Success Stories

HVAC Fan Shaft Repair

The Challenge An automotive manufacturing company was hearing heavy vibration of a fan shaft on top of the roof, so they called Unconventional Solutions out for an emergency repair to fix a cracked shaft. The shaft was located in a penthouse HVAC building on the roof of a warehouse used for heating. The shaft was…
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Paper Mill Pipe Repair

The Challenge The Paper Mill Plant contacted the USI Team having an issue of leaking, corroded, eroded pipes that are not only impossible to replace, but that they needed to find a solution to extend the life of the pipes without replacing them. The USI Team came up with an adequate solution to avoid replacing…
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Treated Water Pipe Leak Repair

The Challenge A Steel Mill was losing 50 to 70 gallons/minute on a 10 inch chemically treated water pipe. This leak was costing the plant almost $4,000 a day in chemical treatment costs.  They attempted to use a mechanical clamp, but because of the nipple, they were not able to get a tight seal and continued…
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Stainless Steel Conveyor Grip Repair

The Challenge The grip system on this stainless steel flat top conveyor was wearing off every 2-6 weeks, leaving a slippery condition for workers getting in and out of moving trucks on the assembly line. Unconventional Solutions was called in to eliminate the frustration and solve the problem.   The Solution The conveyor surface was…
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Auto Plant Striping Pit Repair

The Challenge The striping pit at this Michigan auto plant – the area cars get their racing stripes – was accumulating damage from condensation and moisture penetration.  The plant was built on a wetland, which contributed to persistent groundwater penetration. Numerous treatments were applied over the years, but nothing was keeping the water out and…
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Hydraulic Cylinder Repair

The Challenge This hydraulic cylinder on an automotive assembly line hoist was scored and pitted causing loss of hydraulic oil and lifting efficiency. The resulting hydraulic fluid leak could lead to a potential slip, trip or fall to a coworker. The plant was looking at a repair of the hydraulic cylinder that would cost them…
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TANK – Seam/Rivet Repair

The Challenge A Chicagoland refinery had a holding tank that was suffering from corrosion and erosion on the seams and rivets.  They were looking for an economical solution to keep them up and running, rather than an expensive and long-lead replacement.  The USI team had just the right solution for this issue. The Solution The…
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TANK – Floating Roof Repair

The Challenge A Major Tank Farm and Pipeline Company for North America had a tank in NW Indiana that they needed to get 2 more years out of, without a major replacement of the roof. This floating roof was failing and leaking vapors into the air causing EPA issues. Their Engineering Firm contacted USI for…
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Facility Maintenance

University Hospital Chiller – 2020

The Challenge Over the past 5 years, this University Hospital has been experiencing galvanic corrosion in many of their chillers, causing tubes to plug.  Unconventional Solutions, Inc. has had success with the refurbishment of their chillers in the past to lower their energy cost.  So needing to refurbish another chiller here in 2020, they did…
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5 Reasons to Reconsider Tank and Infrastructure Repair Operations

In 2021, OSHA is pushing harder than ever to reduce the number of injuries and fatal accidents contributed directly to welding and has labeled it a “high priority” in its operations. The US Bureau of Labor Statistics declared that welding poses unique risks to over 500,000 workers due to explosions, falls, crushing, electrocutions and asphyxiations.…
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