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SINTEMAR Resinas Epoxi Devcon – Application Case History
 

SINTEMAR Resinas Epoxi Devcon – Application Case History

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Devcon Application Case History

Devcon Application Case History

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    SINTEMAR Resinas Epoxi Devcon – Application Case History SINTEMAR Resinas Epoxi Devcon – Application Case History Document Transcript

    • Amusement Parks Agriculture Automotive Industry Building Industry Cement Industry Coal Preparation Construction Marine Biology Machine Shops Mining Industry OEM Contractors Petrochemical Plants Power Plants Processing Plants Pulp & Paper Mills Refineries Steel Mills Textile Mills Transportation Industry Utility Plants Water Treatment Plants Maintenance and Repair Solutions
    • Contents Amusement Parks Agriculture Automotive Building Maintenance LOCATION REPAIR / REBUILD / MAINTAIN 59 Exchanger Tube Sheet 62 Inspection Door 69 Floor Coating 101 Cement Floor 124 Rubber Rolls LOCATION REPAIR / REBUILD / MAINTAIN 122 Cement Floor LOCATION REPAIR / REBUILD / MAINTAIN 67 Door Holding Fixture LOCATION REPAIR / REBUILD / MAINTAIN 13 Floor Coating 14 Cement Floor 16 Cement Floor 40 Floor Coating 45 Cement Floor 52 Floor Coating 73 Floor Coating 87 Floor Coating 94 Floor Coating 105 Floor Coating 123 Floor Coating 128 Expansion Joint Coal Preparation LOCATION REPAIR / REBUILD / MAINTAIN 23 Screw Conveyor Trough Construction LOCATION REPAIR / REBUILD / MAINTAIN 3 Expansion Joint 4 Urethane Wheel Machine Shop LOCATION REPAIR / REBUILD / MAINTAIN 48 Anti-Skid Loading Dock / Floor Marine Biology LOCATION REPAIR / REBUILD / MAINTAIN 131 Adhere Monitoring Transmitter Cement Manufacturing LOCATION REPAIR / REBUILD / MAINTAIN 2 Conveying Pipe 7 Silica Elevator 8 Fan Housing 34 Conveyor Belt 43 Agitator 49 Chute Lining 50 Fan Housing 72 Conveyor Belt Mining LOCATION REPAIR / REBUILD / MAINTAIN 9 Filter Plate 19 Conveyor Belt 20 Floatation Cell Coating 21 Ball Mill Shell 25 Rubber Flange Connector 28 Pump 31 Conveyor Belt 35 Pump 47 Expansion Joint 63 Conveyor Belt 66 Rubber Wear Ring 71 Ball Mill Cover 74 Ball Mill Mobile Chute 93 High Voltage Cable 99 Hydraulic Hose 119 Lining Victaulic® Elbows 129 SAG Mill Feed Chute Side Rail Sealing 134 Milling Line Equipment Grouting 135 Copper Concentrate Elbow Lining 136 Pump Liner 139 Ball Mill 140 Ball Mill Trunnion Repair & Lining 141 Mine Conveyor Belt Diverter Lining OEM Contractor LOCATION REPAIR / REBUILD / MAINTAIN 95 Machine Sump Coating Petrochemical LOCATION REPAIR / REBUILD / MAINTAIN 6 Channel & Pipe Repair 56 Floor Coating 115 Water Box Cover 117 Pump 132 Primary Cooling Water Feed Pump 133 Hamilton Water-Jet Diffuser
    • Contents Processing LOCATION REPAIR / REBUILD / MAINTAIN 33 Cement Floor Acid Environment0 Pulp and Paper Refinery LOCATION REPAIR / REBUILD / MAINTAIN 17 Pump Motor Concreter Pad Steel Mill LOCATION REPAIR / REBUILD / MAINTAIN 10 Valve 65 Stamping Press Alignment 111 Bearing Housing 121 Bag House Tube Sheet Textile Mill LOCATION REPAIR / REBUILD / MAINTAIN 24 Heat Exchanger Outer Shell Transportation LOCATION REPAIR / REBUILD / MAINTAIN 86 Paddle Wheel Shaft Hub 64 Feed Bowl Coating 75 Airport Runway 79 Sea Gateway 102 Urethane Bus Bumper 109 Bearing Race 125 Broom Box Chute Coating Utility LOCATION REPAIR / REBUILD / MAINTAIN 