What is horizontal electroplating for hydraulic rods, tubes and long cylindrical components? There are components that are so large that trying to hard chrome plate them is impossible. And if you do plate it vertically, you will need to do one half, then the other half creating a seam in the hard chrome plating that it simply does not work. How can it be hard chrome plated evenly? That’s where horizontal electroplating, a specialized hard chrome plating technique, comes into play.
What is Horizontal Electroplating?
Horizontal electroplating is where you take long cylindrical components such as hydraulic rods, tubes and industrial rollers are hard chrome plated while lying horizontally in a very large tank. The large tank allows for even hard chrome plating on the entire part, resulting in a uniform chrome layer that holds tight tolerances in a single pass.
For engineers and buyers who specifically have hydraulic cylinders, press rolls or precision shafts, the uniformity is critical to the working of these components. We’re going to go through how horizontal electroplating works, why having a long tank works, who relies on it and the cost of purchasing a new rod or having the rod.
How Horizontal Electroplating Works
Like we mentioned at the beginning of our discussion, horizontal electroplating goes sidewise. So, can a very long component hand and be lowered into a deep tank? Again, probably not. The long parts are simply too long in length and cannot fit in one lowering. The only way this can be done is half dipped, then the other half to be dipped. This doesn’t work for most engineers because a seam forms which can be difficult for the part to wear evenly, or maybe even work properly.
A horizontal tank will be very long in size. Most facilities have the crane built into the facility for easy maneuvering and lowering into the tank. The anodes are positioned within the tank parallel to its surface from one end to the next. Once submerged, the entire component sits in the chromic acid bath at one time creating an even finish.
Because every inch of the part is the same distance from the anodes, the electrical current reaches the surface evenly. The result is a hard chrome deposit with consistent thickness, hardness, and finish. Exactly what the customer ordered and needs.
Uniform Distribution of Hard Chrome is Critical to the Wear of the Component
There’s one thing we know for sure: hard chrome deposits build faster where current density is high and slower where it is low.
Dennis and Such, in their widely referenced text Nickel and Chromium Plating, describe how anode shape, spacing, and conformity to the part are the tools companies use to control this effect on engineering deposits (Dennis and Such, 1993). Their guidance is common sense. If you control the geometry, you control the thickness. And, EN-CHRO Plating agrees with their assessment.
The tank design that is sized for long cylindrical plating allows for anodes to be strategically placed along the full length of the part. The plating company, like EN-CHRO, are able to maintain control of the current distribution.
ASTM B177, the Standard Guide for Engineering Chromium Electroplating, reinforces this approach. It addresses racking, anode arrangement, and thickness control as core variables for producing functional chrome that meets engineering drawings (ASTM International, B177/B177M).
En-CHRO Plating Tank Capabilities
EN-CHRO Plating’s tanks are specifically designed and used for new hard chrome plating and repair hard chrome plating of long, cylindrical components like hydraulic rods and industrial rollers. The tank dimensions support for optimal anode placement, which again, is crucial for uniform current distribution across the entire part. The result is controlled hardness.
| Capability | Specification |
| Diameter range (specialty services) | 3/16″ up to 16″ |
| Maximum length (specialty services) | Up to 39 feet |
| Long tank capacity | Up to 39 feet long at 3″ to 8″ diameter |
| Various diameters | Up to 30 feet long |
| Chrome thickness | .001″ to .010″ or more |
| Chrome hardness | 68 to 72 RC (Rockwell C) |
| Services | New hard chrome plating and chrome finish repair |
| Facility | Centrally located in Illinois, serving customers across the U.S. |
A hardness of 68 to 72 RC places the deposit above the norm. Lausmann, writing in Surface and Coatings Technology, documents that electrolytically deposited hard chrome plating combines this high hardness with a low coefficient of friction and strong wear and corrosion resistance This is why it remains a standard for hydraulic and roller applications (Lausmann, 1996).
Horizontal Tank vs. Sectional Plating
We briefly discussed sectional plating, or plating one half of the component, then the other. Each transition creates a potential overlap or a seam. This may not be the most desirable solution for most. Let’s take a look at the difference between horizontal plating all at once, versus plating in sections or half at a time.
| Factor | Horizontal Single Pass | Sectional Plating |
| Thickness consistency | Uniform along full length | Risk of steps at overlap zones |
| Quality control | One continuous deposit to inspect | Multiple zones to measure and blend |
| Grinding allowance | Smaller, predictable stock | Often larger to remove transitions |
| Handling | Single setup | Multiple setups and repositioning |
| Labor and lead time | Lower | Higher |
| Damage risk | Reduced handling | More handling of heavy parts |
Benefits of Horizontal Electroplating
Single Pass Hard Chrome Plating Delivers a High Quality Result
EN-CHRO Plating’s horizontal electroplating tank removes the need for plating components in sections, which can create inconsistencies and quality issues in a final product. One continuous deposit means the product will wear evenly and the hardness is even from one end to the next.
