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Failure Investigation & Root Cause Analysis

When equipment fails, the real cost is rarely the part itself; it’s downtime, lost production, safety risk, quality escapes, and repeated rework if the underlying cause is not properly identified. Failure Investigation and Root Cause Analysis (RCA) is a structured engineering process that determines what failed, why it failed, and what must change to prevent recurrence. At Barair Systems Limited we take an evidence-led approach: inspection, measurement, materials and loading review, and where needed, verification calculations or FEA to confirm the true failure drivers. The result is practical, implementable recommendations rather than speculation.

Typical problems we solve

  • A component repeatedly cracks, breaks, wears rapidly, or distorts in service
  • A welded fabrication fails at a weld toe, joint, or heat-affected zone (HAZ)
  • A shaft, coupling, bearing, or fastener fails unexpectedly
  • A structure deflects too much, causing misalignment, vibration, or secondary failures
  • A pipework or pressure-related assembly leaks, deforms, or shows local overstress
  • Failures occur only at certain operating conditions (temperature, speed, duty cycle, vibration)
  • The same “fix” keeps being applied but the failure returns
  • You need a credible technical explanation for internal reporting, insurers, or suppliers

How we work (step-by-step)

  • Initial triage and evidence preservation
    We clarify the failure symptoms, operating context, and ensure key evidence is preserved (failed parts, photos, logs, maintenance notes).

  • Site inspection and measurement
    We inspect the failed area, measure geometry, alignment, wear, and identify secondary damage or clues (fretting, corrosion, impact marks, overheating).

  • Define the failure mode
    For example: fatigue, overload, buckling, wear, corrosion, stress corrosion cracking, misalignment-induced loading, thermal effects, vibration resonance.

  • Review loads and duty
    We confirm what the component is truly seeing in service, including; shock loads, eccentricity, duty cycle, and operator practice.

  • Engineering verification
    We apply targeted calculations and/or FEA to validate stress, stiffness, bolt/weld utilisation, buckling risk, or contact pressures.

  • Identify the true root cause(s)
    Often there are multiple contributors (e.g., poor alignment + high stiffness gradient + weld detail + unexpected duty). We separate primary from secondary causes.

  • Recommendations and prevention plan
    We provide practical design/process changes that prevent recurrence, including verification of the proposed fix where appropriate.

  • Implementation support (optional)
    If required, we support redesign, supplier communication, retrofit design, installation planning, and verification of the corrected design.

Deliverables (what you receive)

Depending on scope, typical deliverables include:

  • Failure investigation report (PDF) with evidence, findings and conclusions

  • Clear statement of failure mode(s) and the causal chain

  • Supporting checks (hand calculations and/or FEA summary where appropriate)

  • Practical recommendations (design changes, material changes, weld detail changes, alignment/installation changes, maintenance changes)

  • Optional: marked-up photos / annotated diagrams to clearly show evidence

  • Optional: supplier-facing summary to accelerate corrective action and reduce disputes

What we need from you (inputs)

To run an effective investigation, we typically request:

  • Photos/video of the failure and surrounding assembly (before dismantling if possible)

  • Failed parts retained where practical (even fragments can be valuable)

  • Operating conditions: loads, speed, pressure, temperature, duty cycle, environment

  • Maintenance history, recent changes, and any abnormal events (jam, overload, impact)

  • Drawings/CAD if available (or we can reverse-measure critical features)

  • Details of materials, heat treatment, coatings, weld procedures if relevant

  • Any prior “fixes” attempted and whether the failure timing changed

Common failure modes (examples)

  • Fatigue cracking from cyclic loading, vibration, or stress concentrations

  • Overload due to shock events, unexpected duty, or incorrect assumptions

  • Buckling or local instability in slender parts or thin plates

  • Wear / fretting due to micro-movement, contamination, poor lubrication

  • Corrosion / erosion accelerated by environment or flow conditions

  • Thermal effects including differential expansion and loss of preload

  • Joint issues: bolt preload loss, slip, bearing failure, weld detail weaknesses

Related case studies

Typical deliverables

  • Evidence-led failure investigation report (PDF) with photos/measurements where required

  • Clear identification of failure mode(s) and causal chain (root cause vs contributing factors)

  • Targeted verification checks (hand calculations and/or FEA summary where appropriate)

  • Practical corrective actions to prevent recurrence (design, material, installation, maintenance)

  • Supplier/customer-facing summary to accelerate agreement and corrective action

  • Optional support through redesign, retrofit implementation and verification of the fix

Call to action

If you have a recurring failure, an unexplained breakage, or equipment that is not performing reliably, request a design review. We’ll take an evidence-led approach, identify the true root cause, and provide practical actions to prevent recurrence.

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