1 Transformer Oil Leak 11 Stainless Steel Runner 12 Power Pole 15 Motor Pad 18 Water Circulating Pump 27 Scrubber Wet / Dry Interface 32 Pump 37 Coal Crusher 39 Transformer Oil Leak 41 Pump Impeller 42 Coupling Bolt 46 Transformer Oil Leak 53 Coal Pipe Elbow 54 Pump Impeller 55 Water Box Channel 77 Transformer SF6 Gas Leak 80 Head Gate Seal Interface 81 Recovery Cyclone Urethane Lining 83 Cooler Head 85 Heat Separator 88 Valve 89 Valve 90 Pump Impeller 91 Valve 92 Exterior Pipe 98 Transformer Oil Leak 104 Pump 106 Man Hole Seal 108 Tank 110 Pump 112 Pump 113 Exhauster Fan 114 Coal Pulverizer 118 Valve Gate 120 Coal Diversion Gate 130 Transformer Oil Leak LOCATION REPAIR / REBUILD / MAINTAIN 44 Expansion Joint 51 Pump 57 Cyclone Cone 58 Rotary Bark Dryer 68 Paper Machine Component Coating 70 Conveyor Belt 76 Forklift Paper Clamp 82 Conveyor Belt 97 Steel Conveyer Roll Coating 103 Pulp Grinding Stone 107 Pump 116 Pump 127 Pump Motor Concrete Pad 138 Auger Power Plant LOCATION REPAIR / REBUILD / MAINTAIN 26 Rod Mill 84 Adhere Wood Block Flooring to Metal Water Treatment LOCATION REPAIR / REBUILD / MAINTAIN 22 Concrete 29 Cone Valve 30 Agitator 36 Pipe 38 Centrifuge Chute 60 Pump Impeller 61 Ball Valve 96 Pump Coating
    • Location 1 Transformer Oil Leak Repair One Minute Epoxy / Flexane® 80 Putty 2/14/96 B. C. Hydro Utility Power Distribution Problem: Inspection of 4Kv and 12Kv transformers revealed excessive leaking oil from both the bushing, flange and fastener areas. The leaking was so severe that either side of the transformer tank was covered with a thick film of oil. De-energizing and installing new gaskets would require a 6 week shutdown. Shutdown and repair cost was estimated to be $70K. Solution: Leaking or repair areas of the transformer were sandblasted to a SSPC-SP5 white metal finish. One Minute Epoxy was applied to plug all active leaks. Following confirmation that all leaks had stopped, repair areas were chemically cleaned using Cleaner Blend 300. Both FL10 and FL20 Primers were applied and each allowed to cure or dry for 15 minutes. Using both primers will improve Flexane 80 Putty adhesion from 25 pli to 50 pli. Flexane 80 Putty was applied to a thickness of 1/8”, extending beyond the One Minute Epoxy by 1-2 inches. GoJo hand cleaner was used to smooth and sculpt Flexane 80 Putty following gel point. Devcon’s repair cost was $4.5K with only a 3 day shutdown..
    • Location 2 Pipe Repair Ceramic Repair Putty / Brushable Ceramic 3/22/95 Canada Cement Lafarge Cement Manufacturing Problem: These pneumatic conveying pipes would receive extreme abrasive wear from processing fine cement particulate. The previous method of repair was to fabricate new pipes. Fabricating new pipes was an expensive repair procedure and caused flange and fastener misalignment when re-assembling due to heat distortion. Solution: Repair surfaces were sandblasted to a SSPC-SP5 white metal finish. Surface area was then chemically cleaned using Cleaner Blend 300. Ceramic Repair Putty was applied to worn areas deeper than 1/8”. Following a partial cure of Ceramic Repair Putty, (4 hours), Brushable Ceramic was applied to a thickness of 25 mils. Following a partial cure of Brushable Ceramic, (4 hours), a second coat of Brushable Ceramic was applied a 25 mils. . Brushable Ceramic encapsulated the repair areas and provided a long lasting, abrasion resistant, protective surface coating.
