Field Welding Repair for Damaged Excavator Bucket: Onsite Solutions That Save Time and Money

Excavators are the workhorses of construction, demolition, mining, and utility operations. The bucket—especially on a heavy-duty machine—is the point of impact, grinding, prying, lifting, and breaking. Over time, even the toughest buckets develop cracks, worn cutting edges, busted welds, or plate deformations. If not addressed quickly, these issues can lead to full bucket failure and lost production.

In this case study, we’ll show how Industrial & Mining Services (IMS) responded to an urgent service call for a cracked excavator bucket on a construction site outside Atlanta, Georgia. Our team mobilized, performed structural field welding, restored full function, and avoided costly replacement delays for the contractor.

Common Causes of Bucket Damage

• Repeated contact with rocky or frozen material
• Excessive prying or overloading
• Failure of prior welds or aftermarket plates
• Structural fatigue from long-term use
• Impact with hidden obstacles (e.g., concrete, rebar, boulders)

The Situation: Cracked Bucket on a 45-Ton Excavator

The client, a grading contractor in North Georgia, was using a Volvo EC480EL excavator for heavy excavation and trenching. After several weeks of hard ground conditions, the operator reported that the bucket was flexing and producing loud clicks during use.

A site inspection revealed:

• 24-inch crack along the side plate
• Hairline fractures near weld seams
• Metal fatigue on one ear
• Deformed heel plate area

IMS Response: Field Welding Excavator Bucket Repair

A certified IMS mobile welder arrived within hours with a full rig and performed the following services:

Step 1: Bucket Prep and Crack Evaluation

• Grinding, wire brushing, and cleaning
• Carbon arc gouging to expose clean metal
• Stop-hole drilling at crack tips
• Plate straightening with hydraulic jacks

Step 2: Structural Welding

• SMAW welding using E7018 rods
• Cross-pattern weld layers
• 3/8" reinforcement plate stitched on sidewall
• Hard-facing welds on cutting edge for abrasion resistance

Step 3: Final Inspection

• Visual and hammer-sound test
• Magnetic particle inspection
• Final grinding and rust primer coating
• Full load scoop and stress test performed onsite

Project Summary

Category	Detail
Machine Model	Volvo EC480EL (45-ton class)
Repair Time	~6 hours onsite
Replacement Cost Saved	$7,500+
Downtime Avoided	3–5 days
Reinforcement	3/8" steel plate, side wall

Why Field Welding Beats Replacement

• Same-day repair turnaround
• Lower cost than new bucket or shop repair
• Durable, long-lasting welds
• No need to remove the machine from site
• Certified, insured mobile service

Safety Protocols

• Fire watch on standby
• Welding shields and barriers in use
• Hydraulic lockout/tagout before welding
• Full PPE worn at all times

What Sets IMS Apart

• AWS-certified structural welders
• Fully outfitted mobile welding rigs
• Available for emergency dispatch 7 days a week
• Familiar with CAT, Komatsu, Volvo, Hitachi, and more
• Can reinforce with AR400/AR500 plate upgrades

Relevant Keywords This Page Targets

• excavator bucket crack repair
• field welding service for buckets
• mobile excavator repair georgia
• heavy equipment structural welding
• cracked bucket welding near me
• onsite bucket reinforcement
• excavator cutting edge repair
• excavator ear weld repair

Client Testimonial

“IMS was the only welding service that could come out the same day—and they fixed our cracked bucket without pulling us off the job. Quality work, great welds, no more flex.”
– Job Superintendent, Site Prep Co., Atlanta GA

Need Onsite Excavator Bucket Repair?

IMS offers fast, affordable, and certified field welding services for cracked or worn excavator buckets, loader arms, booms, and more. Our crews cover Metro Atlanta, North Georgia, and the Southeastern U.S.

Contact IMS today for bucket repair at your jobsite—get back to work fast with mobile welding you can trust.