Restoring a Corroded Secondary Containment Area in a Steel Mill

Restoring a Corroded Secondary Containment Area in a Steel Mill

The Problem


Restoring a Corroded Secondary Containment: A steel mill faced severe corrosion issues in its secondary containment area caused by continuous exposure to hydrochloric acid at elevated temperatures. The erosion of the concrete trench was critical, necessitating immediate and effective repair to prevent further damage. An engineering firm called in Unconventional Solutions, Inc. (USI) to train and supervise the general laborers at the steel mill during the coating application process to ensure the prevention of future erosion.

The project faced significant challenges. Both USI and a representative from the coating manufacturer were heavily involved in training the general laborers on the correct application of the coating. This intensive training and supervision spanned over four weeks. The experience highlighted the importance of having a qualified contractor for coating applications to ensure a long-lasting and quality repair.

The Substrate

Concrete: The containment area, primarily composed of concrete, required thorough neutralization and repair before the application of protective coatings.

The Solution

The USI team developed and executed a multi-step process to restore this corroded secondary containment area effectively:

  1. Neutralizing the Concrete:
    • Due to the highly acidic environment, the first step was to neutralize the concrete. The area was treated to achieve a neutral pH level, ideally between 7 and 10, to ensure the surface was safe for repair and coating applications.
  2. Rebuilding Eroded Areas:
    • Duromar RPC Repair Polymer Concrete was used to rebuild the eroded sections of the containment area. This product provided a strong foundation for the subsequent coating applications.
  3. Primer Application:
    • One coat of Duromar DF 1303 was applied as a primer. This step ensured that the final coatings would adhere properly and provide maximum protection.
  4. Final Coating Application:
    • Two coats of Duromar HPL HPL-4320 were applied to the repaired areas. The first coat was applied in red, and the second in gray. This color-coding allows maintenance crews to easily identify when the coating begins to wear off and a recoat is necessary, ensuring continuous protection.

Products Used

  • Duromar RPC Repair Polymer Concrete: Used to rebuild eroded areas of the concrete substrate.
  • Duromar DF-1303: Applied as a primer to ensure proper adhesion of the final coatings.
  • Duromar HPL-4320 Red: Applied as the final protective coatings, providing long-term corrosion resistance and facilitating maintenance monitoring.
  • Duromar HPL-4320 Gray: Applied as the final protective coatings, providing long-term corrosion resistance and facilitating maintenance monitoring.

The Outcome Despite the challenges, the project was completed successfully. The intensive training and supervision ensured that the general laborers applied the coatings correctly, resulting in a durable and effective restoration of the containment area. The dual-color coating system provided an added layer of security, allowing for easy monitoring and maintenance. The client was pleased with the results and the professional approach taken by USI, reaffirming the importance of using qualified contractors for such critical applications.



For effective and long-lasting corrosion protection solutions, trust Unconventional Solutions. Our expertise in training and supervision, combined with high-quality products, ensures your projects are completed to the highest standards. Contact us today for your industrial repair and coating needs.

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