    • Location 3 Expansion Joint Repair Flexane® 94 Liquid 2/11/97 Hyundai Construction Problem: Undersea road support structures required moving onto a submergible barge for placement into the sea. To provide a smooth and level surface on the barge deck, ITW Chockfast was used. Due to the enormous weight of the support structures, and the flexing of the barge from rolling seas, cracking occurred. Surface cracking and hollow, uneven expansion joints caused extreme difficulty when rolling the support structures onto the barge. Solution: Because of extremely high compressive strength and excellent flexibility, Flexane 94 Liquid was used to fill expansion joints and repair cracked areas on the barge deck. Crack and expansion joint areas were roughened and then chemically cleaned using Cleaner Blend 300. Expansion joints were filled or stuffed with a polypropylene backer. This prevented Flexane 94 Liquid from migrating deep into the concrete. FL20 Primer was applied and allowed to cure or dry for 15 minutes. Flexane 94 Liquid was poured into the expansion joints and cracks. Flexane 94 Liquid provided a smooth, flexible, (350% elongation), level surface allowing the structure to be moved easily and safely.
    • Location 4 Urethane Wheel Manufacturing Flexane® 94 Liquid 1/20/97 Hyundai Construction Problem: Undersea road support structures required moving onto a submergible barge for placement into the sea. The structures enormous weight needed to be supported and moved onto the submergible barge. Common rubber could not be used as wheels due to low compressive strength. Common rubber would lose it’s cylindrical shape and cause the structure to seize when moved. Solution: Because of extremely high compressive strength, Flexane 94 liquid was molded and manufactured into wheels and as compressive shock absorbing pads. Flexane 94 Liquid easily supported the weight and allowed the structure to be moved easily and safely. When manufacturing parts, Devcon Release Agent must be used for easy part removal or separation from the mold.
    • Location 5 Coal Dust Valve Repair Titanium Putty / Brushable Ceramic 2/15/94 Canada Cement Lafarge Cement Manufacturing Problem: Fine coal dust particulate would cause extreme wear to the seal areas on this valve. Because the wear was 1/8”, the seal was compromised allowing coal dust to seep through the valve when in the closed position. Solution: The repair area was roughened using a grinder and wire wheel attachment. Repair area was then chemically cleaned using Cleaner Blend 300. A generous coating of release agent was applied to the butterfly valve. Titanium Putty was mixed and applied to the valve body, rebuilding the missing metal. The Titanium Putty was smoothed, sculpted and feathered using acetone. The butterfly valve with release agent applied, was closed and used as a forming mold. Following a 4 hour cure, the valve was opened. Three coats of Brushable Ceramic were applied totaling 25 mils. Brushable Ceramic encapsulated the repair areas and provided a long lasting, abrasion resistant protective surface coating.
    • Location 6 Channel, Valve and Pipe Repair Ceramic Repair Repair / Brushable Ceramic 2/2/97 P. T. Badak Pertamina Petrochemical Liquid Natural Gas Manufacturing Problem: Vessel and exchanger channels, valves and piping would receive extreme corrosive damage from the process of manufacturing liquid natural gas. Each manufacturing train would be completely refitted every 3 years. Equipment and machinery replacement would not only be cost prohibitive, but would cause realignment and fitting problems when reassembled. Solution: All repair and coating surfaces were sandblasted to a SSPC-SP5 white metal finish. Complete repair areas were chemically cleaned using Cleaner Blend 300. All corroded areas over 1/8” deep, were filled using Ceramic Repair Putty. Following a partial cure of Ceramic Repair Putty, (4 hours), Brushable Ceramic was applied to a thickness of 30 mils. Brushable Ceramic encapsulated the repair areas and provided a long lasting, low co-efficient to friction, chemical resistant protective coating. Following a partial cure of the first coat of Brushable Ceramic, (4 hours), a second coat of Brushable Ceramic was applied, again to a thickness of 30 mils. Devcon’s repair procedure is estimated to save hundreds of thousand of dollars annually.
