Case Studies

Case Studies

Witness real-life examples where our Brush Plating transformed mechanical components, breathing new life into these critical machineries. These examples not only showcase the versatility of our technology but also underscore its efficacy in restoring, enhancing, and extending the operational life of mechanical components across diverse industries.

To view our case studies. View us on a desktop / computer.

Case 1: Worn out Steam Turbine Casing

The steam turbine casing, a vital element in power generation, had weathered years of wear and tear. The toll of time had left its mark, compromising the performance and efficiency of this essential component. A full replacement seemed inevitable, but we saw an opportunity for a different outcome.

Restoring to Original Dimension

Carefully and meticulously, we rebuilt the worn-out areas on the steam turbine bearing and seal housing using copper plating. Our precision ensured that the original dimensions were faithfully recreated, guaranteeing a seamless fit and optimal functionality. Brush plating technology is portable due to its simple and compact design. The lightweight and versatile setup allows for easy transportation, enabling on-site plating and reducing the need for component disassembly, making it highly convenient and efficient.

A Brand-New Aesthetic: Nickel Capping

To complete the transformation, we applied nickel capping, giving the restored steam turbine casing a finish that was nothing short of brand new. The worn-out areas were now unrecognizable, replaced by flawlessly restored sections that exuded durability and aesthetics. The entire process took less than a week to restore it back to its pristine condition.

Why Choose Sterling Impreglon Asia?

time

Decades of Expertise

With roots dating back to 1989, our experience is your assurance of quality. 

time

Targeted Solutions

Our precision-focused approach ensures that only necessary areas are restored, saving time and money. 

time

Sustainable Future

Through minimized waste and energy efficiency, we contribute to a greener tomorrow. 

time

Diverse Applications

From turbines to marine components to oil tools connections, we elevate performance of your critical mechanical components across the varied industries.

Mooring Winch Installation onboard a marine vessel with 2 engineers wearing safety helmet survey the damaged area

Case 2: Mooring Winch

At the heart of maritime operations, components like mooring winches stand as sentinels of safety and efficiency. Mooring winches often secure the shipboard end of mooring lines, provide adjustment of the mooring line length, and compensate for any changes in draft and tide. Our latest work takes us into the depths of repair, where corrosion's aftermath meets Sterling Impreglon Asia's commitment to meticulous restoration.

The Challenge: Corrosion Pitting Strikes

When a mooring winch shaft arrived, its battle scars were evident – the telltale signs of corrosion pitting threatened its structural integrity. The very heart of secure mooring stood compromised, calling for an intervention that would restore not only the shaft but also maritime assurance.

Selective Intervention

We targeted the damaged areas, embracing precision in opening them up for the restoration process.

Expert Copper Plating

The damaged regions found renewal through brush copper plating, a testament to our commitment to structural revitalization

Hand-Blending Mastery

The art of hand blending followed, returning the surface to its original dimensions with seamless integration.

Aesthetic Finish

The final touch – nickel capping – presents an appearance as impeccable as its operational prowess.

The Sterling Impact

time

Critical Maritime Integrity

Our approach preserves the essence of mooring winches, ensuring they stand ready to secure vessels.

time

Precision Restoration

Each step is a promise of structural resurrection, minimizing downtime, reducing unnecessary costs, and optimizing function.

time

Global Maritime Reach

With a legacy spanning decade, our contributions extend across oceans and maritime industries.

Case 3: Armour against Galling

Oil tool connections, the lifeline of drilling operations and the oil & gas industry, are not immune to galling - a phenomenon where surfaces weld together under pressure and friction.


The repercussions are severe: compromised performance, costly repairs, and operational downtime. But why does it happen?

Understanding Galling: The Culprit and the Consequence

Galling occurs when two metal surfaces, often under extreme pressure, seize together and exhibit signs of adhesive wear.

The result? Increased friction, wear, and potential damage to the connection threads

Button

Surface Transformation

Brush copper plating creates a protective layer, preventing direct metal-to-metal contact. 

Enhanced Lubrication

The plated surface reduces friction and wear, fostering smoother operation.

Operational Efficiency

Oil tool connections treated with brush copper plating endure extended service life and reduced maintenance, resulting in cost savings and lesser downtime.

