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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.

Rethink Your Repair Operations – 5 Reasons To Avoid Hot Work Permits

In 2024, OSHA is pushing ever harder to reduce the number of injuries and fatal accidents contributed directly to welding, and has labeled such a “high priority” in its operations. This article goes over how to avoid welding and hot work permits all together.

The US Bureau of Labor Statistics further declared welding poses unique risks to over 500,000 workers due to explosions, falls, crushing, electrocutions and asphyxiations. (www.wcwelding.com)

With these realities, something different must be implemented to keep your operations safer and more efficient. As a result, the most innovative companies are contributing to the strong and wise decision to turn to the application of Resimac and or Duromar epoxy coatings and metal repair products for:

  • Metal Repair / Cold Weld Alternatives
  • Repair of Leaking Pipes and Worn Equipment
  • Chemical Tank Linings / Tank Patching
  • Chillers and Heat Exchanger Refurbishment
  • Corrosion protection

At USI Groups, we have already partnered with the following companies to address their issues and avoid hot work permits with Resimac solutions:

As an additional benefit, we provide the application education necessary to succeed with all of our products. This article is your invitation to allow us to provide the same innovation to your company. Click on the link below to select your quantity and we will ship Resimac to your facility immediately.

If you would also like to speak with us for more information and the processing of your order, we can be reached at 248-735-7000.

Either way, it is our privilege to serve you and we look forward to our long-term relationship with you.

Resimac Resimetal 101

Resimac Resimetal 101 Metal Repair Paste

Resimac Resimetal 101 is a two component solvent free epoxy metal repair compound designed to fill surface erosion & corrosion on metallic surfaces. The material can be applied to mechanically or abrasive blast cleaned surfaces and once cured will retain high mechanical adhesion to metallic substrates. The thixotropic nature of the product means it can be applied at thicknesses up to 25mm without sagging and can be machined to fine tolerances.

Resimac Resimetal 101 Typical Applications

  • Worn or damaged pump shafts
  • Worn bearing housings
  • Worn keyways
  • Cracked pump or valve casings
  • Damaged flanges
  • Cracked engine blocks
  • Scored hydraulic rams
  • Leaking Tank Seams

The Resimetal 100 series products are capable of repairing a wide range of metal components. The full series is described in brief below, if you need more details please navigate to that product linked below.

Resimac Resimetal Metal Repair Product Range
101 Metal Repair Paste – High build engineering grade repair paste – Current Product!
103 Metal Repair Stick – Fast curing putty for emergency repairs
104 Metal Repair Fluid XF – Fast curing fluid for application to oily surfaces
105 Aqua Stick Fast – curing putty for underwater repairs
106 Metal Repair Paste XF – Fast curing engineering grade repair paste
108 Pipe Repair Tape –  Rapid curing moisture activated repair bandage

Resimac Resimetal 104 XF

Resimac Resimetal 104 XF Metal Repair Fluid

Resimac Resimetal 104 XF Metal Repair Fluid a two component solvent free fast curing epoxy repair fluid. The product has been designed to be applied to surfaces where only manual or mechanical surface preparation can be performed and to surfaces contaminated with low viscosity oils and lubricants.

FEATURES

  • ​Solvent free epoxy technology
  • ​Brush or applicator tool applied
  • Apply to manually prepared surfaces
  • Apply to oil contaminated surfaces
  • Fast cure – hard dry in 45 minutes
  • Approved by NWEL for onsite transformer repairs​

TYPICAL APPLICATIONS

  • ​Leaking Pipe Joints
  • Leaking Tank Seams
  • Transformer Repairs
  • Leaking Flange Fittings
  • Anti slip coating for metal decks and stairs
  • Resurfacing of corroded steel plates

The Resimetal 100 series products are capable of repairing a wide range of metal components. The full series is described in brief below, if you need more details please navigate to that product linked below.

