Explore real world case studies showcasing high performance repair and protection solutions
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Rapid Concrete Repairs that keep you running
Who It’s For
This session is useful for:
Plant Manager
Facilities Manager
Maintenance Manager
Maintenance Supervisor
Reliability Manager
Engineering Manager
Plant Engineer
Project Manager
Capital Projects Manager
Construction Manager
Operations Manager
Operations Director
Director of Facilities
Director of Maintenance
Industrial Facilities Manager
Manufacturing Manager
Production Manager
EHS Manager
Safety Manager
Warehouse Manager
Today, we’ll discuss rapid concrete repairs that help keep your operations running. Our guest speaker is Doug Klingensmith, Vice President of Sales and Marketing at Unconventional Solutions. In his day-to-day role, Doug works directly with clients to solve complex issues involving corrosion, erosion, abrasion, chemical attack, and metal repairs. He is passionate about helping customers repair equipment instead of replacing it, avoid unplanned downtime, and return to service as quickly as possible.
Thank you for the kind introduction, Chris.
Having worked in this industry since 1995, I was once told by a wise contractor that there are only two types of concrete: concrete that has cracked and concrete that’s going to crack. Concrete simply doesn’t hold up well against rock salt and de-icing chemicals.
Today, we’ll discuss concrete repairs and the cost of downtime. Traditional concrete typically becomes firm within 4–12 hours, can withstand rain after 24 hours, and is ready for foot traffic within 3–7 days. However, standing water can wash out the surface, so puddling must be avoided.
Concrete requires approximately 28 days to reach its full design strength and stop releasing moisture. Protective coatings should not be applied until the concrete has cured for roughly 28–30 days. Applying a coating too early can trap moisture and cause it to peel.
At Unconventional Solutions, we use non-cementitious repair materials for damaged concrete, particularly in chemical containment areas and heavy industrial flooring applications. For example, our 570 XF patch repair is ready for foot traffic in just two hours and can handle heavy loads within four to five hours. It can also receive a chemical-resistant lining immediately after installation.
Some of you have asked about DuraMar MagCrete. Traditional concrete typically reaches compressive strengths of 2,800–4,000 PSI, while DuraMar MagCrete can reach 5,000 PSI in just one hour under normal temperatures.
Here’s a great example of when a non-cementitious epoxy repair compound makes more sense than traditional concrete. These steps at one of our military academies were in very poor condition, and graduation was only 28–30 days away. Removing the existing concrete with a jackhammer and repouring it would have been nearly impossible.
The contractor used Resimac 576XF and Resimac 71LW, but then lost 15 days of work due to rain. That left only 15 days or less to complete the project. As you can see, the finished repair turned out beautifully. A UV-stable epoxy coating was then applied to blend the repair into the surrounding surface, and the steps were ready in time for graduation.
We typically recommend four or five products for concrete patching that can restore service in hours instead of days. The 570XF comes in convenient small kits and reaches a compressive strength of 12,000 PSI—three to four times stronger than most traditional concrete.
During a dolly pull adhesion test, the surrounding concrete fails before the epoxy bond does. Unlike some products available at hardware stores that may last only one or two seasons, these epoxy systems are designed for long-term performance, including freeze-thaw conditions.
The 576 Quartz Screed and 577 Chem Screed are especially durable because we first apply a penetrating tack primer that creates a tenacious bond with the concrete. Within 48 hours, the 576 Quartz Screed, 577 Chem Screed, and DuraMar MagCrete can reach approximately 12,500 PSI in compressive strength.
DuraMar MagCrete is also ideal for cold-weather applications, including temperatures below freezing—down to -15°F. For steel mill environments, where molten steel may reach concrete temperatures of 1,000–1,500°F, DuraMar MagCrete can withstand temperatures up to 2,000°F.
Here’s another example from a Marathon loading facility near Catlettsburg Refinery. Because shutting down the loading and unloading docks for weeks wasn’t an option, repairs were completed over the weekend—starting around 3 p.m. Friday and finishing by 4 p.m. Sunday—so the facility could be back in service Monday morning. A chemical-resistant coating was then applied over the repair.
