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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.

A different way to think about Corrosion Control in Maintenance. S2S Product Line from Valkyrie Enterprises

Who It’s For

This session is useful for:

  • Fleet Managers

  • Equipment Managers

  • Machinery Managers

  • Asset Protection


About the Speaker

Dave Evans is the Director of Commercial and Industrial Business Development for Valkyrie Enterprises. His career includes decades of executive management expertise working as a senior executive in the protective coatings and corrosion industry. Dave holds NACIP 3 and AMP PC credentials and has been an AMP instructor for 37 years.


A different way to think about Corrosion Control in Maintenance. S2S Product Line from Valkyrie Enterprises.

Most corrosion doesn’t occur in laboratories. It occurs on a real-world structure like the picture that’s in the slide. This is actually a picture of a bridge that an engineer sent to me that he was taking a look at, and he wanted to make sure that whatever they were doing was the right thing that they were doing, but they had some constraints that they couldn’t work around. A lot of times when you take a look at the situation that’s in the picture, you can’t do perfect surface preparation, or maybe you don’t have the downtime and can’t close the structure. Or maybe you just don’t have the funding at that present time to do it.


Why Traditional Coatings Struggle in Maintenance:

A lot of times the specification is written around applying traditional coating systems to new steel construction. A lot of times it depends on something like a commercial blast cleaning or maybe even something that’s more critical, like near white or white, where they need an anchor profile, typically two to four mils or something like that. Their corrosion-resistant properties are dependent on how well they actually can adhere to a mechanically prepared surface, typically abrasive glass cleaning. And lots of times they’re sensitive to moisture, surface contamination, salt contamination, and those kinds of things.

What S2S offers is a different approach:

It’s not to replace traditional coding systems. They offer some unique solutions to difficult situations where maybe you can’t abrasive blast clean for any one of a number of reasons, or you don’t have the ability to spray apply a coating.
  • Penetrates and migrates into rust, seams, pits and surface irregularities where corrosion begins.
  • Displaces moisture from steel surfaces
  • Combines corrosion inhibition with flexible barrier protection
  • Not dependent on perfect surface preparation ion for performance
The Valkyrie Corrosion Shield line of products is actually our workhorse line of liquids and the idea here is they they provide extended corrosion protection, long-term corrosion protection to steel, aluminum, different kinds of metallic surfaces. They come in different thicknesses based on how long-term corrosion protection you really need and what kind of items, like salt, fog, resistance, and cyclic corrosion testing, you need. Whitewater flow code is another example of something that’s very unique. If you’ve ever tried to prepare a surface and coat a surface that requires confined space entry, you know it’s very, very unique, can be very costly, and can be very dangerous. Valkyrie offers coating systems, especially this void and router flow code, where you don’t need to have confined space entry to make the coding system work. We’ve used it on, you know, certainly lots of builders and void spaces on barges and ships, but also on unique applications like monopiles for offshore wind towers and structural supports for offshore oil platforms. And then at the other end of the scale, we make products similar to the dielectric spray, which has tremendous insulative qualities. It comes in an aerosol and is used on dielectric components, circuit boxes, and battery terminals, and the idea is that it’s a substitute for dielectric grease. It’s easy to apply; if you need to remove it, it’s super easy to remove and much easier than the alternative.

Where this approach works best:

The Valkyrie S2S products fit into multiple industries. We grew up in the marine business. S2S has been in business since 2004, and their primary focus was marine when we started, and they have a tremendous relationship with the US military, especially the Department of Navy, but we’ve also expanded to bridges and highways, different kinds of construction equipment, and anything that requires either long-term or short-term corrosion protection. The common thread between all of them is generally in-service steel or other metals that require maintenance so that they don’t corrode, or you want to stop the corrosion, not just simply convert it from rust into something else, where you have moisture or salt exposure and you don’t have the ability to do outstanding surface preparation at that time.

How S2S Fits into Corrosion Management:

  • Compliments traditional costing systems

  • Addresses corrosion challenges where traditional coating systems struggle

  • Supports maintenance without full shutdown.

S2S doesn’t replace traditional coating systems. It extends asset life where mechanical adhesion-based systems struggle.

