The service life of wire ropes and chains, which are among the most valuable consumables on vessels, is directly dependent on the surface condition of the winch drums, sheaves, and windlasses they come into contact with. Wear, corrosion, and deformations that form on these surfaces over time cause the ropes to be crushed, their strands to break, and their structure to deteriorate, creating both enormous costs and serious operational safety risks. As İntermak, by reconditioning these critical surfaces with precision machining methods, we both protect your expensive ropes and chains and ensure the safe operation of your deck machinery.

Assessment and Disassembly: The process begins with the reception of the winch drum, rope sheave, or windlass part to be repaired at our workshop. The part’s surface is first inspected for cracks and structural damage using NDT (Non-Destructive Testing) methods. The rope grooves are then measured using special profile gauges to determine the existing amount of wear and profile distortion. Following the assessment, auxiliary elements on the part, such as bearings, are carefully disassembled in preparation for the machining process.

Analysis and Component Inspection: The measurement results and NDT findings are analyzed by our engineers to determine the repair strategy for the part. Based on the original groove profile required for the rope or chain dimensions, a decision is made on how much material to remove or whether excessively worn areas should be built up with welding. The goal is to restore the surface as close as possible to its original and ideal form while maintaining the part’s structural integrity.

Repair and Assembly: According to the approved work plan, the part is precisely mounted on a suitable machine tool, such as a lathe or boring mill. Our expert operators then proceed:

• Winch Drum and Rope Sheave Grooves: They are re-machined at the correct radius and angle to perfectly match the rope’s structure.

• Windlass Gypsy Wheel: The pockets and seats are cleaned and repaired to ensure the chain links fit perfectly.

• Warping Heads (Warping Ends): Notches and wear on their surfaces are turned down until they reach a smoothness that will not damage the rope. When necessary, these surfaces are restored to their original form through these processes after the application of hard-facing weld build-up.