The Problem with Conventional Repair

Most industrial facilities address equipment wear through temporary fixes — welding patches, replacing worn plates, or running equipment to failure. These approaches create a cycle of recurring downtime, escalating repair costs, and unpredictable production losses.

The conventional weld-and-patch method provides only short-term relief and does nothing to address the root cause of wear.

Documented Results

• 3x to 5x increase in equipment working life vs. conventional repair
• Significant reduction in recurring repair frequency and downtime
• Measurable improvement in output capacity and operational reliability
• Full documentation of before/after performance metrics
• In-situ application — no need to remove components to workshop

What Turnkey Means for You

Strategem takes single-point responsibility for the entire scope — initial engineering design through procurement, fabrication, civil construction, erection, automation integration, and final commissioning. You receive a fully operational system, ready to run.

No sub-contractor management. No coordination gaps. No partial handovers. One contract, one team, one outcome.

• Mechanical engineering design and fabrication
• Electrical engineering, wiring, and panel integration
• Automation, PLC, SCADA, and instrumentation
• Civil & structural work at site
• Equipment re-erection and precision alignment
• Capacity enhancement and process optimization
• Final commissioning, load testing, performance sign-off

Project Management Standards

Every project is managed to strict quality, safety, and timeline standards. Our project managers use structured work breakdown, milestone tracking, and documented quality checkpoints at every phase.

The Case for O&M Outsourcing

Managing in-house maintenance teams for complex industrial equipment is expensive, technically demanding, and increasingly difficult as equipment becomes more sophisticated.

Strategem's O&M outsourcing model transfers this burden to a specialized engineering team — allowing your organization to focus entirely on production while we ensure equipment availability and reliability.

• Planned preventive maintenance scheduling and execution
• Breakdown response and rapid repair using proprietary technologies
• Condition monitoring and predictive maintenance implementation
• Spare parts management and procurement optimization
• Trained on-site engineering workforce
• Performance reporting, KPI tracking, and uptime guarantees
• Application of Weld Paste, OTR Care & fluid management products

O&M Contract Models

Strategem offers flexible engagement models to suit different operational contexts.

Why Furnace Upgrades ROI

Furnaces and boilers in heavy industry operate continuously under extreme thermal and mechanical stress. As they age, efficiency degrades — fuel consumption rises, output falls, and safety margins narrow.

Strategem's furnace aftercare team works with clients to quantify the exact payback period for targeted upgrades, delivering energy savings and extended component life that far outweigh the investment cost.

Upgrade Services

• Replacement of fuel-inefficient combustion systems with high-efficiency alternatives
• Pulse firing schemes and self-recuperative burner systems
• Energy efficiency control and monitoring upgrades
• Furnace lining enhancement for improved thermal retention
• Process modification for increased productivity or process change
• Health & safety compliance upgrades for aging installations
• Uplift and relocation of existing furnace plant
• Engineering studies and site investigations for future upgrade planning
• Retro-fit projects for existing Strategem and third-party furnaces
• Automation, process control, and data logging integration

The Mining Challenge

Mining operations run around the clock under punishing conditions. HEMM, conveyor systems, crushing equipment, and coal handling infrastructure are subjected to continuous abrasion, erosion, and impact — making them among the most maintenance-intensive assets in any industry.

The cost of unplanned downtime in a mining operation can reach hundreds of thousands of dollars per day. Conventional repair approaches — weld patching with MS plates, temporary rubber linings, reactive replacement — provide only short-term relief. Strategem ends this cycle.

Our Mining Solutions

• Weld Paste P-6064 applied to all high-wear impact, erosion & abrasion zones
• OTR Care — scientifically engineered repair of Off-The-Road tyres (KAVLAR Technology)
• Life enhancement of HEMM: Draglines, Shovels, Dumpers
• Coal Handling Plant (CHP) modernization and revamp
• Crusher, feeder, roller, apron feeder, and flap gate revamp
• Chute liners and transfer point protection
• Stacker-Reclaimer modernization
• Fluid management: hydraulic & transmission oil purification

The Cement Maintenance Challenge

Cement manufacturing equipment operates under extreme conditions — high temperatures, continuous abrasion from clinker and raw material, and the relentless mechanical demands of grinding operations.

