Rebuilding of Thruster Gear Housing
Rebuilding of Thruster Gear Housing
Location
Rotterdam, Netherlands
Job and report done by
CC World Wide / Repair Management, NL
Wencon products used
Rapid, Coating White, Coating Blue, Cleaner, Application Tools
Corroded Thruster Gear Housing
In early 2011, a critical issue arose with the thruster gear housing of a vessel . The housing was severely corroded and damaged, threatening the operational integrity and efficiency of the thruster system. This problem, if not addressed promptly and effectively, could lead to significant downtime and financial loss for the vessel operator.
The Solution
Surface preparation
The unit was blasted to SA 2½ using sharp-edged blasting media, achieving a surface roughness of at least 75 microns.
The unit was then placed in a warm environment for 12 hours to allow salt to sweat out.
After this period, the unit was blasted again to SA 2 ½ to ensure a pristine surface ready for application.
Cleaning
Following the second blasting, the unit was cleaned thoroughly using Wencon Cleaner to remove any residual contaminants.
Damage repair
The depth of the damage necessitated the use of a brush to apply Wencon Rapid into the deepest holes and corners, ensuring complete contact with the metal surface.
Using a spatula, the housing was meticulously rebuilt layer by layer to its original shape. Wencon Rapid, known for its metal-like properties and excellent adhesion, proved highly effective in restoring the corroded and worn sections.
Corrosion protection
To prevent future corrosion, a two-layer system of Wencon Coating was applied.
The first layer was brushed on, followed by a second layer, providing robust resistance to oil, water, saltwater, and various diluted acids and alkalis. The coating’s heat resistance up to 250°C (482°F) added an extra layer of protection in harsh marine environments.
Final curing and finish
After curing overnight, the rebuilt gear housing was ready for final machining, drilling, and finishing touches.
The contact surface, which had been heavily damaged, was restored to its original shape and functionality.
Thruster Gear Housing Restored
The refurbishment process was completed successfully, resulting in a thruster gear housing that was not only restored to its original condition but also better protected against future corrosion.
The application of Wencon Coating ensured that the steel was effectively separated from seawater, mitigating the risk of bimetallic corrosion for many years to come. This solution proved to be highly cost-effective, offering significant savings compared to the cost of a new unit and minimizing operational downtime.
