Electrical Motor Repairs & AC/DC Motor Rewinding

Mining Process Plant Design & Turnkey Mineral Beneficiation Plants

CSS Engineering provides comprehensive electrical motor repair services, including specialist AC and DC motor rewinding, full mechanical and electrical refurbishment, and the supply of new motors where repair is not economically or technically viable. Our objective is to restore motor reliability, optimise performance, and minimise downtime across industrial and mining applications.

When a motor fails, rewinding and refurbishment is often the most cost-effective solution to return the unit to service without compromising efficiency or lifespan. Where required, CSS Engineering also supplies new motors matched to duty, application, and operating conditions.

CSS Engineering provides comprehensive electrical motor repair services, including specialist AC and DC motor rewinding, full mechanical and electrical refurbishment, and the supply of new motors where repair is not economically or technically viable. Our objective is to restore motor reliability, optimise performance, and minimise downtime across industrial and mining applications.

When a motor fails, rewinding and refurbishment is often the most cost-effective solution to return the unit to service without compromising efficiency or lifespan. Where required, CSS Engineering also supplies new motors matched to duty, application, and operating conditions.

What Is Motor Rewinding?

Motor rewinding restores motor performance by replacing damaged or degraded stator windings while retaining the original motor core and mechanical components. Typical scope includes:

Removal of failed copper windings
Thorough cleaning and inspection of the stator core
Core-loss testing to verify magnetic integrity
Installation of new windings with correct insulation class
Reassembly to original OEM operating standards
Final electrical and mechanical performance verification

Motor rewinding restores motor performance by replacing damaged or degraded stator windings while retaining the original motor core and mechanical components. Typical scope includes:

Removal of failed copper windings
Thorough cleaning and inspection of the stator core
Core-loss testing to verify magnetic integrity
Installation of new windings with correct insulation class
Reassembly to original OEM operating standards
Final electrical and mechanical performance verification

Full Motor Repair &

Overhaul Capability

In addition to rewinding, CSS Engineering undertakes complete motor repairs, which may include:

Bearing replacement and shaft inspection
Seal replacement
Rotor inspection and balancing
Terminal box and connection refurbishment
Alignment checks and mechanical tolerances verification
Mechanical shaft and/or part engineering

All repairs are supported by documented testing and inspection procedures to ensure service-ready condition.

Motor Rewinding Process

Our rewinding workflow is structured to ensure consistency, traceability, and dependable results:

Pre-inspection, data capture, and electrical testing
Removal of damaged windings and stator cleaning
Core-loss testing to confirm stator integrity
Installation of new copper windings

Insulation, lacing, and mechanical securing
Varnish impregnation and controlled baking
Final assembly, inspection, and performance testing

Pre-inspection, data capture, and electrical testing
Removal of damaged windings and stator cleaning
Core-loss testing to confirm stator integrity
Installation of new copper windings
Insulation, lacing, and mechanical securing
Varnish impregnation and controlled baking
Final assembly, inspection, and performance testing

Supply of New Electric Motors

Where rewinding or repair is not feasible, CSS Engineering can supply new AC and DC electric motors, selected to suit the required power rating, speed, duty cycle, and operating environment. This ensures a seamless solution from assessment through to commissioning.

KEY BENEFITS OFRewinding vs Replacement

Up to 50% cost saving compared to new motor procurement Restores original efficiency and performance when correctly executed Reduced downtime compared to long lead times on new motors Sustainable solution through reuse of core materials

Where rewinding or repair is not feasible, CSS Engineering can supply new AC and DC electric motors, selected to suit the required power rating, speed, duty cycle, and operating environment. This ensures a seamless solution from assessment through to commissioning.

KEY BENEFITS OFRewinding vs Replacement

Up to 50% cost saving compared to new motor procurement
Restores original efficiency and performance when correctly executed
Reduced downtime compared to long lead times on new motors
Sustainable solution through reuse of core materials

CSS Engineering’s motor repair, rewinding, and supply services provide a reliable, cost-effective solution to extend motor service life while maintaining performance and operational confidence.

gearbox repairs

Repairing of a gearbox/drive unit can cost less than a new replacement unit and repair turnaround time can be expedited pending extent of damage.

We repair all types of gearboxes such as SEW, David Brown, Hansen, Flender, Falk, Fenner, Renold, Bonfiglioli, Siemens, Nord, to mention just a few.

Repairing of a gearbox/drive unit can cost less than a new replacement unit and repair turnaround time can be expedited pending extent of damage.

We repair all types of gearboxes such as SEW, David Brown, Hansen, Flender, Falk, Fenner, Renold, Bonfiglioli, Siemens, Nord, to mention just a few.

QUALITY
ASSURANCE

We exclusively use materials and components of selected, consistent quality. Internal test & repair certificates guarantee high quality gear systems solutions.

PROFICIENT
TECHNICIANS

Irrespective of Gear System OEM, our technicians have been expertly trained and excel through great technical know-how and flexibility.

SERVICE
PERFORMANCE

All gear systems are repaired in our extensive Machining and Fabrication workshop. This enables us to minimally outsource spares/parts and ensure delivery periods are adhered to.

THE BENEFITS OF

gearbox repairs

Shorter turn around times and cost effectiveness.
Repairs of any type and brand of industrial gearboxes.
Bringing your process back up to 100% operational availability in the shortest possible time.
Replacement parts are fabricated in our extensive gearbox parts production facilities with our comprehensive machinery and equipment.

Electrical motors production range and service offerings

Refurbishing and rewinding of the following:

AC Motors.
DC Motors.
Stator/Rotor Units.
Two Speed Motors.
Brake Motors.
Gearbox Motors.
Special Shaft Extensions.
Flameproofing SANS60079.
Dust Ignition Proofing 60079.
All work is guaranteed and in accordance with SABS ISO9001.
Class “H” Insulation.

BEARINGS &
SEALS

Our parts are sourced from reputable suppliers. We do not compromise on quality thus optimizing performance and mechanical lifespan. Our clients are unique and should be treated as such.