For comparison, standard concrete typically has a compressive strength of 3,000–4,000 PSI, while some high-strength products may reach 5,000–6,000 PSI. Our materials offer significantly higher performance:
- 571 Lightweight: Can be troweled vertically up to 2–3 inches thick without forms.
- DuraMar MagCrete: Up to 11,500 PSI.
- 570XF: Up to 12,000 PSI.
- 576 Quartz Screed: Up to 12,500 PSI.
- 577 Chem Screed: Similar strength to the 576, with the added benefit of being a novolac epoxy repair mortar.
The 577 Chem Screed provides excellent chemical resistance, withstanding hydrochloric acid concentrations of approximately 34–36% and sulfuric acid spills ranging from 93% to as high as 98%. It’s an ideal choice for repairs exposed to aggressive chemicals.
The 571 Lightweight is especially useful for applications like transformer stations, where concrete supports may have extensive damage and large sections of concrete are missing.
Remove all loose and deteriorated concrete before beginning the repair. The 571’s adhesive strength is greater than that of the surrounding concrete, so the weak concrete must be eliminated first.
In this example, the finished repair looks excellent. The team used our white 550 roofing membrane for waterproofing, though the white 555 can also be used for waterproofing repaired areas.
It’s important to remember that we offer multiple concrete repair solutions—not just one product. Chris has highlighted our five primary materials:
- 570XF: Best for smaller repairs, such as trip hazards, slips, and falls. These incidents are among OSHA’s most commonly reported workplace injuries and can cost companies approximately $22,000–$23,000 per incident.
- 571LW: Designed for lightweight repairs on vertical, overhead, and suspended surfaces.
- 576 Quartz Screed: Our workhorse for large areas of damaged concrete. It can be screeded over existing concrete and is used with our 503 tack primer. The 503 can also help dustproof newer concrete.
- 505 Damp: A damp-bonding concrete dustproofing material and primer for wet concrete surfaces.
- 577 Chem Screed: Designed for areas exposed to aggressive acids and caustic chemicals. The 576 can also be used in these environments, but it requires an additional chemical-resistant coating. The 577 provides chemical resistance in a single application, helping facilities return to service faster.
- DuraMar MagCrete: Developed to meet specific performance requirements, including application in temperatures as low as -15°F and resistance to temperatures up to 2,000°F.
Here’s another example from a wastewater treatment plant in Kalamazoo, completed around 2001 or 2002. According to the maintenance manager, the finished repair has performed extremely well.
We also repaired steps at one of our first warehouses in 2005, and as of 2026, they still have no cracks. These materials are designed for long-term repairs—not temporary fixes.
The 576 can also be used for grouting and aisle repairs, with overnight forklift traffic typically allowed after about 24 hours. The 577 is the ideal choice for acid-resistant applications, while DuraMar MagCrete offers additional versatility for demanding environments.
Expansion joints should be properly chipped and prepared before the next shift. However, 570XF should not be used to fill expansion joints; it is designed for quickly repairing damaged concrete.
One of our early projects was completed at Fermi Nuclear Power Plant, where the cooling tower walls were in extremely poor condition. The facility purchased approximately $40,000 worth of 571 Lightweight material for the repairs and was extremely satisfied with the results.
These products provide a faster way to restore damaged concrete and return areas to service. Traditional concrete reaches only about 40% of its strength after three days and approximately 70% after seven to eight days. By comparison, these repair materials can often be ready for full use in hours or days—not weeks.
QUESTIONS:
Q: What is the biggest mistake an applicator can make when a plant needs an area back in service the same day—one that could prevent them from achieving the promised rapid return-to-service time?
A: The biggest mistake is failing to properly remove the damaged concrete. Applicators should use a hammer to identify hollow areas and chip out anything that sounds loose or compromised. Even if the surface looks sound, hollow concrete often indicates deterioration underneath.A second common mistake is underestimating the amount of material needed or using the wrong application tools. Proper surface preparation, accurate material calculations, and the right equipment are essential for achieving fast return-to-service times.
Q: When evaluating a concrete repair, what key factors help determine whether to repair the existing concrete or remove and replace it entirely?
