Innovative In-Place Shaft Repair at a Children’s Hospital

Innovative In-Place Shaft Repair at a Children’s Hospital

The Problem

Hospital Shaft In-Place Repair: A large shaft at a children’s hospital was showing signs of extreme wear, posing a significant challenge due to its size and location. The traditional approach to repair – involving the removal of the shaft, creating large openings in the hospital’s structure, and installing a replacement – was not only costly but also time-consuming, with an estimated completion time of weeks or months. To avoid these extensive disruptions and high costs, the hospital consulted with the USI Team for an unconventional, efficient solution to repair the shaft in place.


The Substrate

The material of the shaft in need of repair was steel, a common choice for such structures due to its strength and durability. However, even steel is susceptible to wear and damage over time, especially in high-use areas like hospitals.

The Solution

Unconventional Solutions provided a strategic and efficient repair process:

  • Cleaning and Degreasing: The first step involved thoroughly cleaning and degreasing the shaft with USI Universal Cleaner. This preparation was crucial for ensuring the subsequent materials would adhere properly and perform effectively.
  • Surface Abrasion: To create an optimal surface for the repair material, the damaged area of the shaft was abraded using an MBX Bristle Blaster. This tool created a “clean and rough” finish with a 2.5-4mil anchor pattern, essential for the repair paste’s adhesion.
  • Application of Resimetal 101 Metal Repair Paste: Resimetal 101 Metal Repair Paste, a high-performance metal repair compound, was then applied using a spatula. This material is known for its durability and effectiveness in repairing metal surfaces.
  • Forming and Shaping: A form clamped onto the shaft ensured the repair material maintained the correct shape and compressed it to prevent voids. Resimac 904 Release Agent was used to prevent the paste from adhering to the form, allowing for easy removal.
  • Finishing: After a set time of only 2 hours, emery cloth was used to smooth the surface and remove any parting lines. The repair cured to full hardness and was ready for service in 72 hours.

Products Used


For efficient and innovative in-place repair solutions in critical environments like healthcare facilities, trust Unconventional Solutions. Our expertise ensures quick and effective repairs, reducing downtime and costs. Contact us for your repair needs.


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