    • Location 7 Silica Elevator Repair Wear Guard™ Fine Load 3/23/96 Canada Cement Lafarge Cement Manufacturing Problem: The existing ceramic tiles would receive extreme abrasive wear and damage from processing silica. The wear was so severe that the tiles required immediate replacement. This repair process was considered time consuming and expensive. Solution: The elevator substrate and ceramic tile edges were roughened using a grinder and wire wheel attachment. Complete surface area was then chemically cleaned using Cleaner Blend 300. Wearguard Fine was applied to a thickness matching that of the original ceramic tiles. Wear Guard Fine Load was smoothed and contoured using acetone as a thinning agent following gel point. Wear Guard Fine Load provided a long lasting, abrasion resistant repair to the damaged ceramic tiles of this elevator system.
    • Location 8 Fan Housing Repair Ceramic Repair Putty 3/24/96 Canada Cement Lafarge Cement Manufacturing Problem: This fan housing would receive extreme abrasive wear from processing coal dust. The wear was so severe that coal dust would leak through the existing cracks creating the risk for explosion. Solution: Complete repair area was roughened using a grinding machine and wire wheel attachment. Surface was then chemically cleaned using Cleaner Blend 300. Ceramic Repair Putty was applied to repair cracks and replace missing, worn ceramic tiles. Ceramic Repair Putty provided a long lasting, abrasion resistant lining while sealing previous leak areas.
    • Location 9 Filter Plate Repair Ceramic Repair 5/14/97 Precision Casting Repair Mining Problem: The exposed edges of these filter plates would receive extreme corrosive and abrasive wear from a mineral and chemical slurry. Solution: Filter plate repair area was sandblasted to a SSPC-SP5 white metal finish. Complete repair area was chemically cleaned using Cleaner Blend 300. Ceramic Repair was applied to rebuild all worn, corroded and cavitated areas of the filter plate edges. Following complete curing of Ceramic Repair, (24 hours), the edges were ground machined to a precision finish. Finish tolerances requirement was .012”. Brushable Ceramic was strongly recommended to encapsulate repair areas and provide chemical resistance. This customer elected to use an industrial paint.
    • Location 10 Valve Repair Flexane® 80 Putty 7/9/93 Geneva Steel Steel Manufacturing Problem: The protective rubber lining inside this cooling system valve and it’s cover, received extreme abrasive wear from processing a slurry combination of sand and water. The previous method of repair was to return to original equipment manufacturer for relining. Relining cost was estimated to be $1K. Solution: Repair surfaces including the damaged rubber lining and the metal substrate were roughened using a grinder and wire wheel attachment. Surfaces were then chemically cleaned using Cleaner Blend 300. FL10 Primer was applied to all exposed metal surfaces and allowed to cure or dry for 15 minutes. FL20 Primer was applied over the complete repair area including the FL10 primed metal. FL20 was allowed to cure or dry for 15 minutes. Flexane 80 Putty was applied to all damaged areas rebuilding the missing rubber. Flexane 80 Putty was smoothed and contoured using a putty knife. Flexane 80 Putty provided a long lasting, abrasion resistant protective lining. Devcon’s repair cost was $100.
    • Location 11 Stainless Steel Turbine Runner Repair Ceramic Repair Putty / Titanium Putty 2/18/95 Ontario Hydro Saunders Generating Station Utility Power Generation Problem: These turbine runners would receive extreme cavitation wear from the high volume flow of water. Cavitation on runners causes secondary problems such as vibration and off balancing. Runner replacement cost was estimated to be 50K. Solution: The complete repair area was first roughened using a grinder and wire wheel attachment. Repair surfaces were then chemically cleaned using Cleaner Blend 300. Ceramic Repair Putty was applied rebuilding missing eroded metal. Ceramic Repair Putty was smoothed and feathered using acetone following gel point. Following a full cure of Ceramic Repair Putty, (16 hours), Ceramic Repair Putty was sanded to a smooth finish. Devcon’s repair cost was $400.00.
