Customer Solutions

Industry: Heavy Industry - Power

This wind tower had become damaged over time and r

Wind Tower - Case Study

This wind tower had become damaged over time and required refurbishing because it was severely corroded. The customer was looking for a high performance long-term repair solution. The steel tower was prepared by using a Bristle Blaster, which mimics the results of grit blasting, to a near white metal finish, or a NACE Grade 2. One coat of 3M Scotchkote Epoxy Primer GP 120, an epoxy high solids steel protection system, was applied to the severely corroded areas. Then, two coats of 3M Scotchkote Encapsulation Coating Polynox 136 was applied.

3M,Scothckote,Thortex,Metal-Tech RG, Metal-Tech FG

Bearing Housing Repair - Case Study

A bearing housing was very badly worn on both the inside and outside. It was repaired without being dismantled. The roller bearing was fixed in the housing. All gaps were sealed with 3M Scotchkote Urethane Metal Repair RG 501. After these were sealed, 3M Scotchkote Metal Surfacer FG 502 was injected with a cartridge between the roller bearing and the bearing housing. The bearing housing was back in service in a few hours.

3M, Scotchkote, Thortex, Grano-Tech, Floor-Tech SP

Beverage Power Plant Floor Repair - Case Study

The floor in the power plant of a major beverage manufacturer was badly damaged from constant chemical attack. Following strict EPA guidelines, USI had the solution they needed. The damaged concrete was repaired with 3M Scotchkote Epoxy Concrete Repair 474, followed by 3M Scotchkote Epoxy Sealer SP 810. Then, it was finished with 3M Scotchkote Epoxy Coating 175UC to protect from future chemical damage.

3M,Scotchkote,Thortex, Cerami-Tech HG, Cerami-Tech

Bronze Impeller Refurbishment - Case Study

A power plant had a bronze impeller that had extensive corrorsion and deterioration of the base metal. Looking for a cost effective alternative, the power plant used 3M Scotchkote Epoxy Ceramic HD Surfacer HG 519 to provide the impeller with excellent abrasion resistance and 3M Scotchkote Epoxy Ceramic Surfacer FG 512 for extra protection and a smooth finish.

3M, Scotchkote,Thortex, Corro-Tech GP, Uni-Tech UV

Chemical Storage Tank Repair - Case Study

This chemical storage tank at a heating plant was suffering from heavy corrosion. The tank was coated with 3M Scotchkote Epoxy Primer GP 120, our anti-corrosive epoxy, then finished with 3M Scotchkote Urethane Coating UV 840, a polyurethane finish designed for long-term protection of brickwork, concrete, steel, and aluminium.

3M,Scothckote,Thortex,Chemi-Tech UC,two component,

Chimney Stack Refurbishment - Case Study

The internal surface of this 30 ft wide by 750 ft high chimney stack had deteriorated over the last twenty years since it was built. A high performance, chemical resistant finish was selected for the internal steel tube of this chimney, which operates at a maximum temperature of 284oF. The surface to be coated, totalling 23,562 ft², was abrasive blast cleaned. All loose abrasive dust and debris was vacuum cleaned away. All pitted areas were filled, after which two coats of our two component, solvent-free epoxy coating 3M Scotchkote Epoxy Coating 175UC were applied.

3M,Scotchkote,Thortex, Cerami-Tech EG, Cerami-Tech

Containment Area Protection - Case Study

This concrete containment area had been earmarked for refurbishment. However, all they needed was a high performance coating that would resist acid. They first used 3M Scotchkote Epoxy Ceramic Rebuild EG 513, a metal repair compound, to rebuild metal components. Next, 3M Scotchkote Epoxy Coating 175UC, a high performance, solvent-free coating, was used to provide chemical resistance even under total immersion conditions.

3M,Scotchkote,Thortex, Flexi-Tech Primer, Flexi-Te

Expansion Joints - Case Study

The concrete walls and floor of this 150 ft × 150 ft × 15 ft secondary containment unit, which houses a 60 ft high gasoline tank, had developed cracks. Following a site survey, it was established that there were 52 vertical and horizontal cracks and joints to seal which totaled over 4800 linear feet. The areas to be repaired were grit blasted using an angular abrasive and treated with 3M Scotchkote Rubber Repair Systems Elastomer Primer. 3M Scotchkote Elastomer 80 EG was then applied.

