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.
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Ball Mill Room Concrete Floor Rebuild
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
Chemical Resistant Coatings
Chemical Resistant Coatings with Chris Mathson and Wayne Jobling from Resimac.
Protective systems for the energy and Oil and gas sectors
Wayne and Chris are product and technical managers. The default coating that they usually talk about is 511 UCEN.
511 UCEN:
Suitable for permanent immersion; chemical storage, and secondary containment: chemical bunds
Key Properties:
- Brush and roller application
- Plural feed airless spray
- High build, 2-coat application
Chemical Resistance:
- Hydrochloric acid (HCI) up to 38% concentration
- Sulfuric acid (H₂SO₄) up to 98% Concentration
- Sodium hydroxide/Caustic (NaOH) up to 50% concentration
- Alcohols, amines, fuels and solvents
Ensuring the correct system is selected
Ask Key Questions:
- What is the issue I am trying to solve? What are the substrates I need to coat?
- Steel, concrete, GRP, etc., a mixture of substrates?
- Are there inherent structural issues that require resolving prior to coating?
What are my operating conditions?
- Chemicals and concentrations
- Operating temperatures and pressures
What are my constraints?
- Time limitations to carry out the work/return to service
- Weather issues, i.e., ambient temp, moisture
- Limited ability to correctly clean and prepare the area
- How long do I need it to last for?
Once we have the proper recommendation and specification, all items need to reviewed and talked about. All the different Resimac coatings have specification sheets for you to follow. There are a range of solutions. What is the problem, and what are you trying to fix? There are solutions.
When it comes to chemical resistance, the Resimac coatings can be applied to other areas that have a chemical exposure. (Short-term exposure)
Questions:
- What are some different factors that might change a surface preparation requirement?
- Can these coatings be spray applied, or are they all roller applied?
Special Guest Lynn Hurdman from Peat Sorb
Welcome to another USI Tech Talk, as we welcome Lynn Hurdman from Peat Sorb. She is the expert in her industry.
Lynn is from Canada, Peat Sorb is a Canadian company, and there isn’t a chemical or liquid that Peat Sorb can’t handle. There is no response, no incompatibility, and no health problems at all. Peat Sorb was the only one that had a net zero in the atmosphere, according to awards from the USDA. All government agencies and contractors must buy Peat Sorb.
Check out some of the questions that were asked during the #TechTalk:
- About how long with the traditional peat sorb float on water while it’s absorbing a hydrocarbon?
- Can you talk about the Michigan State University’s Botany class and the studies that they did with oil on a hot sod field?
- Can you talk about Certification’s as far as Coast Guard and the EPA?
- What kind of acids does Peat Sorb absorb?
- What is the disposal protocol with used peat sorb with hydrocarbons?
- Under what conditions does peat sorb underperform or fail?
- Fire Departments, and they use a clay-based product, but in talking with them and trying to show the benefits of peat sorb, their questions are “What do I do on those windy days”