Higher Production Capacity
The horizontal tank accommodates numerous components being hard chrome plated all at once. That capacity helps fleets of cylinders or batches of rollers to have the same consistency.
Lower Labor and Fewer Imperfections
Hard chrome plating long parts in a single pass reduces potential imperfections, handling damage, and labor costs. Less repositioning of a heavy 30 foot rod also means less opportunity for dents or scratches, all of which were repaired prior to the components being hard chrome plated.
Long Service Life
A uniform, correctly specified hard chrome layer protects the base metal from uneven wear and corrosion. The electroplating process keeps parts and components protected, lasting for years.
Industries Served
EN-CHRO Plating provides horizontal electroplating chrome finish repair for a wide range of industries. The table below shows the industry and the typical components that regularly need repair and hard chrome plating.
| Industry | Typical Components |
| Hydraulics and Pneumatics | Piston rods, cylinder tubes, plungers |
| Printing | Printing rolls, anilox and impression rollers |
| Textile | Calender rolls, guide rollers, drafting rolls |
| Heavy Machinery and Industrial Equipment | Boom cylinders, shafts, pins |
| Oil and Gas | Pump plungers, sucker rods, valve stems |
| Medical Device | Precision shafts and guide rods |
| Manufacturing and General Engineering | Linear shafts, press rams, spindles |
| Chemical Processing | Pump shafts, agitator shafts, rolls |
| Food Processing | Sanitary rollers, conveyor shafts, forming rolls |
Repairing Large Components for an Even and Durable Finish
EN-CHRO Plating has the unique ability to restore or refurbish parts and components that require hard chrome plating repair. When a large component is in need of plating, the truck drives directly into our facility to unload. Our experienced team analyzes the component and takes note of imperfections and understands if the wear was evenly distributed or not. All of these are noted and shared with the customer so they are aware of the condition of the component. Once repaired, we show the customer that this component has now been brought back to its original specification. That is a considerable amount of money and time saved by restoring to the original condition.
Common Causes of Component Needing Repairs
Hard chrome plating wears down over time. Here are a few reasons why:
- Abrasive wear from contaminated hydraulic fluid or process material
- Scoring and scratches from damaged seals or debris
- Chemical attack in processing
- Pitting and corrosion at exposed areas
- Impact damage during operation
When any of these appear, you can count on the expertise of EN-CHRO Plating to communicate its condition and deliver a great product.
A Typical Repair at EN-CHRO Plating
Let’s take a closer look at the process we go through in the preparation process.
- Inspection and measurement of the worn component
- Stripping the damaged chrome layer from the metal
- Grinding or machining to restore a consistent and even surface
- Horizontal hard chrome plating restored back to specification
- Inspection to ensure all imperfections have been repaired
- Final grinding and polishing to ensure any imperfections have been fixed
- Quality inspection before returning to the customer
Repair vs. Replacement
Ordering new large industrial rollers or similar components can take a lot of time. Refurbishing those parts with EN-CHRO Plating is faster and far less costly.
| Consideration | Chrome Repair | New Replacement |
| Lead time | Typically shorter | Often long for custom rollers |
| Cost | Fraction of new part cost | Full manufacturing cost |
| Base material | Original core is reused | New material and machining |
| Fit | Restored to original dimensions | Must match existing equipment |
| Sustainability | Keeps components in service | Consumes new raw material |
What to Include with Your RFQ
When a quote is received, it’s understood that you want the answer to the quote back as quickly as possible. Supplying details helps to determine the anode setup and grinding stock. Here’s what to include:
- Part drawing with overall length, diameter and plated area
- Required final chrome thickness and tolerance
- Surface finish requirement (Ra) after grinding
- Base material and any heat treatment
- For repairs: photos of the damage that you are aware of
Sharing the operating environment matters as much as the drawing. A rod in a food plant washdown area and a rod on an offshore pump experience very different conditions, and the chrome thickness should reflect that.
Frequently Asked Questions
What type of parts use horizontal electroplating?
Long, cylindrical parts such as hydraulic rods, cylinder tubes, industrial rollers and shafts are ideal because a horizontal tank plates the full length in one pass.
How thick can a hard chrome deposit be?
EN-CHRO Plating applies chrome from .001″ to .010″ or more, depending on the wear, corrosion, and dimensional requirements of the application.
How hard is hard chrome plating?
The chrome layer measures 68 to 72 on the Rockwell C scale, providing excellent wear resistance and a low friction surface.
What size parts can EN-CHRO Plating handle?
Specialty services range from 3/16″ to 16″ in diameter with lengths up to 39 feet. Parts 3″ to 8″ in diameter can be up to 39 feet long, and various diameters can be plated up to 30 feet long.
Is chrome repair cheaper than buying a new roller?
In most cases, yes. Refurbishing reuses the original core, so repair is typically faster and far less costly than ordering a new custom roller.
Get to Know EN-CHRO Plating
EN-CHRO Plating has been helping engineers find solutions to surface coating challenges for over 40 years. From new hard chrome on a 39 foot hydraulic rod to restoring a worn printing roll, the team delivers precise, reliable results built to last.