3M,Scotchkote,Thortex,Cerami-Tech EG, Cerami-Tech

Fan Impeller Refurbishment - Case Study

A carbon steel impeller on a dust extraction fan had been subjected to ''heavy wear.'' All loose material was scraped away. The surface of the impeller was degreased using 3M Scotchkote 020 Cleaner and then blasted cleaned. Our multi-purpose ceramic epoxy 3M Scotchkote Epoxy Ceramic Rebuild EG 513 was used to rebuild the deeply pitted areas prior to the application of two coats of 3M Scotchkote Epoxy Ceramic Surfacer FG 512. One coat of 3M Scotchkote Epoxy Ceramic Surfacer CR 511 was then applied.

3M,Scotchkote,Thortex,Cerami-Tech EG, Cerami-Tech

Gate Valve Repair - Case Study

The surfaces of this gate valve had been subjected to severe erosion and corrosion as a result of the very aggressive operating conditions. All loose material was scraped away. The surfaces were then blast cleaned. Our multi-purpose ceramic epoxy 3M Scotchkote Epoxy Ceramic Rebuild EG 513 was used to rebuild the internal surfaces of the gate valve, after which 3M Scotchkote Epoxy Ceramic Surfacer CR 511 was applied.

3M,Scotchkote,Thortex,Cerami-Tech FG, two coats, a

Heat Exchanger Refurbishment - Case Study

To refurbish a heat exchanger tube sheet, all dust and loose material was scraped away. The surface of the heat exchanger tube sheet was then abrasive blast cleaned. Since the tube sheet was in relatively good condition with no deeply pitted areas, two coats of 3M Scotchkote Epoxy Ceramic Surfacer FG 512 were applied directly to the blasted surface.

3M,Scotchkote,Thortex, Cerami-Tech EG, Chemi-Tech

Hydroelectric Turbine Refurbishment - Case Study

A turbine at a hydroelectric power plant was badly worn after years of use without protection. A protective coating was required to protect the equipment from future erosion, corrosion, and cavitation attack. 3M Scotchkote Epoxy Ceramic Rebuild EG 513 was applied to build the surface back up and protect it from futher corrosion.

3M, Scotchkote,Thortex,Pump, Cerami-Tech CR, Chemi

Intake Pump Housing Refurbishment - Case Study

3M Scotchkote Epoxy Ceramic Surfacer CR 511, resurfacing and lining system, and 3M Scotchkote Epoxy Coating 162EP were used to refurbish an intake pump badly cavitated after years of service in a salt water environment.

3M,Scotchkote, Thortex,Uni-Tech MC Primer,Uni-Tech

Metal Storage Tanks - Case Study

The corrosion on these metal storage tanks was so bad that the stuctural integrity was threatened and required immediate repair. The tanks were blasted to remove corrosion and other contaminants. Uni-Tech MC Primer was applied. Then two coats of our polyurethane coating 3M Scotchkote Urethane Coating UV 840, a UV stable, high performance coating, were applied to provide long term protection.

3M, Scotchkote, Thortex,Corro-Tech GP, Wall-Tech L

Nuclear Power Station Cooling Tower Basin Repair - Case Study

The client was having problems with the cooling tower basin at a nuclear power plant. The concrete wall was cracked and wearing away, casuing corrosion on the exposed metal. The exposed rebar was coated with 3M Scotchkote Epoxy Primer GP 120, a high build epoxy designed to provide excellent, long-term corrosion protection in one coat. The concrete was repaired with 3M Scotchkote Epoxy Concrete Mortar LW 405, a lightweight mortor repair that is excellent for vertical or overhead surface repairs.

3M,Scotchkote,Thortex, Cerami-Tech CR, Cerami-Tech

Processing Pump Refurbishment - Case Study

Pumps at a processing company were in poor condition, effecting their efficiency. 3M Scotchkote Epoxy Ceramic Rebuild EG 513 was used to rebuild the corroded areas inside the pump. The internal surfaces of the pumps had two coats of 3M Scotchkote Epoxy Ceramic Surfacer CR 511 applied and the external surfaces were coated with two coats of 3M Scotchkote Epoxy Primer GP 120 for a like-new finish.