Q&A Highlights

From what you’ve seen in the field, where does S2S actually save the most money? Labor reduction, extended inspection intervals, or reduced rework?
Where it works best is where you’ve got areas that are, well, I’m going to break it into two or three different things. Let’s talk about areas where you can abrasive blast clean, but you’ve still got corroding steel. I’m going to make it up, but let’s say you’re in a saltwater marine environment close to the ocean and you’re doing structural steel on a bridge. Now, while S2S isn’t going to provide aesthetic value like, probably, a polyurethane on the steel where you can’t abrasive blast clean, it’s a simple application. You knock off the loose rust and make sure that it is clean, and it doesn’t even have to dry. You can then apply the product with a spray, brush, roller, or whatever it takes. You know you with some of the items you can flood coat if you want. So long-term corrosion protection, absolutely. The beauty of it is. Let’s say down the road when you have the funding and you want to paint it, how do I remove it? What’s the next maintenance site? With a high-pH detergent, something like Simple Green or one of the products that is out there, you can certainly remove it with warm water and a high-pH detergent and abrasive glass, clean it, and put on there whatever you want to do later on.

It says if someone is evaluating this against a traditional coding system, what scenario makes S2S the obvious choice, and where could you say it’s not the right fit?
It’s not the right fit for most kinds. Well, any kind of immersion in a liquid, OK. And I don’t mean water, but let’s say, for the sake of example, you’ve got a, you know, sour crude oil or gasoline or something like that. Absolutely not. But where it does work very, very well is where you’ve got a situation where I need to provide long-term corrosion protection. I want to do it with my own plant maintenance personnel that can’t use abrasive glass cleaner, don’t want to, don’t have the time, or whatever. It may be, and I mean a long-term corrosion protection, in that that kind of scenario works tremendously well. The other thing is we make anti-corrosion tapes. If I need to tape-wrap something in paste, I can have corrosion resistance that will last for decades depending on the application and how I want to do it.

Have you seen or heard of it causing any CP interference? Does it have NSF or NSF 61?
No, none at all


Have a project coming up and want to compare corrosion protection options, give us a call today.

Contact Unconventional Solutions (USI):
Email: office@usigroups.com
Phone: 248-735-7000

Gridguard HD Plus

Who It’s For

This session is useful for:

  • Pipeline owners, engineers, corrosion teams, and inspectors evaluating rock shield performance and CP compatibility 

  • Contractors and crews who want easier handling, fewer cold-weather headaches, and faster lowering operations 


About the Speaker

Jamie Blanco has worked closely with installers and engineers to translate real-world challenges into practical solutions. She has been with JDR Enterprises for nine years and played a key role in the development and approval of Gridguard HD Plus, serving as a manufacturer’s representative focused on advancing rock shield performance and adoption.

Gridguard is manufactured in Madison, Georgia.


Why Rock Shield Matters

Rock shield is used to:

  • Protect the coating from rock impact during backfill—and ideally continue that protection after burial

  • Help prevent coating damage that can lead to long-term corrosion 

  • Support the overall corrosion-control system, including cathodic protection 

A “good” rock shield shouldn’t only survive the backfill—it should protect the coating long-term without becoming a contributor to coating failure risks


Common Challenges (Field + Engineering)

Field challenges crews deal with

  • Heavy rolls, moisture retention, freezing, and handling problems that slow installation and raise safety concerns 

  • Difficult use with cradles/rollers leading to lost time and money

Engineering concerns

  • Cathodic protection compatibility is one of the first questions raised with rock shield selection 

  • Thick materials that hold water, abrasion risk against coatings, and unvetted/untested products being used in the field 


What to Ask Before You Approve Any Rock Shield

Use these as a quick checklist for your next spec review:

  • Does the design eliminate void spaces where small fragments can get trapped? 

  • Has it been tested for CP flow during burial and compaction (not just unburied tests)? 

  • Does installation require heat welding—and if so, what are the risks of heat near the coating? 

  • Does it retain moisture or freeze in cold weather, creating handling delays? 