    • Location 12 Power Pole Repair Flexane® 80 Liquid Fast Cure 3/21/96 Ontario Hydro Utility Power Distribution Problem: These utility power poles would receive extreme damage from nesting woodpeckers. The woodpecker would peck a nest as deep as five feet from the entrance hole. This damage would leave only a wooden shell offering little resistance to wind, ice, and snow. The damaged pole could no longer support the weight of the cables and required replacement. Power pole replacement cost was estimated to be $4K Solution: An injection port was first drilled into the power pole above the repair area. Wooden dowels were place into the void. Placing wooden dowels reduced the volume of Flexane 80 Liquid Fast Cure required to fill the void. Flexane 80 Liquid Fast Cure was injected through the injection port. Flexane 80 Liquid flowed evenly throughout the void rebuilding the missing wood. Devcon’s repair cost was $300.
    • Location 13 Floor Coating Floor Patch™ / Epoxy Coat™ 7000 2/17/95 Bender Engineering Inc. Building Maintenance Problem: The floor area of this laboratory would receive extreme damage from incidental contact with mild chemicals. The current alkyd paint was peeling in several locations. Solution: All loose peeling paint was removed using a paint scraper. The complete surface area was then roughened using a blastrac machine. Exposed cracks were filled using Floor Patch. Following a partial cure of Floor Patch, (4 hours), Epoxy Coat 7000 was applied to a thickness 0f 8 mils using a 1/4 nap paint roller. Epoxy Coat 7000 provided a long lasting chemical resistant protective coating.
    • Location 14 Floor Patch™ / Epoxy Coat™ 7000 8/5/94 Bender Engineering Inc. Building Maintenance Problem: The grouting around this drain was washed away by corrosive cleaning solutions. This has caused the tiles to become detached. Solution: All broken or loose tiles were removed. Complete surface area was roughened using a grinder and wire wheel attachment. The repair area was then chemically cleaned using Cleaner Blend 300. Floor Patch was applied as a mortar replacing missing or worn tiles. Following a partial cure of Floor Patch, (4 hours), Epoxy Coat 7000 was applied to a thickness of 8 mils using a 1/4” nap paint roller. Epoxy Coat 7000 provided a long lasting, chemical resistant protective coating Floor Repair
    • Location 15 Rebuilding Motor Pads Deep Pour Grout March 1998 Baltimore Gas & Electric Power Plant Problem: A centrifugal water pump pad was badly eroded and the pump plate became very loose. Severe vibration occurred and the anchor bolts became loose in the concrete. Over a period of time “chunks” of concrete broke away causing the plate to become very sloppy. Solution: The loose concrete was removed using a surface grinder. All loose particles were blown away with high pressure air. The surface was then cleaned with a degreaser to remove all oil and grease. Fir strips were used to “dam” the edges of the pump pad. The pump base plate was balanced on the concrete surface. Then Deep Pour Grout was poured onto the pad and allowed to “self level”. After 16 hours the plate was secure in the epoxy and ready for the pump to be re-connected.
    • Location 16 Floor Repair Floor Patch™ 5/12/96 Bender Engineering Inc. Building Maintenance Problem: These guard posts would become dislodged from the occasional contact with forklifts. Solution: Complete repair area was roughened using a grinder and wire wheel attachment. Surface area was then chemically cleaned using Cleaner Blend 300. Floor Patch was applied using a trowel, rebuilding the damaged or missing concrete. Fasteners were placed through the guard post and into the uncured Floor Patch. Following a full cure of Floor Patch, (24 hours), the fasteners were tightened.
    • Location 17 Rebuilding Motor Pad Deep Pour Grout and 1-Minute® Epoxy March 1998 Coastal Refinery Petrochemical Plant Problem: Concrete motor pad becomes broken up after intense vibration of pump motor vibrating over time. Broken and spalled concrete needed to be removed and the area cleaned of all loose fragments. A wooden form will be placed in the area to be rebuilt, spanning the spalled area of the motor pad. Then a new set of anchor bolts placed to secure the motor. Solution: After the loose concrete was removed from the surface, a pine form was anchored in place using 1-Minute Epoxy to secure to concrete an d seal area from any grout traveling under the form. Then Deep Pour Grout was mixed and poured into one side of the hole. The material moves freely displacing air as the grout fills all crevices. The material self levels nicely for a smooth finish. A anchor bolt is placed into the grout approx. 20 minutes after the pour. After 24 hours the motor is mounted back onto the pad.
