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Category: Success Stories

Crusher Shaft Repair

The Challenge This shaft of a single toggle jaw crusher was exhaustively used in a mining facility.  The shaft weighed 3,000 pounds and originally cost over $20,000.  The journal areas had been excessively worn as a result of the aggressive working environment and many years of use. Four areas of heavy wear were identified for…
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In Place HVAC Shaft Repair

The Challenge This Children’s Hospital had a large shaft that was damaged with extreme wear. They were looking at a high-cost project that would take weeks or months to execute. Large holes in the walls or roof would have been created (and then fixed!) to lift out the damaged part and bring in a long-lead…
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Spare Part – Valve Corrosion Protection

The Challenge This major natural gas company needed a solution to keep their larger critical spare parts corrosion free while in storage for an unknown future date of use. They need to keep larger, more expensive spare parts on hand, and ready to use, because when a part like that is needed for replacement, they…
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Crude Oil Pit Rebuild & Protection

The Challenge This old crude oil pit was exhibiting decay from years of neglect. Some concrete areas were worn down to the reinforcement. Repair budget was a key issue, so Unconventional Solutions worked together with the customer to find the most economical solution without the expense and time of a complete tear-out and re-pour of…
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Power Plant Warehouse Floor Repair

The Challenge Years of heavy use, forklift traffic, water, cleaning chemicals and salts had severely damaged this floor at the primary warehouse of a Michigan Power Plant. The customer needed a long term solution that could be installed over the weekend, during a unit outage, to minimize inconvenience and downtime and save money by not…
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Leeching Trench Repair

The Challenge This Refinery had a concern with soil contamination by ethanol solvents and hydrocarbons. They contacted Unconventional Solutions for a system that would repair, protect, and upgrade the trench to give them a long-term solution to protect the environment without costly tear-out and re-pour of the entire trench. The Solution The affected area was…
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PCB Encapsulating System

The Challenge This Major Electrical Company Service Centers floor had PCB  (Polychlorinated Biphenyl’s) contamination from transformer oil spilling on it, as back in the 70’s, a crew had pulled a leaking transformer along the floor. They wanted to become the hero for their employees by providing a safe environment to work.  They avoided paying Millions…
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High Build Flooring System

The Challenge A 50+ year old floor was creating a potential OSHA Reportable of a Trip, Slip or Fall at a Major Gas Utility Company. They contacted the USI Team for a long-lasting solution that would repair, protect and upgrade the flooring that was currently in place. The Solution The Flooring System that the USI…
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Acid Tank Relining

The Challenge USI’s reputation for Technical Support, Training & Trouble Shooting, had a fellow SEMPPES’s Member (South Eastern Michigan Power Plant Society) recommend USI to this Power Plant that needed help with a new acid resistant lining. The first step was determining if the wall thickness was adequate for the relining by doing a UT…
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Automotive Tunnel Water Leak Concrete Repair

The Challenge This Automotive Company had a tunnel that was leaking for over 10 Years! This tunnel is used for getting from one building to another underground during rainy or snowy weather. They had 3 different contractors come in to fix the situation and all 3 of those solutions had failed. They contacted the USI…
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