The Problem
A magnesium plant in Northern Michigan received a report from KTA Engineering of Pittsburgh after an asset integrity inspection. The report recommended that the facility repair metal and concrete structures on the Ball Mill Room floor to prevent further deterioration and safety issues. KTA recommended three manufacturers for the repair products—one of which was Resimac.
The project required precise coordination and a rapid turnaround, as the repairs needed to be completed within a 72-hour window to avoid costly downtime.
The Solution
Unconventional Solutions, Inc. (USI) was chosen to supply the materials and provide on-site technical expertise. Two of USI’s certified AMPP Inspectors were present throughout the project to ensure surface preparation, mixing, and overcoat windows met all manufacturer standards.
The surface preparation began by chiseling and removing all loose concrete, followed by high-pressure water blasting to clean the area. Turbo heaters were used to accelerate the drying process to stay within the tight project timeline.
Once the surface was dry, the team applied Resichem 503 SPEP, a solvent-free epoxy primer designed for concrete. To bulk-fill the damaged area, contractors mixed 50 lbs. of clean, dry silica sand, 50 lbs. of irregular-shaped pea gravel, and 1 liter of Resichem 503 SPEP. This mixture was used to line and level the pit.
While the primer remained tacky, another crew followed behind, applying approximately ¼ inch of Resichem 576 Quartz Screed. Turbo heaters were again used to expedite curing.
By the next morning, the Ball Mill Room floor was fully cured, operational, and safe—eliminating trip, slip, and fall hazards while restoring structural integrity to the concrete.
Products Used