    • Location 18 Rebuild Water Circulating Pump Sprayable Ceramic Ceramic Repair Putty. February 98 B G & E Power Power Plant Problem: Rebuilt intake water circulating pump that has been worn through caviation over the years. The veloute areas have seen quite a bit of erosion of metal. The pump is so large that the plant wants to spray a coating onto the surface for easy of application for the mechanics Solution: First the pump area is sandblasted to a SSPC 10 finish. Then degreased using our Cleaner Blend 300 which leaves no residue. This leaves a good 3-5 mil profile for application of our materials. Ceramic Repair Putty is applied to the large spalled areas of metal over 1/8” deep. This helps to fill in these worn areas. Next the Sprayable Ceramic is coated at a 20-30 mil coating in one pass over the entire pump. A wet film gauge is used to gauge the thickness. After 6-8 hours a second coat of the Sprayable Ceramic is coated onto the pump for a finish of 40-60 mils. This makes for a strong chemical and abrasion resistant coating.
    • Location 19 Conveyor Belt Repair Flexane® 80 Putty 5/14/97 General Chemical Mining Problem: This primary haul conveyor belt received a 1/4” x 1/4” gouge along the entire belt (3,000 ft. long) from a dropped chute. The damage was so severe that the belt was near torn through. Solution: Repair area was roughened using a grinder a wire wheel attachment. Surface area was then chemically cleaned using Cleaner Blend 300. FL20 primer was applied and allowed to cure or dry for 15 minutes. Flexane 80 Putty was applied to the damaged or gouged area, then smoothed and contoured using a putty knife.
    • Location 20 Flotation Cell Repair Brushable Ceramic and Ultra Quartz™ January 1998 Noranda Mine (Brunswick Mine Division) Mining Problem: Floatation Cells see tremendous corrosion by the fact that the ore is abrading the sides of the tanks constantly! Any coating you apply must have great abrasion resistance. Galvanic corrosion occurs at the steel surfaces rather quickly once abrasion starts! The floor of the Floatation Cell sees the sediment of the ore which is very abrasive, and needs repairing regularly. Solution: The Flotation Cells are first blasted to a SSPC -SP5 white metal blast to remove all corrosion from the surface. Any large holes are filled in with Titanium Putty. Next Brushable Ceramic is rolled onto the area using a 1/4” nap roller. Two coats are recommended . Each at 14-18 mils thick. Between coats the coating is checked for a “holidays” with a Leak Detector Kit. The finish coating provides a tough durable abrasion resistant finish against the aggregate. The floor is troweled with 3/8” of Ultra Quartz for final protection. The Ultra Quartz is troweled up the side wall approximately 4 inches for a seamless finish.
    • Location 21 Ball Mill In-feed Shell / Head Repair Plastic Steel® B Liquid 2/5/94 Newmont Gold Mining Problem: The mating area between the ball mill shell and the head would receive extreme wear from an abrasive slurry washout. The wear was so severe that the metal was worn in excess of 1/8” deep. Solution: The complete repair area was roughened using a grinder and wire wheel attachment. Following roughening the complete area was chemically cleaned using Cleaner Blend 300. Eight holes were drill equally spaced around the diameter of the mating area. The mating area void was then sealed from the outside using PorRok. Sealing the mating area void eliminated any migration or flowing of Plastic Steel Liquid. Plastic Steel Liquid was then mixed using a drill and mixing tool. Following mixing, Plastic Steel Liquid was poured into the mating area void using a funnel. The funnel improved flow rate. Pouring started at the lowest point injection holes. A steel plate was welded over the holes when the Plastic steel would reach the hole. This process continued until the void was completely filled. Replacement of the Mill Head was estimated at $160K. Devcon cost of repair was only $10K!