Resimac Resimetal Metal Repair Product Range
101 Metal Repair Paste – High build engineering grade repair paste
103 Metal Repair Stick – Fast curing putty for emergency repairs
104 Metal Repair Fluid XF – Fast curing fluid for application to oily surfaces – Current Product!
105 Aqua Stick Fast – curing putty for underwater repairs
106 Metal Repair Paste XF – Fast curing engineering grade repair paste
108 Pipe Repair Tape –  Rapid curing moisture activated repair bandage

 

Resimac Resimetal 106 XF

Resimac Resimetal 106 XF Metal Repair Paste

Resimac Resimetal 106 XF Metal Repair Paste is a fast curing two component solvent free epoxy metal repair compound. The product has been designed for use on a wide range of metallic surfaces and once cured is readily machinable.

FEATURES

  • Solvent free epoxy technology
  • 5 minutes usable life
  • Fully cured in 60 minutes
  • Bonds to any metal surface
  • ​Applied by spatula or applicator tool
  • High build capability (1″ without slumping)
  • Can be applied underwater
  • Apply to manually prepared surfaces
  • High mechanical strength

Resimac Resimetal 106 XF Typical Application

  • Damaged Pump Shafts
  • Leaking Tank Seams
  • Underwater Hulls
  • Cracked Pump or Valve Casings
  • Cracked Engine Blocks
  • Underwater Structures
  • Damaged Flanges
  • Underwater Surfaces

The Resimetal 100 series products are capable of repairing a wide range of metal components. The full series is described in brief below, if you need more details please navigate to that product linked below.

Resimac Resimetal Metal Repair Product Range
101 Metal Repair Paste – High build engineering grade repair paste
103 Metal Repair Stick – Fast curing putty for emergency repairs
104 Metal Repair Fluid XF – Fast curing fluid for application to oily surfaces
105 Aqua Stick Fast – curing putty for underwater repairs
106 Metal Repair Paste XF – Fast curing engineering grade repair paste – Current Product!
108 Pipe Repair Tape –  Rapid curing moisture activated repair bandage

Resimac Resimetal 108

Resimac Resimetal 108 Pipe Repair Tape

Resimac Resimetal 108 Pipe Repair Tape is a high performance rapid curing moisture activated repair bandage specifically developed for the repair of leaking pipes. 108 Pipe Repair Tape is ideal for systems operating up to 218psi with a maximum operating temperature of 120C.​ The tape is manufactured from woven polyester fabric which is impregnated with a polyurethane resin that is activated by water. The pipe repair bandage can be applied to leaking pipes and be fully cured within 30 minutes.

FEATURES

  • Solvent free polyurethane technology
  • Fast curing—Touch dry 30 minutes
  • Suitable for metallic, GRP & plastic surfaces
  • No shrinkage
  • Up to 750psi pressure resistance once cured
  • Resists 270˚C operating temperatures

The Resimetal 100 series products are capable of repairing a wide range of metal components. The full series is described in brief below, if you need more details please navigate to that product linked below.

Resimac Resimetal 100 Series Metal Repair Product Range
101 Metal Repair Paste – High build engineering grade repair paste
103 Metal Repair Stick – Fast curing putty for emergency repairs
104 Metal Repair Fluid XF – Fast curing fluid for application to oily surfaces
105 Aqua Stick Fast – curing putty for underwater repairs
106 Metal Repair Paste XF – Fast curing engineering grade repair paste
108 Pipe Repair Tape –  Rapid curing moisture activated repair bandage – Current Product!

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Navigating the Hazards: A Comprehensive Guide to Slips, Trips, and Falls Prevention in the Industrial Sector

In the bustling realm of industrial workplaces, slips, trips, and falls constitute a significant threat to employee safety and operational efficiency. The Centers for Disease Control and Prevention (CDC) reported that in 2020, a staggering 18% of all nonfatal work injuries resulting in days away from work were attributed to these incidents. Fast forward to 2023, and the financial repercussions are even more alarming, with Liberty Mutual reporting that slips, trips, and falls cost US businesses an estimated $17 billion. Today we delve into the major causes of these accidents, their implications, and how innovative solutions can significantly reduce their occurrence.

