Case Study

Solution To Repair Instead of Replace Reduced Claim By $1.5M

 Fire Damage on Aluminum Casing Line 

Case Study

Fire Damage

Services Provided

Repair vs. Replace

Fire Damage on Aluminum Casing Line

The Situation

A fire ignited during resin tank repairs at an automotive casting plant, disrupting power and causing a high-production aluminum casing line to cool and solidify. The event halted operations and damaged pressure vessels and equipment that dated back decades, had been customized over time, and no longer had original equipment manufacturer support. Given the extended lead times required to build a new line, the facility needed a rapid, technically sound restoration strategy to meet production commitments.

Equipment Impacted

  • Casing Line

  • Resin Tank

  • Pressure Vessels

  • Supporting Equipment

Value-Driven Solutions

Restoration and Equipment Assessment

A comprehensive engineering evaluation was conducted to assess damage to the resin tanks, pressure vessels, and associated machinery and equipment. The assessment focused on determining whether highly customized and aging system components could be safely restored to pre-loss condition despite the absence of OEM support and unique production configurations.

 

Partnership and Recertification Planning

Collaboration was established with specialized restoration and pressure vessel recertification experts to develop a targeted rebuild plan. The restoration strategy included repair of tanks and mechanical components while ensuring equipment met operational and certification requirements to resume production.

 

Safety Compliance Integration

The restoration plan incorporated updates to electronics, pneumatics, hydraulics, plumbing, programming, and safety infrastructure to meet current code and operational requirements. Equipment layout modifications, including pressure vessel placement and enhanced system controls, were implemented to improve safety and long-term reliability.

 

Fire Damage on Aluminum Casing Line

The Results

Repair Over Replacement Strategy

Engineering analysis verified that the aluminum casing line and supporting machinery could be restored to pre-loss condition within the required five-month production timeline, eliminating the need for a full system rebuild.

Claim Cost Reduction

The repair strategy reduced the overall claim exposure by approximately $1.5 million compared to replacement costs associated with constructing a new production line.

Reduced BI and Production Recovery

The restoration and recertification efforts enabled production capabilities to resume more quickly than new system construction would have allowed, helping the facility maintain customer commitments and minimize operational downtime.

Case Studies

Real Claims, Real Results

Fire Damage on Aluminum Casing Line

Solution to Repair Instead of Replace Reduced Claim By $1.5M

Breakdown of CNC Machine

Repair vs. Replace Solution Reduces Claim By $600,000

Damaged Car Wash Systems

Reduced Claim by $32K

Damaged in Transit - Corrugated Box Making Machine

Missing seals and transit mishandling

Explosion at Condo Association

$1M+ in Equipment Retained Through Repair vs. Replace

Explosion at Ethanol and Ethanol Co-Products Plant

Claim Reduction Over $9M

Explosion at Ethanol and Ethanol Co-Products Plant

Reduced Claim By Nearly $6M

Explosion in Saturator Converting Line

Prevented $12 million in Business Interruption

Fire at Chemical Processing Facility

Lead Time and Reduction by Over $15M

Fire at Livestock Rendering Plant

Uncovered $4.5M in Betterments

Fire Damage at Concrete Batch Plant

Repair vs. Replace Significantly Reduces Claim Costs

Fire Damage on Film Line

Lead Time Cut by 14 Months, Reducing Costs by Over $1.5 Million

Fire Damage on Metal Processing Equipment

Reduced Claim Cost by over $700,000

Fire Damage with Healthcare Equipment

97% Reduction in the Claim

Fire in Electrical Control Systems

Reduced Claim by Nearly $1M

Fire Loss of Life Science Equipment

Reduced Claim Costs More Than $3.5M

Fire/Water Damage at Aluminum Beverage Can Manufacturing

Result in Reduced Claims Cost of Nearly $3M

Flood Loss at Indoor Water Park

Reduced Claim by $400k with Pre-existing Findings

Freezing Pipes & Water Damage In Boiler System

Solution to Repair Mitigates BI and Reduces Claim Over $85,000

Hail Storm at Manufacturing Facility

$11k Repair Instead of $800k Replacement

Lighting Surge at Packaging and Printing Facility

Restoring to Pre-loss Reduced Claim by $2.9M

Mechanical Breakdown at Gun Manufacturing Facility

Reduced Business Interruption by 14 weeks

Mechanical Failures on Horizontal Grinder

Identified Failures Stemming from Inadequate Repairs

Tornado Hits Agricultural Equipment Manufacturer

ROM Reduced by Millions with ILC’s Involvement

Water Damage at Chemical Feed Water Line

$1.6M Reduction in Pre-existing Conditions

Water Damage to MRI Machine

Medical Equipment Repair Costs Reduced by over $100,000.

Water Damage with Fire Pump System

Reduced Repair Cost by almost $4k

The Experts Behind the Best Outcome.

Submit an Assignment