A: In most cases, I recommend repairing the existing concrete rather than removing and replacing it. Full replacement only makes sense when speed isn’t a priority and the facility can afford to lose a loading dock or manufacturing area for several weeks.
For exterior concrete, replacement may also face the same long-term damage from de-icing chemicals used during winter. When minimizing downtime matters, a properly prepared repair is usually the better solution.
Q. Are these products UV-stable on their own, or do they require a protective topcoat?
A. I wouldn’t describe these products as fully UV-stable, but they do offer good UV resistance. For example, the repair we completed at our former warehouse in Milford, Michigan, showed no discoloration. The primer may yellow over time when used alone, but that doesn’t necessarily mean it’s breaking down.
According to AMP, epoxies may lose approximately 0.5 to 1 mil per year from UV exposure. However, because these products are applied at a much greater thickness, UV exposure typically has little practical impact.
If you have any more questions, we’ll be sending out a survey to everyone who attended to ensure we’re providing maximum value with these discussions. You can also reach out to us at 248-735-7000 or via email at office@usigroups.com.
Peat Sorb – Sustainable Maintenance: Green without Compromise
Who It’s For
This session is useful for:
Facilities Manager
Environmental Consultant
Sustainability Officer
Operations Manager
Property Manager
Maintenance Supervisors
Building Engineers
Project Manager (Construction/Renovation)
Building Engineer
Product Manager (Eco-Friendly Products)
Heath and Safety Officer
Corporate Social Responsibility (CSR) Manager
Waste Management
Hazardous Waste Management
Today, we’re excited to have Lynn Hurdman from Peat Sorb Corporation with us. She’ll be sharing her expertise on their Peat Sorb absorbent. Lynn has extensive experience in the industry and is one of the most knowledgeable people I know in the absorbents market. We’ll wrap up with a Q&A session at the end, so thank you for joining us!
Welcome to our Peat Sorb seminar! I have a brief amount of time to share some important highlights about the absorbent industry and the sectors we’re involved in, including oil and gas, government, and heavy industry.
It’s essential to understand that Peat Sorb is different from the absorbents you might be familiar with, like Oil-Dri and Oil Gator. Unlike those, Peat Sorb has no chemical reactivity with any substances and effectively absorbs all hydrocarbons. We have lab tests showing non-detect levels for mercury, arsenic, and various petroleum categories, including alcohols, ethers, and acids. Plus, it’s landfill-friendly and doesn’t leach.
We’ve also introduced a new blend that can absorb contaminated water and solidify it with hydrocarbons. The original blend focuses on separating hydrocarbons to provide clean water. This gives us two pathways to achieve economical and environmentally friendly results that protect our ecosystems.
Peat Sorb is shipped globally, and I’d like to briefly highlight its use in Nigeria, where soil toxicity and chemical variety are significant issues. In accredited lab tests, we identified a total petroleum count of over 31,000. After just one day of using Peat Sorb, that number dropped to 23,000, and by day 14, it was down to 1,700. While we didn’t continue testing beyond that, it’s clear we could have reached non-detect levels.
In Brazil, we helped Peat Sorb clean up 2 million liters of crude oil from the ocean, showcasing the significant impact we can have on both soil and water. These are just a few examples of what Peat Sorb can achieve.
No other absorbent can truly meet everyone’s needs, but so far, we have been successful in doing just that. For instance, BP, which operates the fifth-largest refinery in the U.S., contacted me on a Sunday about a significant spill—over an acre and six inches deep, primarily involving hydrogen sulfide and benzene. We were already prepared for spill response with our inventory and shipped our product to the site. It was effective, but then the situation changed when she called me back to say that melting snow and ice were complicating matters. Thankfully, we had our new blend, designed for absorbing both water and hydrocarbons. She expressed how invaluable our product was in that situation and is willing to speak to anyone in the oil and gas sector about how we set best practices and save the day.
In addition to oil and gas, there’s been a recent executive order in the U.S. mandating that federal agencies and contractors make specific purchasing decisions. This means Peat Sorb has become a required option under both President Biden and the previous administration. This recognition is significant, especially as it falls under the bio-based, bio-preferred program. Among all tested absorbents, we were the only one to receive USDA certification for having a net zero carbon footprint.