Case 4: Welding Spark Damage on Cylinder Rod

A dredger cylinder rod, spanning over 8 meters in length, was damaged by welding sparks. The task ahead was daunting as the repair had to be done on-site, but we were prepared to restore its functionality and aesthetics.

Adhesion Testing

The coating on the cylinder rod is a CEC 2.2 (Ceramax Engineered Coating). Adhesion test needed to be carried out before proceed of actual work. This cylinder rod was more than 8 meter in length (25ft)

Widening and Blending

We opened the affected section, preparing it for the restoration process

Precision Copper Plating

Our copper plating technique rebuilt the damaged areas using copper brush plating, preserving the original dimensions.

Dimensional and Level Check

A final inspection ensured precision alignment and adherence to original specifications.

Seamless Integration

The plated surface was meticulously blended to mirror the surrounding surface, ensuring a smooth transition.

Bringing Back the Shine

Nickel capping was the finishing touch, delivering an appearance that rivalled the rod's original condition.

Advantages of Sterling's Brush Plating Technology

time

Precise Restoration

Original dimensions, seamless blend, and precise alignment for optimal performance. 

time

Meticulous Attention to Details

No job is too large or complex for our team's expertise. Moreover, our stringent checks guarantee that the restored component meets the required dimensions.

time

Partner with Sterling Impreglon Asia

Whether it is marine components, heavy industrial machines, or beyond, our Brush Plating technology restores life to mechanical components. 

Case 5: Calender Roll Restoration

The calender roll, a true workhorse in industrial processes, applies continuous heat and pressure to shape, densify, smooth, and enhance the properties of materials. It is the driving force behind the quality and consistency of Polypropylene (PP) sheets and blocks. However, the relentless wear and tear over time took its toll on this vital component.

Brush Copper Plating

The first step involved grinding open the damaged sections, widening them to prepare for plating while ensuring the integrity of the roll's core structure.


We employed our renowned Brush Copper Plating technique to rebuild the damaged areas. This method guarantees precision and durability, ensuring that the roll performs at its best.

Meticulous Blending

Post-plating, we meticulously blended the rebuilt sections, smoothing them down to their original dimensions, ensuring seamless functionality.


The calendar roll underwent a final polishing process, enhancing its surface finish to meet the highest quality standards.

Final Polishing and Nickel Capping

To crown the restoration, we completed the job with nickel capping, not only ensuring structural integrity but also restoring its aesthetic appeal.

Precision Restored

The restored calendar roll now stands as a testament to Sterling Impreglon Asia's commitment to precision and excellence. It once again contributes to the production of top-quality Polypropylene (PP) sheets and blocks, ensuring reliability and consistency in manufacturing.

Case 6: Hydraulic Cylinders

In our relentless pursuit of excellence, Sterling Impreglon Asia recently undertook a transformative repair project. The mission: to breathe new life into a pair of hydraulic cylinders marred by corrosion pittings.


The hydraulic rods presented a significant challenge with deep corrosion pittings compromising their structural integrity. Sterling Impreglon's approach involved a meticulous process to restore the cylinders to their optimal condition

Grinding

We precision-ground the damaged areas, widening them for plating without deepening the existing pits.

This strategic approach ensured effective repair without compromising the integrity of the hydraulic rods.

Brush Copper Plating

Brush Copper Plating Excellence: Our proprietary Brush Copper Plating technique came into play, rebuilding the damaged areas with precision. This step is crucial to reinforcing the structural integrity of the rods.

Blending and Finishing

After plating, we seamlessly blended the repaired areas, ensuring a smooth transition from plated to original surfaces.


The final touch involved Nickel Capping, not just ensuring functionality but also restoring the aesthetic appeal of the hydraulic rods.

Dimensional Check

Quality is non-negotiable. Before concluding the project, a comprehensive dimensional check was conducted to guarantee that the repaired sections adhered to the requested measurements and tolerances.

Button

OUR STATISTICS

Over 500 customers satisfied with their renewed component

836

Repair Jobs Completed

275946

Oil & Gas Components Plated

148

Overseas Trainings Given

Reach Out a Specific Project? Let’s Talk About It

Contact Us

Share by: