Case Studies
For over 20 years, USI has provided protective coatings and corrosion prevention products proven to protect our nations most critical infrastructure and industrial machinery. Along the way we have documented many projects and pain points we have been able to help our partners repair, protect and upgrade.
Most Recent Articles
Diesel Tank Refurbishment for Long-Term Protection
The Problem
A steel tank, integral to the operations of a facility, began showing signs of deterioration. Its coating was cracking and failing, and the color had dulled significantly due to continuous exposure to the elements. Concerned about the integrity and longevity of their tank, the facility sought a durable solution that would not only restore the tank’s appearance but also reinforce its resistance to the harsh outdoor environment.
The Substrate
- Steel: The tank was made of steel, a material valued for its strength but prone to corrosion when its protective coatings fail.
The Solution
Unconventional Solutions Inc. (USI) took a systematic approach to refurbish the tank:
- Surface Preparation: USI began by abrasive blasting the entire surface of the tank. This crucial step ensured the removal of the old, failing coating and created the proper anchor profile for the new protective system.
- Primary Sealant Application: Next, Viscotaq ViscoSealant was applied to the tank chime area, where the steel tank met the concrete base. Viscotaq ViscoSealant is known for its exceptional adhesion properties and elasticity, providing a strong, waterproof seal.
- Protective Wrapping: The application of Viscotaq ViscoSealant was followed by the installation of Viscotaq EZ Wrap over the entire tank chime area. This wrap formed a robust protective seal around the tank chime, safeguarding the area against water ingress and corrosion.
- Final Coating: To complete the refurbishment, USI applied two coats of Resichem 555 in white to the entire surface of the tank. This product was specifically chosen for its high UV resistance, protecting the tank from the damaging effects of sunlight, and its superior corrosion resistance properties.
Products Used
- Resichem 555 in white: A UV-resistant coating providing long-term protection against the elements.
- Viscotaq ViscoSealant: Applied to seal the critical intersection of the tank and its base.
- Viscotaq EZ Wrap: Used to reinforce the sealant and provide an additional layer of protection.
The Outcome
The comprehensive solution implemented by USI effectively restored the tank’s protective coatings, addressing both aesthetic concerns and structural integrity issues. The dual-coat approach using Resichem 555 in white not only enhanced the tank’s appearance with a fresh, bright color but also provided a reliable defense against future UV damage and corrosion. As a result of USI’s meticulous work, the tank is well-equipped to withstand the rigors of the outdoor environment, ensuring its continued service and reliability for years to come.
Emergency Watermain Repair of a Corroded 24” Pipe
The Problem
A 24” engineered steel watermain, which was previously protected with cold applied tape, encountered an unforeseen accident. It was struck by a fiber optic directional bore, causing a score at the bottom of the pipe. Over time, the damaged area succumbed to corrosion, and rust permeated through the steel, leading to the need for urgent repair to prevent water loss and maintain service integrity.
The Substrate
- CA6 Bedding with a FA6 backfill: A standard for underground piping, providing a stable base and proper drainage.
- Steel Pipe: The primary material of the watermain, known for its strength but also vulnerability to corrosion when damaged.
The Solution
The repair process required immediate and effective action:
- Pipe Assessment and Removal: A section measuring 13 feet of the damaged 24” steel watermain was meticulously cut out. This section contained the area that was struck and had since rusted through.
- Pipe Replacement: A new 13-foot section of steel pipe coated with fusion-bonded epoxy was prepared. This type of epoxy coating is known for its corrosion resistance and is often used in pipelines for its robustness.
- Welding and Securing: The new pipe section was securely welded into place with new butt straps. These straps served to connect the new section seamlessly to the existing pipeline infrastructure, ensuring the structural integrity of the watermain.
- Corrosion Protection Application: After the welds were completed, Viscotaq ST, a visco-elastic sealant tape, was wrapped around the welded seams. This product is chosen for its outstanding adhesion properties and its ability to prevent water ingress and corrosion.
- Outer Protection: To provide additional protection and mechanical strength, a PVC Outerwrap was applied over the Viscotaq ST. Measuring 6 inches by 100 feet, this outerwrap ensured that the entirety of the repair site was shielded from environmental factors.
Products Used
- Viscotaq ST 12”x33’: A visco-elastic sealant tape providing a strong, water-resistant bond over the welded areas.
- PVC Outerwrap 6” x100’: Serves as the final protective layer to the repair site, enhancing durability.
The Outcome The emergency repair of the 24” steel watermain was executed swiftly and effectively, minimizing service disruption and preventing extensive water loss. The combination of Viscotaq ST and PVC Outerwrap ensured a watertight and corrosion-resistant seal, restoring the integrity of the watermain. This solution not only rectified the immediate problem but also contributed to the long-term reliability of the water distribution system, a vital resource for the community served by the water plant.
For durable and reliable watermain repair solutions, Unconventional Solutions offers the expertise and high-quality products necessary to address even the most challenging pipeline issues. If your infrastructure requires expert attention, contact us to ensure a swift and robust repair.
Viscoelastics 101: Revolutionizing Water and Wastewater Treatment
In the complex world of water and wastewater treatment, finding innovative and efficient solutions is crucial for ensuring safety, sustainability, and compliance with environmental standards. Among the various technologies and materials at the disposal of industry professionals, viscoelastic materials stand out due to their unique properties and versatility. As your technical advisors specializing in water and wastewater facilities, we offer an in-depth understanding of how viscoelastic materials can revolutionize treatment processes, along with comprehensive training, troubleshooting, and technical support to maximize their benefits.
Understanding Viscoelastic Materials
Viscoelastic materials exhibit both viscous and elastic characteristics when undergoing deformation. This means they have the ability to both flow like a liquid under sustained pressure and return to their original shape like an elastic solid once the pressure is removed. This dual nature makes viscoelastics particularly useful in a variety of applications, from industrial processes to everyday products.
In the context of water and wastewater treatment, viscoelastic materials are valued for their ability to absorb and dissipate energy, reduce vibrations and noise, and improve the mechanical efficiency of treatment processes. Their unique properties enable them to be used in filtration, sludge processing, and even in the maintenance and protection of equipment.
Applications in Water and Wastewater Fields
Tank Repair: See how a tank with a large crack in need of repair was fixed within hours instead of days using Viscotaq Viscoelastic Sealant.
Potable Water Pipeline Protection: Contaminated soils can jepordize critical for water pipes. The Viscotaq viscoelastic system can be used to successfully prevent hazardous contaminants from inflitrating these pipelines at gaskets and joints.
Tank Chime Repairs: In this case study USI used viscoelastic sealant and wrap to seal a 1-1/2 inch gap that needed to be filled. Viscotaq products were used to create a seal and long lasting corrosion protection for this tank.
Our Services
Understanding the full potential of viscoelastic materials in water and wastewater treatment requires a deep dive into their properties, applications, and best practices for implementation. That’s where we come in. Our services include:
- Comprehensive Training: Equip your team with the knowledge they need to effectively utilize viscoelastic materials in your treatment processes.
- Troubleshooting: Encounter an issue? I offer expert troubleshooting to quickly resolve any challenges you may face.
- Technical Support: From selection to implementation, receive ongoing technical support to ensure optimal use of viscoelastic materials.
Schedule a consultation today
Are you ready to explore how viscoelastic materials can enhance your water or wastewater treatment processes? To discover the full range of possibilities and to ensure your facility is leveraging the latest innovations in treatment technology, schedule a consultation with me today. Together, we can optimize your operations, reduce costs, and achieve superior treatment outcomes.
Contact USI at 248-735-7000, email cs@usigroups.com or fill out the form below now to schedule your consultation and take the first step towards a more efficient and innovative treatment facility.