For those of you involved in heavy metals, I have a distributor in Peru who is contracted with local mines to provide Peat Sorb for all their mining needs.
Due to the ongoing war, there’s been significant talk about a global fertilizer shortage. Peat Sorb offers a solution, as it can be repurposed into a fertilizer. After absorbing heavy metals, oil, gas, or any other liquid, the peat breaks down and neutralizes the toxicity, resulting in nondetect levels of harmful substances. Additionally, peat is rich in essential minerals like calcium, iron, manganese, and phosphorus. This allows us to deliver a nutrient-enriched additive to the soil, enhancing its quality and boosting crop yields. So, remember, when using Peat Sorb, don’t just dispose of it in a landfill—consider repurposing it for its added value.
QUESTION 1:
How do people typically dispose of Peat Sorb after, you know, after they’ve used it to absorb hydrocarbons?
Lynn Hurdman: First and foremost, we encourage the reuse of peat, as it may retain additional performance attributes and wicking capacity, making it not just a one-time use product. After it becomes saturated with hydrocarbons, it can be safely incinerated, and we have lab tests to support this. While it is also safe for landfill disposal since it won’t leach, local regulations might require you to follow hazardous waste guidelines, even though it is perfectly safe for landfills.
Christopher Williams: Understood. You mentioned incineration earlier. What kind of energy recovery can be achieved from the hydrocarbons during incineration?
Lynn Hurdman: Great question! According to our lab tests, one pound of encapsulated oil in Peat Sorb can generate 15,500 BTUs. So, yes, it can indeed be repurposed as a fuel alternative.
QUESTION 2:
For someone who is currently using clay-based absorbance or traditional oil dry, what are the biggest differences they would notice when switching to Peat Sorb?
Lynn Hurdman: I’m not quite following. Was there a spill where someone used Peat Sorb?
Christopher Williams: Yes, there was a spill, and it wasn’t the first one at that location. After using Peat Sorb, he noticed that it actually pulled the stain out of the concrete, which was due to oil contamination.
Lynn Hurdman: Right. That’s exactly what you should expect to see. Peat Sorb has wicking properties, allowing it to draw contaminants into its cellular structure. Additionally, peat serves as a foundational element for fossil fuels, which is why it seeks to reconnect with related substances and incorporates them into its structure.
QUESTION 3:
Can Peat Sorb absorb and break down polymer at wastewater treatment plants?
Lynn Hurdman: Yes, Peat Sorb can absorb polymers. It has been used in pulp and paper mills before, as polymers can be quite hazardous—similar to a banana peel in terms of risk. So, Peat Sorb effectively absorbs the polymer and helps break it down.
QUESTION 4:
Can Peat Sorb extract oil from concrete? As we’ve already mentioned, it has a tendency to pull contaminants out. A follow-up question might be about the timeline: if, for instance, the stain is five years old, could it still potentially remove it?
Lynn Hurdman: Yes, that’s the direction I was heading. Essentially, you need to re-liquefy and reactivate the oil since it’s trapped in the concrete. We use brake cleaning fluid, which seems effective in rejuvenating it. Then, you apply the Peat Sorb and agitate it with a stiff broom, allowing you to extract the oil from the pores again.
Christopher Williams: That’s really fascinating to me—being able to pull out a stain that’s been there for years. I might have to try that in my garage. We have another question: how much Peat Sorb is needed for a gallon of oil spill? What’s the one-to-one comparison?
Lynn Hurdman: Typically, we recommend a one-to-one ratio. However, viscosity does play a role. When we say one-to-one, it’s based on the viscosity of the oil being similar to SAE 30 motor oil. If the oil is thicker, you may need to adjust that to a two-to-one ratio. But we start with one-to-one based on SAE 30 motor oil viscosity.
QUESTION 5:
How heavy is Peat Sorb prior to being used and how heavy is it after cleaning the spill?
Lynn Hurdman: Our absorbent is incredibly lightweight. You can think of it like tobacco—it’s extremely light and consists of fine particulates. Even after absorbing hydrocarbons, it remains lighter compared to oil dry, which is made from heavy clay and tends to get heavier. So, we’re only slightly heavier due to the weight of the absorbed hydrocarbons.