Understanding the Cost of Slips, Trips, and Falls

Slips, trips, and falls are not just physical hazards; they are substantial financial burdens. The direct costs include medical expenses, workers’ compensation, and legal fees, while indirect costs encompass lost productivity, training replacement employees, and repair or replacement of damaged equipment. With the cost reaching $17 billion, it’s evident that these incidents are a major drain on resources.

Identifying the Major Causes

Slips usually occur when there’s a loss of traction between the shoe and the walking surface. Common culprits include wet or oily surfaces, occasional spills, weather hazards, and loose, unanchored rugs or mats. Trips happen when an object obstructs one’s path, such as clutter, exposed cables, uneven walking surfaces, or poor lighting. Falls can be a result of slips and trips or may occur from heights or into openings in the floor.

The Implications of Slips, Trips, and Falls

Beyond the immediate physical harm to employees, these incidents can lead to significant operational disruptions. They affect morale, increase absenteeism, and can even lead to severe legal consequences for non-compliance with workplace safety regulations.

Prevention: Key Strategies and Solutions

Preventing slips, trips, and falls requires a multifaceted approach, incorporating both procedural changes and physical solutions.

  1. Routine Safety Audits: Regularly inspecting the workplace for potential hazards is crucial. This includes checking for spills, obstructions, and ensuring all areas are well-lit and signposted.
  2. Employee Training: Conducting regular slips, trips, and falls safety talks can significantly raise awareness and educate staff on preventive measures.
  3. Maintaining Clean and Orderly Workspaces: Encouraging a culture of cleanliness and organization goes a long way in preventing these incidents.
  4. Investing in the Right Solutions: This is where Unconventional Solutions comes into play. Our range of industrial repair and maintenance products can be instrumental in mitigating the risks associated with slips, trips, and falls.

Unconventional Solutions: Your Ally in Accident Prevention

Unconventional Solutions offers a variety of products tailored to enhance workplace safety and prevent these costly incidents.

  • Test Your Current Floor: Schedule a floor coefficient of friction test. (technical way of saying “how slippery is this surface?”)
  • Anti-Slip Coatings: These coatings can be applied to floors to increase friction and reduce the likelihood of slips, especially in areas prone to wetness.
  • Quickly Remove Hazards: Peat Sorb cleanly and completely encapsulates hydrocarbons on any surface. This safe, biodegradable product can go a long way to avoiding slips on wet surfaces. An essential to any chemical containment kit.
  • Floor Marking Systems: Clearly marked walkways and hazard areas can significantly reduce confusion and the potential for accidents. USI fast Cure line striping can make sure that your aisleways and hazardous area are clearly marked.
  • Repair Products for Uneven Surfaces: Quick-fix solutions for cracks, uneven surfaces, or potholes can prevent trips and falls effectively.

USI can help even if you need a total floor makeover. Fixing cracks, leveling flooring and applying an epoxy coating with grit to create the safest workplace possible. Repairing and coating your concrete isn’t just a great way to increase workplace safety, a clean well coated floor presents well for investors and other stake holders. Reach out today for a site visit if you would like us to come and assess your current flooring.

Conclusion: Making Safety a Priority

In conclusion, while the statistics from the CDC and Liberty Mutual highlight the severity of the issue, they also underscore the importance of proactive prevention. By understanding the causes, implications, and implementing effective solutions like those offered by Unconventional Solutions, businesses can safeguard their employees, boost productivity, and save billions in potential costs.

To learn more about how Unconventional Solutions can help your business prevent slips, trips, and falls, email us at CS@usigroups.com or call 248-735-7000. Remember, a safer workplace is not only a regulatory requirement but a cornerstone of successful and sustainable operations.

photo of a shiny warehouse floor that has been encapsulated

2023 an Unconventional Year in Review

2023 was an exciting year for us. We built our new website (thanks for visiting), welcomed incredible new team members, and began work on one of our most exciting projects yet.

