Case Studies - Vermati Engineering

Real Results. Proven Under Pressure.

From ports and utilities to aviation and energy — we deliver critical repairs, fabrications, and upgrades on compressed timelines with full QA compliance.

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Past Performance / Case Studies

Ports & Maritime

Gantry Crane Gearbox Rebuild in 10 Days

Completed: June 2023 10 days

Challenge: Crane down; terminal losing >$250k/day; OEM lead time 6–8 weeks.

Solution: Rapid machining of shaft journals, bearing fit restoration, precision gear inspection, oil flushing & contamination control.

Outcome

Return to service on first lift; vibration down 38% vs. pre-failure; zero leaks at 30-day check.

Timeline: 10 calendar days Savings: $1.5M+

Gearbox Rebuild Precision Machining NDT Inspection

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Ports & Maritime

Container Yard Winch Drum Refurb + Coating

Completed: March 2023 14 days

Challenge: Severe pitting in marine environment; rope damage risk.

Solution: Weld build-up with qualified WPS; finish machining; NACE-aligned surface prep; high-build coating.

Outcome

Rope life extended 2–3×; unplanned downtime eliminated for the season.

Timeline: 14 days ROI: 4:1

Weld Repair Corrosion Protection Coating

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Utilities & Water

ASME Pressure Vessel Fabrication with Full QA

Completed: January 2024 23 days

Challenge: Needed code compliance and accelerated schedule before outage window.

Solution: Code design verification; certified fabrication; hydrostatic test; internal epoxy system; external high-build.

Outcome

Passed third-party inspection on first presentation; commissioned on time.

Timeline: 21 days fab + 2 days testing Zero NCRs

ASME Pressure Vessel Hydrotesting

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Utilities & Water

Wastewater Pump & Piping Emergency Rebuild

Completed: August 2023 9 days

Challenge: Plant at risk of overflow penalties; 10-day outage cap.

Solution: Reverse-engineered impellers; CNC sleeves; gasket kit; on-site alignment.

Outcome

Flow restored; efficiency +11% vs. baseline; avoided penalties.

Timeline: 9 days Efficiency: +11%

Pump Rebuild Reverse Engineering Emergency Response

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Construction & Civil Works

Bridge Temporary Works & Heavy Weldments

Completed: November 2023 20 days

Challenge: Night shift window; zero-rework tolerance under DOT oversight.

Solution: WPS/PQR-qualified welds; jig-built assemblies; trial fit; site measurement loop.

Outcome

Install complete in one night; crane hours reduced 25%; no NCRs.

Timeline: 18 days shop + 2 nights field Crane Hours: -25%

Heavy Weldments Bridge Work DOT Compliance

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Construction & Civil Works

Airport Conveyor Structure Retrofit

Completed: February 2024 3 weeks

Challenge: Zero interruption to ops; tight geometry in existing plant.

Solution: Laser scan → CAD; pre-fabricated modules; bolt-up strategy.

Outcome

Commissioned during single night shift; throughput +15%.

Timeline: 3 weeks fabrication; 8-hour cutover Throughput: +15%

Laser Scanning CAD Design Retrofit

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Materials & Cement

Mill Shell Crack Repair & Liner Fit

Completed: September 2023 6 days

Challenge: Progressive cracking risking catastrophic downtime.

Solution: Stop-hole drilling; gouge & fill; stress-relief sequence; machining pads; liner install.

Outcome

Returned to service; scheduled full replacement deferred 9 months; $1.2M downtime avoided.

Timeline: 6 days Savings: $1.2M

Crack Repair Mill Maintenance Liner Installation

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Materials & Cement

Overland Conveyor Section Rebuild

Completed: May 2023 3 weeks

Challenge: Erosion and misalignment causing spillage and fires.

Solution: New trusses; ceramic-enhanced liners; alignment program; belt tracking.

Outcome

Spillage down 70%; belt life +20%.

Timeline: 3 weeks Spillage: -70%

Conveyor Systems Ceramic Liners Alignment

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Oil, Gas & Energy

Jet Fuel Farm Piping Skid Upgrade

Completed: July 2023 24 days

Challenge: Outage limit 48 hours; documentation-heavy environment.

Solution: Pre-built & tested skid; color-coded bolt-up kit; commissioning support.

Outcome

Zero leaks; metering accuracy within ±0.25%; audit passed.

Timeline: 24 days fab/test; 12-hour swap Accuracy: ±0.25%

Piping Skid API Compliance Metering

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Oil, Gas & Energy

Terminal Pump & Gearbox Rapid Rebuild

Completed: October 2023 5 days

Challenge: Berth idle risk; demurrage exposure.

Solution: Sleeve & grind; bearing fit correction; laser alignment; oil flushing.

Outcome

Restart without derate; avoided demurrage; MTBF projection +2×.

Timeline: 5 days MTBF: +2×

Pump Rebuild Gearbox Laser Alignment

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Aviation & Defense

Loader Lift Cylinder Manufacture & Commission

Completed: April 2024 12 days

Challenge: Chronic leakage; spares obsolete.

Solution: Reverse engineering; upgraded seal stack; HVOF rod; bench test.

Outcome

Zero leakage at 90-day check; mean cycle life +3×.

Timeline: 12 days Life: +3×

Reverse Engineering HVOF Coating Cylinder Manufacturing

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Aviation & Defense

Ground Support Fixture Fabrication (Precision)

Completed: December 2023 9 days

Challenge: Fit within confined envelope; repeatability critical.

Solution: 3D scan → CAD; CNC machining; anodized finish; poka-yoke features.

Outcome

Handling time −35%; no FOD events reported.

Timeline: 9 days Time: -35%

3D Scanning CNC Machining Precision Fabrication

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When every hour counts, so does experience.

From certified fabrication to urgent rebuilds and long-term maintenance, Vermati delivers reliability on time, every time.

Request a Rapid Response Quote

Real Results. Proven Under Pressure.

Past Performance / Case Studies

Gantry Crane Gearbox Rebuild in 10 Days

Outcome

Container Yard Winch Drum Refurb + Coating

Outcome

ASME Pressure Vessel Fabrication with Full QA

Outcome

Wastewater Pump & Piping Emergency Rebuild

Outcome

Bridge Temporary Works & Heavy Weldments

Outcome

Airport Conveyor Structure Retrofit

Outcome

Mill Shell Crack Repair & Liner Fit

Outcome

Overland Conveyor Section Rebuild

Outcome

Jet Fuel Farm Piping Skid Upgrade

Outcome

Terminal Pump & Gearbox Rapid Rebuild

Outcome

Loader Lift Cylinder Manufacture & Commission

Outcome

Ground Support Fixture Fabrication (Precision)

Outcome

When every hour counts, so does experience.

Gantry Crane Gearbox Rebuild in 10 Days

Scope

Challenge

Solution

Certs/QA

Outcome