Weld Overlay
Cladding Systems

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Cladding
for the future.

High-Performance Weld Overlay Cladding Systems

Ensure the safety and longevity of your pipelines, valves, and flanges with our state-of-the-art Weld Overlay TIG Cladding Systems. Primarily utilised in the oil and gas industry, weld overlay cladding is the ultimate solution to protect your pipelines, valves, flanges, and other containment vessels from corrosion and wear. At Key Plant Automation, we understand the critical importance of this process, and we offer cutting-edge solutions to ensure your application’s durability and performance.

Our highly versatile automated TIG Weld Overlay Cladding Systems are engineered to deliver exceptional results across various applications. Key Plant Automation specialises in manufacturing automated TIG welding systems for horizontal pipe cladding and vertical valve cladding systems.

Choose from CCS, VCS, HVCS, and PCS Models

Our comprehensive range of models includes CCS, VCS, HVCS, and PCS, allowing you to select the perfect system for your specific needs.

A hybrid weld overlay cladding system

Vertical cladding systems.

Weld Overlay for Valves, Flanges and Plates

For those seeking vertical cladding solutions, our systems incorporate a Column & Boom Manipulator with a Floor Turntable. Optionally, you can add a second turntable or welding positioner to maximise productivity. The manipulator is equipped with Heavy Duty Motorised Slides with 90 and 180-degree rotation options for attaching the welding wire feed unit. The Floor Turntable/Positioner also comes with a preheat option and an anti-backlash gearbox design.

We offer three models: CCS – Compact Cladding System, VCS – Vertical Cladding System, and HVCS – Hybrid Vertical Cladding System

Compact Weld Overlay Cladding System (CCS)

CCS Series

Compact cladding system mounted on a portable skid. Up to 1220mm diameter and 3000kg capacity.

Vertical Weld Overlay Cladding System (VCS)

VCS Series

Modular designed turnkey vertical cladding systems. Up to 1830mm diameter and 15,000kg weight capacity.

Hybrid Vertical Weld Overlay Cladding System (HVCS)

HVCS Series

Hybrid vertical cladding system for welding applciations both vertical and horizontal, at various angles.

CCS – Compact Cladding System

Our CCS Series is a complete turnkey package designed for compact cladding needs. It’s mounted on a portable skid-plate, making it easy to install and ready to weld within just 3-4 hours of delivery at your facility or workshop. This system is capable of weld overlay cladding using TIG hotwire, ensuring the protection and enhancement of various components in a variety of industries.

Key Features:

  • Portable skid-plate design
  • Quick installation
  • TIG hotwire technology
  • Suitable for components up to 1220mm in diameter
  • Weight capacity of up to 3000kg

VCS – Vertical Cladding System

The VCS is a modular turnkey package designed to meet vertical cladding requirements. It includes a heavy-duty column and boom welding manipulator, motorised slides, a KP1100 wire feeder, and a welding torch. You have the flexibility to choose from multiple welding floor turntables or tilting positioners, allowing you to optimise your specific application and workpiece requirements.

Key Features:

  • Heavy-duty column and boom design
  • Motorised slides for precision
  • Multiple turntable and positioner choices
  • Suitable for components up to 1830mm in diameter
  • Weight capacity of up to 15,000kg

HVCS – Hybrid Vertical Cladding System

Our Hybrid Vertical Cladding System (HVCS Series) is a modular turnkey package similar to the VCS Series, offering the same turntable and positioner options. However, the heavy-duty column and boom come with an innovative swivel function, providing you with the flexibility to weld applications both vertically and horizontally at various angles.

Key Features:

  • Versatile welding options
  • Swivel function for flexibility
  • Multiple turntable and positioner choices
  • Suitable for a wide range of applications

Horizontal cladding systems.

Weld Overlay for pipes

For horizontal pipe cladding needs, our PCS Series is a self-contained modular turnkey package designed for overlay cladding of internal pipes. We offer two standard models: PCS6 and PCS12, both capable of welding pipes up to 12.8 meters in length.

The Key Plant system includes a Hollow Bore Headstock with a clamping device and adjustable height support idlers to clamp and support the pipe. Our system can accommodate pipes ranging from 150mm upwards, normally up to a maximum of 600mm diameter, welding internally up to 12 meters in length. A motorised tractor unit handles welding spools with up to 4 welding wires for inconel and special metals on 2 welding heads, increasing production efficiency.

Pipe Cladding System (PCS)

PCS Series

Self contained pipe cladding systems, capable of welding up to 12.8m long pipes.

PCS – Pipe Cladding System

Our PCS Series is a self-contained modular turnkey package designed specifically for overlay cladding of internal pipes. Developed in close collaboration with our customers, this system is based on extensive experience to ensure efficient and precise pipe cladding.

Key Features:

  • Self-contained modular design
  • Ideal for internal pipe cladding
  • Available in 6m and 12m standard models
  • Capable of welding up to 12.8m long pipes

Full control.

KEY 1250 Touch Screen Controller

All our weld overlay cladding systems are controlled by a fully integrated touch screen PC controller. You can easily control machine functions via the PC or handheld remote pendant, with the flexibility to pre-set or adjust settings during the welding cycle. Our system provides display values, alarms, and system parameters through the Live Welder Display and Editor Functions to automatically clad multiple and cross bore options. Moreover, our online diagnostics, operation monitoring, and technical support through internet access enable remote maintenance.

Key 1250 Controller for Key Plant Automation Weld Overlay Cladding Systems
A Key Plant Automation VCS system at a customers facility
Inside view of internal pipe cladding
Inside view of weld overlay valve
Overlay welded pipe
A HVCS machine installation in action

The hot-wire approach.

Hot Wire Solution for Enhanced Weld Deposition

In the welding process, a pulse TIG power source and increased weld deposition are highly desirable. Key Plant recommends heating the filler wire before introducing it into the weld pool, and a separate power source offers a HOT WIRE solution as an alternative to the standard cold wire Tig.

A Key Plant Automation technical support engineer

Weld-ready expertise.

On-Site Installation and Training

Count on our expert Key Plant engineers to provide on-site installation and operator training. Our machines are supplied fully loaded with welding equipment and are set up, ready to weld.

Global reach.
Proven excellence.

Partnering with Key Plant Automation

Key Plant Automation boasts a wealth of experience, supplying industry leaders in cladding and offshore operations across the globe, including Europe, North and South America, Asia, and the Middle East. To date, we have successfully supplied over 180 weld overlay cladding system installations.