Our Biggest Project of the Year

We encapsulated floors at a large facility of an energy service provider in Michigan. Encapsulating a concrete floor can create a few benefits:

  • Protection: Adding a protective layer over concrete flooring can limit wear and tear, scratches, stains, or chemical damage — extending the lifespan of the flooring.
  • Cost Savings: By encapsulating flooring, instead of replacing the surface and concrete, the customer will be saving substantial costs on replacement flooring.
  • Sustainability: Encapsulating prevents concrete from being disposed of, giving it a longer life and stopping the environmental impact that would be caused by the production and installation of new concrete.

The 13,600-square-foot facility had disbonded concrete and fading coating from years of use. To begin the encapsulation process, we used machinery that can grind down the affected flooring and vacuum the resulting dust in one motion, reducing the amount of dust released into the work environment.

We then utilized a saw to cut around several large areas of disbonded floor, then jack-hammered the old flooring to reveal the concrete substrate below. Then the flooring rebuilding process began, as our team used USI Epoxy Mortar Patch Kits.

Once all the damaged areas were repaired, USI’s flexible broadcast primer was applied then, we applied two coats of USI Epoxy Slurry to create a more flexible and, thus, longer-lasting floor for the entire warehouse, plus one coat in all the other areas of the facility.

Next, we coated the entire floor using USI High Build Epoxy in Grey, which provides high impact resistance, high abrasion resistance, and some chemical resistance, with an Aluminum Oxide broadcast throughout for slip resistance. Yellow line striping was then added to any applicable areas using USI Fast Cure Line Striping, which can withstand exposure to many common solvents and chemicals.|

As the warehouse floor nears completion, our team moves onto the dock. For the dock, we will grind the floor for the proper anchor profile and rebuild two bases around two columns, utilizing Resimac 571 LW. Resimac 571’s lightweight makes it ideal for column repairs. Next, the USI team will prime the entire floor of the dock with USI Flexible Broadcast Primer, which is designed for sealing traffic surfaces exposed to vehicular or foot traffic. Next will be the USI High Build Epoxy in Grey and Broadcasting Aggregate, which is recommended for high-traffic and forklift areas and slip-resistant coating.

With a planned 13,000 plus square footage of floor, we’re saving this customer an incredible amount of costs compared to a floor replacement project and reducing the environmental impact of a full replacement project. Needless to say, the entire team here at USI is very excited about the progress and outcome of this project.

Before

During

photo of a warehouse floor that has been grinded downPhoto of a warehouse floor that has been grinded down prior to encapsulationphoto of a warehouse floor prior to encapsulationPhoto of warehouse PVC floor prior to encapsulationPhoto of a hallway prior to encapsulation

After

photo of a warehouse floor with a gate. The floor is shiny and has been encapsulated photo of a shiny warehouse floor that has been encapsulated

photo of a warehouse floor that has been encapsulatedphoto of a warehouse floor that has been encapsulated with grey epoxy

photo of a hallway that has been encapsulated with epoxy

Product Highlights of 2023

When it comes to repairs, Resimac was one of our most popular product lines in 2023. Based in England, Resimac supplies a range of epoxy, polyurethane, and silicon coatings and repair materials to the oil and gas, petrochemical, marine, paper and pulp, water, power generation, and chemical industries. See our full line of Resimac products here.

For protective coatings, Denso is our product highlight of 2023. Denso, a Winn & Coales International branch, produces and supplies corrosion and chemical-resistant coatings and linings for steel, concrete, and timber in harsh environments. Check out our full line of Denso products at our store.

Expanding Pipeline Inspections for 2024

In other news, for 2024, we’re hoping to expand our Pipeline Surface and Coatings Inspections and add new team members to support this growing service.

Our Pipeline Inspections include surface prep, evaluating mills, as well as how thick your protective coatings are under different conditions.

Pipeline Inspections can help prevent corrosion, ensure structural integrity, help your infrastructure adhere to regulations and environmental safety standards, and maximize its lifespan. Contact us today to learn more about our Pipeline Inspections.

Stay Tuned for What Else We Have in Store for 2024

We’re always searching for ways to better serve our customers and deliver the best coating and composite repair solutions. Check out our newsletter and industry news section to stay informed in the New Year.