When a Bowl Mill or VRM goes down for liner replacement or roller segment repair, the entire production line stops — at significant cost. Strategem's solutions eliminate this cycle.

Cement Solutions

• Vertical Roller Mill (VRM) revamp — table, rollers, separator, housing
• Bowl Mill revamp using Weld Paste P-6064 technology
• Crusher revamp — cone, jaw, impact and hammer mills
• Stacker-Reclaimer modernization and life enhancement
• Conveyor belt repair and material handling upgrades
• Anti-corrosive glass flake coating for storage vessels and silos
• Fluid management — hydraulic oil purification systems
• Kiln and pre-heater furnace efficiency upgrades

Steel Plant Engineering Challenges

Steel production demands continuous, high-intensity operation of complex, expensive equipment. Any unplanned outage in the steel value chain triggers immediate production loss and costly recovery — maintenance strategy in steel is not just an operational issue but a strategic one.

• Blast Furnace revamp and life enhancement
• Sinter Plant and Coke Oven Plant modernization
• Mill Section (Hot & Cold Rolling) revamp
• SMS (Steel Melt Shop) equipment upgrades
• Material Handling systems modernization
• Furnace efficiency upgrades and combustion system replacement
• Anti-corrosive glass flake coating for structural protection
• Hydraulic oil purification using Fluid Management System

Application Scope

Why Power Plants Need Strategem

Downtime in a thermal power plant is exceptionally costly — both in terms of lost generation revenue and penalties under power purchase agreements. Every hour a Bowl Mill, boiler tube bank, or CHP conveyor is offline represents tens of thousands of dollars in losses.

Yet conventional maintenance in most power stations remains reactive. Strategem changes this paradigm by applying scientifically engineered solutions that dramatically extend component service life — preventing failures before they happen.

Power Plant Solutions

• Bowl Mill revamp — table segments, rollers, classifiers using Weld Paste P-6064
• Coal Handling Plant (CHP) — complete revamp including conveyors, chutes, transfer points
• Reclaimer & Stacker modernization
• Wagon Tippler revamp and life enhancement
• Boiler tube repair and protection using Weld Paste technology
• Turbine maintenance support and component protection
• Complete plant overhaul management
• Fluid management — turbine oil and hydraulic oil purification

A Specialist Capability

Strategem is one of the few companies in Asia with documented OEM-certified capability to revamp and modernize ship unloaders and port cranes from major manufacturers including ZPMC, TRF, FL Smidth, and Terex.

We take full turnkey contracts covering mechanical, electrical, and automation scope — with minimal operational disruption during modernization works.

• Ship Unloader revamp — full mechanical, electrical & automation scope
• Port Crane revamp — grab cranes, jib cranes, gantry cranes
• Material handling system upgrades — conveyors, hoppers, transfer points
• Anti-corrosive glass flake coating for marine environment protection
• Structural steel inspection, repair, and reinforcement
• Electrical and control system upgrades
• Hydraulic system refurbishment and fluid management

Port Clients & OEM Partners

The Petrochemical Corrosion Challenge

Petrochemical plants, refineries, and offshore installations operate in among the most chemically aggressive environments in heavy industry. Exposure to hydrocarbons, acids, sulfur compounds, saltwater and high temperatures creates a relentless attack on structural steel, storage tanks, vessels, and piping systems.

Corrosion in petrochemical facilities is not merely a maintenance issue — it is a safety-critical concern with direct implications for process integrity.

• Anti-Corrosive Glass Flake Coating for storage tanks, vessels, and structural steel
• Wear-resistant coating for abrasion-prone petcoke and mineral processing equipment
• Off-shore platform equipment revamp and life enhancement
• Conveyor and material handling system modernization
• Fluid management — oil purification for hydraulic and process systems

Application Scope

What is Weld Paste P-6064?

Strategem's flagship proprietary product — a scientifically developed, high-performance repair and protection compound engineered for industrial equipment subjected to severe erosion, abrasion, and heavy impact.

It represents a fundamental departure from conventional hard-facing welding and MS plate patching, delivering measurably superior performance and dramatically extended equipment life.