QUESTION 6:
As a contractor who has experienced cleaning up spills, are you aware of any pipeline companies that will not allow the use of Peat Sorb?
Actually, Kinder Morgan is looking to purchase Peat Sorb in Texas, not BP. In fact, there isn’t anyone who wouldn’t want to buy it because it addresses the problem quickly, efficiently, economically, and in an environmentally friendly way.
If you have any more questions, we’ll be sending out a survey to everyone who attended to ensure we’re providing maximum value with these discussions. You can also reach out to us at 248-735-7000 or via email at office@usigroups.com.
Containment Systems & Chemical Resistant Coatings
Who It’s For
This session is useful for:
Maintenance Manager
Maintenance Supervisor
Maintenance Technician
Reliability Engineer
Reliability Manager
Plant Engineer
Facilities Manager
Facilities Maintenance Manager
Asset Integrity Manager
Mechanical Maintenance Planner
Today, we’re diving into containment systems and chemical-resistant coatings. In the next 10 minutes, we’ll cover how to choose the right containment system and the appropriate chemical-resistant coating for your specific needs. We’ll wrap up with a Q&A session at the end, so thank you for joining us!
The first step in selecting chemical-resistant coatings and containment solutions is to identify your complete stress stack. While chemical resistance is crucial, it’s just one aspect of the overall equation. A coating that performs well in one situation may not be suitable in another, so understanding the total stress stack is essential.
We need to determine what the coating will be required to endure. This includes the chemistry involved—what chemicals are present—as well as temperature considerations. Additionally, we must consider whether this will be an immersion system or if it will experience splashes. Is it secondary containment? All these factors significantly impact chemical resistance and the coatings you choose.
We also need to evaluate any potential abrasion or impact the container may face. What full conditions will the container be subjected to? Finally, consider the substrate and any preparation limits.
Lastly, think about downtime and the cure window. How long can the asset be out of service, and how long will it take to return it to service?
When building out your stress stack, it’s crucial to gather detailed operational specifics—not just the chemical name or pH. While it’s tempting to rely on that information, understanding the specific chemicals involved and their blends is vital for making informed decisions.
Does this system undergo a cleaning cycle? Remember, those cleaning agents are also chemicals, so it’s crucial to ensure protection against them. Additionally, consider any byproducts that might be generated in this environment. You’ll want to discuss concentration levels—what’s your worst-case scenario or peak concentration compared to your normal operating range?
Temperature is another factor to keep in mind. What’s your typical operating temperature, and do you have systems that experience peak operating temperatures? Don’t forget about thermal shock, which occurs when temperatures change rapidly.
Contact type is also essential. Are we dealing with immersion, splashes, fumes, or secondary containment? When discussing secondary containment, it’s important to consider its placement. For instance, if it’s located under a structure where people will walk, you’ll need to think about abrasion resistance from foot traffic or even equipment.
Lastly, consider the frequency of exposure. Will there be continuous immersion, or will it involve batches? Is it a wash-down situation, or could there be emergency exposure in the case of secondary containment? All these factors contribute to the overall stress considerations.
This could involve abrasion, UV exposure, or pressure. Does the container need to be flexible? Is it mobile, and will there be traffic over it? All these factors play a role in determining whether we’re selecting the right coating and how to make that decision.
Understanding your asset and substrate is crucial. Your selection may vary depending on the substrate type. There are excellent primers available that allow various coatings to be applied to different surfaces. For steel, it’s essential to ensure the correct blast profile and to test for soluble salts. You’ll also need to address any existing pitting or corrosion, smooth out welds, and consider edge conditions. The type of steel will influence your product choice as well.
When it comes to concrete, consider its typical moisture level and pH. Are there cracks or potential outgassing issues? You might also need to ask if it’s embedded in a wall or underground, where it could be subjected to hydrostatic pressure. There are solutions for all these challenges, but they’re vital for achieving the best results for your asset.
Regarding existing coatings, it’s generally not advisable to apply a new coating over a severely damaged one. Identifying compatibility is important; many systems come in two colors—a base color, like blue or red, and an overcoat, usually gray. This design allows for easy inspection; if you can see the underlying color, it may indicate damage and signal the need for recoating.
