HVOF Coating
For extreme abrasion in sediment-rich environments (e.g. glacial rivers)
Hydropower turbines face constant exposure to wear factors like sediment erosion, cavitation, and stress from extreme flow conditions. At Global Hydro, we develop cutting-edge shielding technologies to extend component lifetime, reduce maintenance needs, and optimize performance - combining advanced surface treatments, repair processes, and predictive monitoring into a single holistic strategy. Discover how our WearShield program supports your turbine from day one to decades ahead.
Global Hydro offers more than just surface coatings or repairs processes.
With WearShield, we offer an integrated protection strategy - developed, engineered, and applied entirely in-house at our Austrian headquarters. Every solution is based on years of operational experience, advanced materials expertise, and digital innovation.
The problem doesn’t start with failure - it starts when wear goes unnoticed or unaddressed.
Hydropower operators around the world face a shared reality: Sediment abrasion, cavitation, and mechanical stress are no longer rare events — they are daily operational threats. From glacial rivers carrying abrasive loads to ageing runners exposed to turbulent conditions, turbines wear down fast if not protected properly. The result: Loss of efficiency, increased repair costs, unplanned downtime, and shortened turbine lifetime.
Our approach is:
Holistic: From root cause to optimized surface
Modular: Solutions tailored to each turbine and location
Lifecycle-focused: Protection, restoration, and prevention – as needed
This allows us to maximize the durability, performance, and reliability of each component, from Pelton buckets to wicket gate rings.
Reinforced surfaces, advanced coatings, and wear-resistant materials protect your turbine components exactly where it matters.
Reduce maintenance effort, avoid premature replacements, and improve cost-efficiency across the board. WearShield delivers long-term value from day one.
Fast and flexible upgrades for existing plants. Our technologies often require no major design changes and can be applied with minimal downtime. Ideal for refurbishments and extending the value of installed assets.
Our Protection Solutions safeguard turbines and their components against the toughest operating environments. By combining advanced coatings, hardfacing, and surface treatments, we significantly reduce abrasion, cavitation, and structural wear. Each technology is precisely matched to the turbine type and site conditions, ensuring maximum durability, stable efficiency, and extended service life – even in sediment-rich, high-pressure, or turbulent flow situations.
Our Restoration Solution brings worn components back to peak performance – and often beyond their original specifications. Using reverse engineering, precision 3D scanning, and multi-layer cladding, we restore geometry, optimize hydraulic profiles, and reinforce critical surfaces. This approach is sustainable and cost-effective compared to full replacement, making it ideal for extending the lifecycle of valuable equipment.
Our Prevention Solution Hydrox SediSense is a combination of structure-borne acoustic sensors and artifial intelligence. We use data analysis to detect wear risks before they cause damage. With advanced anomaly detection, operators can plan maintenance proactively, optimize operating schedules, and protect turbines from sediment-induced stress.
The result:
longer component lifespan and
a smarter, more reliable hydropower operation.
Discover how our WearShield program can extend the life of your turbine, optimize performance, and prevent costly downtime.
Contact our experts today and find the perfect shielding solution for your plant.
Thierry Burckhart
Director Revitalization
+1 (970) 710 1285
thierry.burckhart@global-hydro.eu Contact
