finland Oy Welding Alloys
Panamericana S.A. de C.V. United Arab Emirates
France Welding Alloys Middle East FZC
Welding Alloys France SAS Morocco
Welding Alloys Maroc Sarl USA
Germany Welding Alloys (USA) Inc.
Welding Alloys Poland
Deutschland GmbH Welding Alloys Polska Sp. z o.o. Vietnam
Welding Alloys Vietnam Co. Ltd.
Russia
ZAO Welding Alloys

www.welding-alloys.com

Welding Alloys Group 2010. WA Cored Wire, WA Integra, 3-DCarb and WA MultiSurfacer trade and registered marks and logos are the property of the Welding Alloys Group.