If the stern roller on an offshore support vessel fails, every hour lost can cost the ship owner many thousands of dollars. But when a UAE-based logistics operator faced a critical bearing issue on one of its anchor-handling tugs, Ocean Power International (OPI) and Thordon Bearings turned critical downtime into a 72-hour turnaround success. By replacing the vessel’s worn bronze components with Thordon SXL water-lubricated bearings, the Dubai-based team restored full functionality, cut maintenance requirements, and eliminated grease from a demanding deck application.
Bronze Costs and Downtime Pressures
The decision to convert from bronze to Thordon polymer was driven by a combination of market and operational realities. Rising global metal prices, longer procurement lead times, and the challenge of keeping support vessels earning revenue have made traditional bearing replacements increasingly uneconomic.
“Downtime is the single biggest cost driver in offshore support operations,” explains Malcolm Barratt, Thordon Bearings’ Regional Manager for Southern Europe, the Persian Gulf and the Mediterranean. “When you combine that with the cost of bronze, it becomes clear that a cleaner, faster, and more durable alternative like Thordon’s proven SXL material makes much more sense.”
Unlike conventional metallic bearings that require regular greasing, SXL is a self-lubricating elastomeric polymer specifically engineered for water or dry-running conditions. Its inherent resilience and abrasion resistance make it ideally suited for heavy-duty deck machinery such as stern rollers, winches, and towing pins, all of which are subjected to high loads, shock, and contamination from seawater or debris.
The Three-Way Alignment
OPI attributes the success of this project to three critical factors: engineering knowledge, product performance, and stock availability.
According to Rafid Qureshi, General Manager of OPI, having local inventory and a trained installation team also meant the job could be completed at record speed. “We maintain an immediate stock of Thordon materials in Dubai for precisely this type of situation,” he says. “Our engineers have fitted SXL bearings in a wide range of marine applications, so we were able to handle the machining and installation in under three days. The result is a bearing system that’s cleaner, safer, and virtually maintenance-free.”
That speed was possible because Thordon designs its polymer bearings to be easy to machine, fit, and align. The material’s controlled elasticity allows for precise interference fits, while its dimensional stability under load ensures the correct hydrodynamic film is maintained once in operation. The combination means faster turnarounds without compromising performance or service life.
How the Material Works
Thordon SXL belongs to a family of elastomeric bearing materials designed to operate where grease-based or oil-lubricated systems are either impractical or undesirable. Its low coefficient of friction, combined with its ability to recover from deformation, provides a reliable load-bearing surface even under marginal lubrication.
Thordon’s research and field data demonstrate that the polymer’s structure enables the formation of a micro-film of water between the shaft and bearing, which is sufficient to separate surfaces and minimize wear without the need for external lubricants. The result is a bearing that runs cooler, cleaner, and longer than metal equivalents in many marine environments.
By removing the risk of lubricant leakage, operators not only reduce environmental exposure but also simplify their maintenance regimes, removing the need for pumps, seals, and grease lines.
Sustainability and Performance in Practice
While environmental considerations play an increasing role in equipment selection, Thordon’s experience shows that operators rarely choose polymer bearings for that reason alone. For most, the decision is about the total cost of ownership and reliability in harsh conditions.
In this case, the conversion demonstrated how a sustainable bearing choice can also be the most practical. The Thordon SXL bearings installed by OPI require no periodic greasing, generate less heat under load, and offer long wear life in abrasive or contaminated water. Combined with Thordon’s global support network and OPI’s on-the-ground expertise, the operator gained a fast and permanent fix with lower future maintenance exposure.
“This project highlights exactly what we mean when we talk about performance and sustainability working hand-in-hand,” says Malcolm Barratt. “It’s not just about being greener; it’s also giving operators a bearing that performs better and lasts longer while removing the environmental risk.”
A Model for Future Retrofits
The Dubai conversion illustrates how polymer bearings are driving maintenance strategies for offshore support vessels and workboats in a new direction across the Gulf region. With materials available locally and experienced distributors capable of rapid response, more operators are beginning to view water-lubricated systems as a mainstream choice rather than a niche technology.
OPI and Thordon see this trend continuing, as fleets modernize and seek reliability gains wherever possible. The 72-hour project shows that with the right product, the right partner, and the right preparation, even critical deck machinery can be upgraded cleanly, quickly, and sustainably.
Source: Thordon Bearings
