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In October of 2001, Robinson Iron was authorized to proceed with the restoration and re-installation of Vulcan. The two legs, lower torso segment, anvil and two anvil support blocks were moved from Vulcan Park to Robinson Iron’s shop in Alexander City, AL on October 29th.

The first step in the restoration process was the removal of the old paint coatings. Since the old coatings contained lead, the removal process required the use of a masonry based coating called Pretox which was applied over the paint surfaces. When the old and new coatings were removed the resulting waste was rendered inert by the Pretox.

After cleaning the components were coated with a zinc thermal spray process. This process involved the application of molten zinc with forced air. An epoxy primer was then applied to the interior of the castings.

Crack repairs were accomplished by reinforcing the interior of the castings with stainless steel plates attached with thru bolts. The crack was then v-notched and welded on the outside with nickel rod. In many cases the cracks were so severe, a new iron casting had to be inserted.

Several new cast components were created for Vulcan in addition to the repair pieces. Robinson patternmakers created patterns for the spear, hammer and a cap for the head. These patterns were used to make sand molds into which molten iron was poured in the foundry.
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Vulcan's first "step" to a complete restoration. 40,000 pounds of Vulcan components loaded at Vulcan Park bound for Robinson Iron in Alexander City, Alabama. Vulcan components arrive safely in Alexander City. Marc Hadaway removes lead based paints from the anvil. Special protective clothing is needed to protect the operator from the lead paint chips as they are removed from the iron casting. A masonry based coating is applied prior to paint removal for abatement purposes.
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The removal of the old lead based coatings is a slow labor intensive process which must be conducted in strict compliance with Federal laws. The workmen wear disposable clothing for additional protection. Scott Howell inspects surface cleanliness on the lower torso segment and right leg in preparation for the next phase of the restoration process. Immediately after the components are cleaned they must be coated to prevent the formation of rust on the bare metal surfaces. Vulcan's anvil had a casting flaw which required repairs using stainless steel bolts. The bolts are installed by drilling and tapping into the casting surface below the flaw. A detailed look at the zinc thermal coating process shows the width of the spray pattern. The operator uses a special forced air hood for protection against inhalation of the zinc fumes.

A zinc thermal spray is being used as a first coating for Vulcan. The process involves molten zinc which is applied with forced air. The zinc provides increased protection for the cast iron and should significantly extend the life of the statue.