3M,Scotchkote,Thortex,Cerami-Tech CR, coal-fired p

Pump Refurbishment - Case Study

After many years of use and being daily subjected to the elements, the cold water pumps at this coal-fired power station had been earmarked for refurbishment. The surfaces of the pump to be coated were abrasive blast cleaned prior to the application of two coats of our solvent-free ceramic epoxy coating 3M Scotchkote Epoxy Ceramic Surfacer CR 511 in contrasting colors.

3M,Scotchkote,Thortex, Metal-Tech EG, Cerami-Tech

Rotary Lobe Blower Refurbishment - Case Study

Process Gas Compressor rotary lobe blowers were found to be severely eroded/corroded.
The rotors were abrasive blasted. All deep areas were filled with Epoxy Metal Repair EG 503 and Epoxy Ceramic Rebuild EG 513 and leveled to provide a suitable rebuild base. One coat of Epoxy Ceramic Surfacer FG 512 was applied followed by two coats of our solvent-free, low friction epoxy coating Epoxy Ceramic Surfacer CR 511. The same procedure was carried out on the head plates, but without the Surfacer CR 511 topcoat. A final coat of Epoxy Ceramic Surfacer FG 512 was applied. The casing was rebuilt using Epoxy Metal Repair EG 503, leveled, and finished with one coat of Surfacer FG 512.

3M,Scotchkote,Thortex, Cerami-Flex, Cerami-Tech EG

Scroll Case Refurbishment - Case Study

The internal surfaces of a 120 ft long / 12 ft diameter hydroelectric power station scroll had deteriorated significantly due to the volume of water and high level of use. It was now in need of complete refurbishment. The Cerami-Flex system was selected. 3M Scotchkote Epoxy Ceramic Rebuild EG 513 was first trowel applied and then a stiff bristle angled paint brush was used to smooth out the high spots and uneven areas. A thickness of 750 microns was achieved. In order to achieve the required finish, the surface of the 3M Scotchkote Urethane Ceramic Rebuild EG 515 was sandblasted. After removing resultant dust, a thin coat of 3M Scotchkote Urethane Ceramic Lining FG 514 was roller applied over the entire surface.

3M,Scotchkote,Thortex,Metal-Tech EG,Universal Clea

Shaft Rebuild - Case Study

3M Scotchkote 020 Cleaner and 3M Scotchkote Epoxy Metal Repair EG 503 were used to rebuild an important piece of machinery which had worn out after years of service. A maintenance inspection found that a welded rapair, performed several years earlier, had worn out once again.
3M Scotchkote Epoxy Metal Repair EG 503 is a two component, epoxy metal repair compound. It provides enhanced corrosion and chemical resistance as well as good mechanical strength in one easy application.

3M,Scotchkote,Thortex, Uni-Tech MC Primer, Chemi-T

Sulfuric Acid Containment Area - Case Study

Sulfuric acid had spilled from the pumps and tanks at this power station. The acid severely corroded the concrete plinths and secondary containment areas. 3M Scotchkote Epoxy Coating 175UC was chosen over 20 other competitive products to cover the 7,500 sq. ft. area. First, the area was primed with two coats of 3M Scotchkote Epoxy Primer MC 145, then an aggregate was scattered into the second coat, where a slip resistant surface was required. This was followed by two coats of 3M Scotchkote Epoxy Coating 175UC providing a chemical resistant surface.

3M,Scotchkote,Thortex, Cerami-Tech EG, rebuild pit

Twin Lobe Refurbishment - Case Study

One coat of 3M Scotchkote Epoxy Ceramic Rebuild EG 513 was used to rebuild the pitted areas of the twin lobe, of which there are two in every Roots Blower, followed by one coat of 3M Scotchkote Epoxy Ceramic Surfacer FG 512. Two coats of 3M Scotchkote Epoxy Ceramic Surfacer CR 511 were then applied to the rebuilt surface of the twin lobe. 3M Scotchkote Epoxy Ceramic Surfacer CR 511 is a solvent-free epoxy coating that provides a smooth, low friction finish, optimum levels of physical & mechanical strength, and superior resistance to erosion and corrosion.

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USI leading the Mid-West in innovative 3M Abrasion, Chemical, Erosion and Corrosion Protection Solutions that protect and maintain buildings, structures, machinery and equipment.

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