These systems are designed for easy recoating; we know the product inside, and we can prepare the surface by roughening it up before applying a new coat. If the coating has been in place for an extended period and shows significant damage, you may need to strip the entire coating off. Lastly, don’t forget to consider the geometry of the asset, including its edges, pits, seams, bolts, and any confined spaces.
What does access look like? This factor will influence our product selection, as there are many excellent products suitable for spraying, while others are designed specifically for brushing or rolling. If your space has complex geometry, we’ll need to focus on the sprayable options.
I came across a saying that I can’t quite place, but it resonates: great chemistry can overcome poor surface preparation. It’s crucial to pay attention to our Technical Data Sheets (TDS) and adhere to the outlined surface prep steps.
Typically, we begin with an inspection. This includes conducting soluble salt tests, moisture checks, and pH assessments where necessary. If there are cracks in concrete, they need to be repaired. For damaged steel structures, it’s essential to address those issues as well. We offer some excellent epoxy repair solutions to fix cracks and pitting, helping to restore any wall loss effectively.
Before applying your coating, the next step is preparation. It’s vital to follow all the necessary preparation steps, especially if you want a long-lasting solution. Most coating failures stem from improper surface preparation.
Once you’ve prepared the surface, you move into the application stage. Here, it’s essential to adhere to all application steps, but an important final step is verification. There are many inspection tools available, and skilled inspectors can ensure there are no holidays or pinholes in your coating, confirming that you’re ready to put it into service.
The last step is to schedule your first maintenance inspection once you return to service. This is crucial for quickly addressing any issues that may arise and for establishing a routine inspection process. Sometimes, you’ll circle back to earlier steps, as illustrated in the triangle setup. All these factors are important for ensuring a durable asset in any environment.
At USI, we focus on product selection, offering a wide range of solutions suitable for various environments. While I can’t list all our brands, the right choice depends on your specific situation—pressure, temperature, and the chemical mix involved, as well as whether the environment will experience heavy abrasion.
We also provide exceptional high-temperature, chemical-resistant products. It’s important to remember that there isn’t a one-size-fits-all solution; every detail matters. Consulting with an expert who understands these products and can ask the right questions when assessing your asset is essential.
Now, let’s open the floor for questions. You can either chat them in or speak them out loud. I see we have a question in the chat: “How do you address existing cracks or damaged concrete before applying a chemical-resistant lining?” Bobby, that’s a great question! Typically, you’ll want to remove any loose materials from those cracks. We have excellent repair products that are more chemical-resistant than the surrounding concrete.
Our lightweight concrete repair systems allow you to build up on a wall without needing forms, and we have options designed for heavy traffic. The approach will depend on the specific environment you’re dealing with, similar to selecting a chemical-resistant coating.
Be sure to clear out any loose concrete, scuff up the surface, and apply a repair patch before putting on the lining. Doug, do you have anything to add?
Doug Klingensmith: One thing to keep in mind, Bobby, is to saw cut around the edges to about a quarter inch deep. This helps create a solid bond for the repair. Whenever possible, opt for a concrete repair system that includes a primer to penetrate the existing concrete, ensuring strong adhesion.
Christopher Williams: Any other questions for us today regarding chemical-resistant coatings or linings, or anything else?
Doug Klingensmith: Chris, one aspect to consider with steel tanks is the importance of stripe coating. It’s best to apply a stripe coat first with a brush to ensure good penetration at the welds and sharp edges, and then follow up with your first coat of chemical-resistant lining before the overcoat window closes.
Christopher Williams: I’ve heard that with stripe coating, you don’t wait for the cure window, right? You apply the stripe coat and then almost immediately proceed to add that extra film thickness around those irregular geometries.
Doug Klingensmith: Yes, that’s typically the best practice. You don’t wait for it to fully cure; just allow it to tack up a bit.
If you have any more questions, we’ll be sending out a survey to everyone who attended to ensure we’re providing maximum value with these discussions. You can also reach out to us at 248-735-7000 or via email at office@usigroups.com.