    • Location 22 Concrete Repair Floor Patch™ FC (fast cure) / Flexane® 80 Liquid 5/14/97 Central Valley Water Water Treatment Problem: The concrete surrounding these hand rails has broken away. This was caused by water collecting inside the hollow aluminum pipes and then freezing. Solution: Loose concrete was broken free. Remaining concrete was roughened using a needle gun. Repair area was then chemically cleaned using Cleaner Blend 300. Floor Patch FC, (90 minute functional cure),was applied, rebuilding the missing concrete. A 1/8” gap was maintained around the aluminum pipe. Following a partial cure of Floor Patch FC, (60 minutes), Flexane 80 Liquid was applied between the outer side of the aluminum pipe and Floor Patch Fast Cure. Flexane 80 Liquid provided a flexible, (350% elongation), thermal cycle resistant cushion between the aluminum pipe and Floor Patch FC to help alleviate freeze thaw situations that might occur.
    • Location 23 Screw Conveyor Trough Repair Ceramic Repair, Brushable Ceramic Blue/Red 3/23/00 West Virginia Synthetic Fuels Coal Prep Problem: Dry coal “fines “ would collect on the trough of the screw conveyer and on the screw flyghts. The constant abrasion will cause cavataion in the trough and prevent proper conveying of the coal. Thusly the trough needed to be rebuilt back to its close tolerance to the flyghts. Solution: First the trough was blasted to a SSPC-SP5 near white blast and solvent wiped. Then Ceramic Repair was applied to the worn gouges and holes in the trough to “build up” the large voids. After the material was cured for at least (4 hours) Brushable Ceramic was applied to a thickness of 30 mils in two coats of 15 mils each. Next the “screw” itself was coated with two coats of Brushable Ceramic (30 mils total) in two coats.
    • Location 24 Heat Exchanger Outer Shell Rebuild Ceramic Repair, Brushable Ceramic 2/20/00 Celanese Fiber Textile Mill Problem: This heat Exchanger is surround by a cloud of chemicals. The vapors from these chemicals attacked the outer shelf the exchanger causing tremendous corrosion and pitting of the metal. L the exchanger started to leak and could nolonger be used in service. WE had to rebuild the entire “metal shell” of the exchanger and get back on line in 48 hours attacking the outside of the core Solution: All loose rust was scraped from the metal shell. Ceramic Repair was applied to the surface at 1/16” thick around the shell. Next fiberglass mesh cloth was laid around the Ceramic Repair while still wet. The cloth was pushed into the epoxy and smoothed out with a plastic scraper. After four hours Brushable Ceramic was coated over the fiberglass cloth at 15 mil thick. After 2 hours another coat of Brushable Ceramic was applied. The entire shell was rebuilt with epoxy and all leaking and rusting completely stopped!
    • Location 25 Rubber Lined Flange Connector Repair Fasmetal™ / Flexane® 80 Putty 4/9/93 Kennecott Copper Mining Problem: This rubber lined flange connector from the floatation cell received extreme wear from a slurry combination of mineral, ore and floatation chemical solution. Previous method of repair was to simply replace the connectors, however a replacement part was not available. Solution: Inside bore area and outside sleeve were roughened using a grinder and wire wheel attachment. Complete repair areas were chemically cleaned using Cleaner Blend 300. Fasmetal was applied to the outside area to replace missing metal and plug holes. FL10 and FL20 Primers were applied and each allowed to cure or dry for 15 minutes. Using both primers will improve adhesion of Flexane 80 Putty from 25 pli to pli. Flexane 80 Putty was applied to the bore area replacing the worn rubber.
    • Location 26 Rod Mill Repair Fast Cure Rubber Repair Putty 3/03/00 Tampa Electric Co. / Polk Power Station Power Problem: Wear plates inside the coal grinding rod mill become worn and sloppy. These open joints cause coal to “hang up” in these areas and loosen the wear plates. This will use efficiency problems in the grinding of the coal Solution: First all the wear plates joints were blasted to a SSPC-SP5 finish. Then the joints were cleaned with a water base degreaser and allowed to dry. Next our Flexane FC Putty was applied using he 400 ml cartridge delivery system using the pneumatic gun. The material was injected into the joints between the wear plates and a mechanic than “smoothed out” the material to bridge the plates. Material was allowed to dry for 24 hours and then put back into service!