Gridguard HD Plus Highlights (At-a-Glance)

Designed for engineering + corrosion teams

  • 6 oz geotextile backing bonded to a bidirectional extruded poly for impact resistance 

  • Geotextile backing intended to assist CP and “will not shield,” with test reports available 

  • Strength comes from the bidirectional poly structure, not “just thickness” 

  • Helps reduce abrasion on the coating and allows water/fines to move around the pipe

  • Eliminates void space concerns (fragment trapping) 

Built for field productivity

  • Light weight: ~0.41 lbs/sq ft (about half of traditional rock shield, per the talk) 

  • Longer rolls: 50 ft vs. 30 ft traditional 

  • Can be used in rollers/cradles without bunching or tearing, speeding lowering operations 

  • Uses less tape (often about half) and can reduce wrap intervals (commonly up to ~12–18″) 

  • Cold-weather flexibility tested to -40°F to -50°F (including wet/frozen conditioning) 

  • UV protection: ~1.5 years built in, plus additional protection from carbon-black wrapping 

  • Made with up to 24% recycled materials 


“Avoid This” — Most Common Field Mistakes

Jamie called out two common install errors that can create downstream issues:

  1. Lip installed “up” instead of down — the lip should be down and wrapped toward the bottom of the pipeline to reduce fragment entry. 

  2. Fabric installed outward — ensure the geotextile is against the coating (not facing out). 


Q&A Highlights

Other applications discussed:
Gridguard material has been used (or explored) in applications beyond pipeline—including under tanks with anodes, under liners, and behind concrete in other projects. 

Hazardous waste / liner cell protection:
A question came up about using it for additional impact resistance in new hazardous waste dump cells where crews currently use geo fabric prior to liners. 

High temperature rating:
When asked about “top temp,” Jamie noted there are melt-point values available (start-to-melt vs. fully-melted), and she can provide those specifics. 


 

Have a project coming up (capital or integrity maintenance) and want to compare rock shield options, CP test reports, or best-fit roll sizes?

Contact Unconventional Solutions (USI):
Email: office@usigroups.com
Phone: 248-735-7000

How to eliminate trips, slips and falls

Today we are going to talk about Unconventional Solutions to avoid trips, slips and falls. Why are we talking about “slips, trips and falls”? Slips and trips are very common and preventable in the workplace. According to the 2025 Liberty Mutual Workplace Safety Index, the annual costs of falls on the same level have gone up to $10.5 billion dollars annually. That’s just the workman’s comp version of it, which doesn’t include overtime and labor, production disruption, rework, or litigation.

Common slips, trips, and falls root cause:

  • Surface defects (cracks, spalls, potholes, settled slabs, broken stair nosing)
  • Housekeeping (cords/hoses, pallets, clutter, poor storage, debris at workstations)
  • Low Traction (smooth concrete, worn coatings, polished floors, wet/greasy areas)
  • Lighting & Visibility (shadows, glare, poorly marked edges, inconsistent floor markings)
  • Transitions & Slopes (ramps, dock plates, thresholds, mats that curl, uneven expansion joins)
  • Weather & Drainage (tracking water/ice indoors, leaks, inadequate entry matting/drains)
  • OSHA expectation (general industry): walking-working surfaces are maintained free of hazards such as leaks, spills, snow/ice, loose board, and protruding objects.

Prevention Strategy:

  1. Inspection: Routine walking-path audits and work orders
  2. Repair: Fix defects fast (same shift if possible)
  3. Improve Traction: Texture, coatings, mats, nosings
  4. Control Water: Drainage, entry matting, spill response
  5. Communicate: Mark edges, standard signage, training

Concrete-focused “quick wins”

  • Patch spalls/potholes before edges break down further
  • Rebuild heaved joints/transitions (dock plates, thresholds)
  • Seal joints & cracks to reduce water intrusion and freeze/thaw damage
  • Add texture/anti-slip coatings in wet process areas
  • Use high-contrast striping at elevation changes

Why composite repairs are different:

  • Fast return to service
  • Enhanced durability
  • 100% solids – no shrinkage
  • Abrasion and impact resistant
  • Better chemical resistance

We have solutions for every situation:

QUESTIONS:

  1. What is the maximum build capability for the 570 Concrete Patch Repair XF—how much can you put down at one time?
    A)  2” at a time.
  2. If it exceeds the 2”, is there another product that we can use to fill larger voids and then topcoat with the 570 Concrete Patch Repair XF?
    A) Yes, you can fill it with crushed gravel under to build up more. After the initial hard drying period of 2 hours, you can apply an additional 2-inch coating.


If you have any questions about our slips, trips and falls product solutions, you can connect with us at www.usigroups.com.

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