Broken Base Bolt Extraction
A customer’s turbine sat offline for five years after its base fasteners broke 3–4 feet below the base flange — a repair they were told was impossible. The only alternative was a $175,000 retrofit involving multiple outside parties, with the broken studs buried under the tower door flange in a working space just 1.70 inches wide.
GEARED modeled the tower base in CAD, then designed, fabricated, and validated custom extraction tooling entirely in-house. The result: broken fasteners removed, turbine back in service, and over $100,000 saved for the customer.
Water Treatment Plant Tank Repair
During a planned maintenance outage, a water treatment facility discovered significant damage to its water distribution box requiring section removal and replacement — under a tight outage window, in a hazardous atmosphere, with difficult access to the work area.
Understanding the impact on local water supply, GEARED rapidly mobilized personnel, tooling, and resources. The team documented the damage on site, modeled the distribution box in CAD, fabricated replacement sections, and removed and replaced the damaged sections of the box and walkway — field measurement through final repair, all handled in-house.
Custom Drone Trailer Retrofit
A customer needed their drone trailer reworked to fit new operational needs. GEARED cut off the existing hitch and fabricated a new gooseneck from raw steel tubing — complete with wiring, 7-way connection, and epoxy paint finish.
The team then designed and built custom flight deck extensions, cutting, bending, and welding aluminum diamond plate into a second fold-out deck, and finished the unit with new decals. From structural fabrication to custom made decals, GEARED took care of the details.