Restoring Precision and Strength – A Tension Rod Repair Success Story

In this case study, we highlight our expert repair of a wire tension rod, demonstrating how we transformed a corroded and damaged rod back to its original precision and structural integrity.

The Challenge: Battling Corrosion Pitting

Tension rods are crucial for transferring high levels of force over long distances, but when corrosion pitting occurs, it threatens their reliability. The wire tension rod in question had deep pitting that compromised its integrity and load-bearing capacity.

Our Solution: The Sterling Impreglon Approach

1. Precision Grinding – Preparing the Damaged Area

The first step was to carefully open the pitted areas, widening it but not deepening. Our goal here is precision—removing only the damaged material without affecting the rod’s structural foundation. By grinding strategically, we prepared the surface for the next phase of the process.

2. Brush Plating with Copper – Building It Back Up

We applied multiple layers of our Brush Copper Plating solution, meticulously building the damaged areas back to their original specifications. The controlled application allowed us to restore the rod without affecting surrounding areas, ensuring both the strength and uniformity of the repair.

3. Smoothing and Blending – Seamless Integration

Once the copper plating was complete, we blended the plated areas with the rod's original surface, ensuring a smooth, continuous finish. This is a critical step for both aesthetic and functional purposes, ensuring no weak points in the final product.

4. Nickel Capping – A Finishing Touch of Durability

The final stage involved capping the repair with our Brush Nickel Plating process. Nickel provides excellent wear resistance and enhances the overall durability of the rod, ensuring it can withstand the rigors of its operational environment for years to come. With Nickel, the plated area looks as good as the original condition.

5. Dimensional Accuracy – Ensuring Compliance with Specifications

After the repair was complete, we conducted a thorough dimensional inspection to ensure the rod was restored to the precise specifications required. Every measurement confirmed that the tension rod was not just repaired but fully rejuvenated, ready to perform like new.

🔧 Advantages of Sterling Approach:

🌟 Precision Quality at Scale: 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.

🎯 Exact Precise Restoration: Original dimensions, seamless blend, and precise alignment for optimal performance.

🛠️ On-Site Excellence: Our restoration process is portable and takes place on-site, minimizing downtime, costs, and logistical challenges.



Contact us: enquiry@sterling.com.sg or visit our website at www.sterlingimpreglonasia.com