How It Works

• Applied cold — no pre-heating or post-weld heat treatment required
• Bonds metallurgically to parent material for a permanent, integral repair
• Extremely high hardness — superior resistance to abrasive particles
• High-impact toughness — withstands repeated heavy impact without cracking
• Applied in the field without specialized welding equipment
• In-situ application possible — no workshop removal needed

Documented Benefits

• 50% to 70% reduction in planned shutdown frequency
• Significant reduction in spare parts consumption
• Zero welding distortion — no thermal HAZ to parent material
• Faster application = shorter shutdown windows
• Lower total cost of ownership vs. conventional repair

The OTR Tyre Challenge

OTR tyres fitted to mining dump trucks, shovels, loaders, and heavy construction equipment represent one of the largest single maintenance cost items in any mining operation. These tyres are imported, attract significant customs duties, and can cost hundreds of thousands of dollars per unit for the largest sizes.

When a tyre is damaged — by cuts, punctures, ply separation, or burst — the conventional response is replacement or abandonment. Conventional repair technologies cannot restore structural integrity required for safe operation. Strategem OTR Care changes this.

What OTR Care Repairs

• Tread area cuts and gashes from rock and debris
• Cavities and voids in the tread and shoulder
• Air pockets within the tyre carcass
• Ply separation in the sidewall and tread area
• Burst repairs at site conditions

The KAVLAR Solution

100% research and development-driven product engineered specifically to repair OTR tyres to safe operational condition. KAVLAR technology — originally developed for high-performance sealing applications — seals and restores damaged tyre structure with bond strength and durability that makes genuine repair (not just temporary plugging) possible.

The Cost of Contaminated Oil

Contaminated hydraulic, turbine, and transformer oil is one of the most pervasive and underestimated causes of premature equipment failure in heavy industry. Water ingress, particle contamination, gas entrapment, and oxidation products degrade oil performance — increasing wear on pumps, valves, bearings, and seals.

The conventional response — periodic oil drain and refill — is both costly and environmentally wasteful. The Strategem Fluid Management System eliminates this entirely.

Fluids Handled

• Hydraulic oil (all viscosity grades)
• Turbine oil (steam and gas turbines)
• Transformer oil (insulating oil)
• Gear oil in mining and construction machinery

Purification Technologies

Why Glass Flake Coating?

Conventional paint and epoxy systems provide only limited protection — water, chemicals, and oxygen gradually permeate through the coating matrix and reach the substrate. Glass flake technology solves this fundamental problem.

Millions of microscopic glass platelets within the coating create a tortuous diffusion path — dramatically extending the time any corrosive agent takes to reach the protected surface.

Performance

• Superior resistance to chemical attack: acids, alkalis, hydrocarbons, solvents
• Excellent resistance to cathodic disbondment in marine and buried applications
• High abrasion resistance — suitable for particulate-laden flow environments
• Wide service temperature range
• Outstanding adhesion to steel, concrete, and GRP substrates
• Dramatically extended service life vs. conventional coatings

Application Areas

Software for Core Sector

Strategem's software development capability is focused exclusively on the real operational and regulatory needs of core sector industries — not generic enterprise software adapted for industrial use.

Environmental Monitoring Suite

• Air quality monitoring and forecasting
• Water quality monitoring and alert systems
• Meteorological parameter tracking: temperature, humidity, rainfall, flood prediction
• Environmental Time Series Analysis — cyclical pattern recognition
• Automatic chart, graph, and histogram generation for regulatory documentation
• Windows-based, GUI-driven — user-friendly for non-technical operators
• Fast, efficient processing of large environmental datasets

Technical Specifications

Product Overview

Strategem Special Steel Sheet is a wear-resistant steel plate product developed specifically for use as structural lining in industrial equipment subjected to high-erosion and high-impact service conditions.

The product delivers significantly longer wear life than standard mild steel (MS) plate — which remains the conventional lining material in most core sector facilities despite its inadequate wear performance.

Performance Characteristics

• High surface hardness for superior abrasion resistance
• Sufficient toughness to withstand repeated heavy impact
• Good weldability for in-situ fitting and attachment
• Compatible with Weld Paste P-6064 for combined hard-facing applications
• Available in a range of thicknesses for different wear service conditions

Application Areas