Case Studies
For over 20 years, USI has provided protective coatings and corrosion prevention products proven to protect our nations most critical infrastructure and industrial machinery. Along the way we have documented many projects and pain points we have been able to help our partners repair, protect and upgrade.
Most Recent Articles
Resimac High Temperature Resistance Coatings
Key considerations before selecting a high-temperature coating
Environmental Use:
- Is this an external protective coating or an internal lining?
- Will the system be subject to CUI (Corrosion Under Insulation) risks?
Chemical Exposure:
- Is there exposure to water, hydrocarbons, acids or alkalis?
- What type of chemicals are present, and at what concentration (ppm)?
- Are they continuous exposures or occasional contact
Temperature Profile:
- What is the constant operating temperature?
- What are the intermittent or peak temperatures?
- How often will the equipment cycle between hot and cold?
Mechanical & Process Conditions:
- Is there thermal shock or rapid temperature change?
- Is the coating subject to abrasion, erosion or impact?
- Will there be pressurized steam or immersion service?
Engineering Repair Metals
- Resistant to dry heat up to 464°F and immersion up to 356°F
- High build application up to 1 inch without slumping
- No shrinkage, distortion, or warping during or after curing
- Resists high temperature fluid flow environments up to 356°F immersion or wet heat and 464°F dry heat
- Suitable for hydrocarbon and aqueous immersion
- Steam-out testing at 428°F / 220°C for 100 hours with no blistering
- Cures at 212-464°$ with no shutdown required
- Solvent-free and surface-tolerant
- Excellent corrosion protection at elevated temperatures
- Single-component, heat-activated epoxy novolac
Resichem 560 Thermal Barrier XF
- Prevents corrosion under insulation (CUI) for long-term durability
- Insulative epoxy coating that minimizes heat transfer & energy loss
- Presents condensation build-up to reduce moisture related damage
Duromar 4300 – High Performance Lining
- Abrasion-resistant, trowel applied
- Temperatures up to 450°F
- Resists high-temperature fluid flow environments up to 265°F wet & 464°F dry-heat
- Suitable for hydrocarbon and aqueous immersion
- Resists high-temperature fluid flow environments uo to 230°F wet and 464°F dry heat
- Withstands continuous immersion in acidic conditions
A unique high-build single-package inert multi polymeric matrix coating designed to provide heat stability and withstand severe cyclic conditions up to 1200°F. It is an excellent choice for coating under insulation (CUI), stacks, chemical plant components, refineries and other areas that require corrosion protection and see elevated temperatures up to 1200°F and -300°F or cryogenic temperatures
Questions asked during the Tech Talk:
- What type of surface prep is required? (8:44)
- How easy is it to repair or to recoat? (10:37)
Bonding an FRP in Winter Conditions
The Problem
A client encountered a unique challenge at a refinery: they needed to remove an old pipe support which was to the pipe and repair the affected area. The repair had to be completed under cold ambient conditions (below 32F) while adhering to strict refinery safety and operational restrictions.
The Substrate
Steel
The Solution
Once the pipe support was removed, the area was cleaned and prepared for the application of Denso Protal 7125. This coating was chosen for its excellent performance in cold weather and its unique ability to act as an adhesive for bonding FRP pads to steel surfaces. A generous coat was applied to the pipe, the FRP pad was positioned in place, and then additional Denso Protal 7125 was applied over the pad to ensure full encapsulation and adhesion. The client could not have been happier with the end result.
How to fix an active leak in 30 minutes or less.
How to fix an active leak in 30 minutes or less. If you would like a white paper about this, visit our website.
Today’s goals: The advantages of keeping composite pipe wrap systems in stock at your facility
Why Care: Did you know a 1/4″ leak on 60 PSI water line can cost you over $4,037.04 month according to local water and sewer authorities. That is $48,444.48 a year. If you have ten of those leaks, it’s costing your company $484,444.80
What is a composite pipe wrap system?
It is a combination of two or more materials differing in form or composition. Consisting of non-metallic fibers (fiberglass, carbon fiber, Kevlar, etc.) saturated with an adhesive matrix material (polyurethane, epoxy, etc.)
How can composite pipe wrap systems by used?
Composites are designed for the repair of corroded or mechanically damaged pipes, vessels, tanks, columns, beans or ships by external wrapping or patching.
Composite Systems Prevent the following:
– Down-time
– Loss production or time off the grid
– Loss of treated water or chemicals
– Employee hours or even over-time
– Possible fines from EPA or other agencies
– Weigh less than mechanical clamps or sleeves that can add extra stress and weight to pipe supports
Case studies to read:
Leaking Wastewater Pipe Repair
https://www.usigroups.com/case-studies/leaking-wastewater-pipe-repair/
Steel Mill Treated Water Pipe Leak Repair
https://www.usigroups.com/case-studies/treated-water-pipe-leak-repair/
Questions:
Does this repair wrap rated for what type of pressure? (8:52)
Do you offer on-site or virtual application support for first-time users? (11:08)
How much time is required from prep to cure? (11:35)
What is the max diameter pipe that can be repaired? (14:11)
Fill out the form to have the guide emailed to you. This guide walks you through a couple of options to repair an active leak on metal pipe as well as the products that can be used in many cases.