    • Location 27 Scrubber Wet/Dry Interface Repair Wear Guard™ Fine Load / Brushable Ceramic 5/30/95 Utah Power [Light Hunter Plant] Utility Power Generation Problem: Interior wet and dry interface of this Scrubber would receive extreme abrasive and corrosive wear from abrasive coal dust, flue gas and H 2 S0 4 . Scrubber was previously coated with a Ceilcote vinyl ester coating. Solution: Vinyl Ester coating was firstly removed using pneumatic chipping hammers. Complete surface area was sandblasted to a SSPC-SP10 near-white metal finish. Following sandblasting, repair and coating areas were pressure washed with ionized water. A second sandblasting was require to remove all traces of oxidization. Complete coating area was then chemically cleaned using Cleaner Blend 300. Two coats of Brushable Ceramic were applied to a thickness of 15 mils. Each coat of Brushable Ceramic was allowed to partially cure for 4 hours. Following the 4 hour partial cure of the second coat of Brushable Ceramic, Wear Guard Fine Load was trowel applied to a thickness of 1/4”. Acetone was used to smooth and contour Wear Guard Fine Load following gel point.
    • Location 28 Pump Repair Ceramic Repair Putty 6/25/93 Johnston Pump Repair Mining Problem: This slurry pump casing received extreme abrasive wear from processing large size ore and high percentage solids. A typical slurry application. The pump was fitted with a Nihard liner. Voids between the casing and liner needed to be filled or sealed to eliminate leaking. Solution: Complete repair areas were first sandblasted to a SSPC-SP5 white metal finish. Surface areas were then chemically cleaned using Cleaner Blend 300. The brass bushing was coated with Devcon’s Release Agent to allow for easy post cure removal. To maintain proper volute dimension, a wood plug was machined, coated with a paste release agent, and fitted into position. Any parts requiring disassembly must be coated with Devcon’s Release Agent. Ceramic Repair Putty was mixed and applied filling in all voids. Following full cure, (24 hours), both the plug and brass ring were removed.
    • Location 29 Cone Valve Repair Wear Resistant Putty 4/14/97 Las Vegas Valley Water District Water Treatment Problem: The faces on this valve would receive extreme wear from processing raw sewage and other foreign materials. Past repair method was to either surface harden [hard face], or simply replace when required. Valve replacement cost was estimated to be $1K. Solution: The valve was sandblasted to a SSPC-SP5 white metal finish. Complete repair area was chemically cleaned using Cleaner Blend 300. Wear Resistant Putty was mixed and applied filling all cavitated and corroded areas. Acetone was used to smooth and sculpt Wear Resistant Putty following gel point. Devcon’s repair cost was $100.
    • Location 30 Agitator Repair Ceramic Repair Repair / Brushable Ceramic 5/15/97 Western Zirconium Petrochemical Chemical Manufacturing Problem: This agitator would receive extreme corrosion and pitting from mixing a solution of 35% Hydrolchloric Acid. Previous method was to replace agitator when worn. Replacement cost for the agitator was estimated at $3K. Solution: The complete agitator was sandblasted to a SSPC-SP5 white metal finish. All repair and coating areas were chemically cleaned using Cleaner Blend 300. Ceramic Repair was mixed and applied to all corroded and cavitated areas deeper than 1/8”. Following a partial cure, (4 hours), Brushable Ceramic Blue was applied to a thickness of 30 mils. Following a partial cure, (4 hours), a second coat of Brushable Ceramic Red was applied, again to a thickness of 30 mils. Brushable Ceramic encapsulated the repair areas and provided a long lasting, smooth chemical resistant coating. Devcon’s repair cost was $500.
    • Location 31 Conveyor Belt Repair Flexane® 80 Putty 5/15/93 Kennecott Copper Mining Problem: This 36” wide conveyor belt would receive extreme impact wear from processing ore. The previous method of repair was to have an outside contractor repair by vulcanizing. This method of repair was costly and frequently caused long unscheduled downtime. Solution: The complete repair area was roughened using a grinder and wire wheel attachment. Following roughening the area was chemically cleaned using Cleaner Blend 300. FL20 Primer was then applied and allowed to cure or dry for 15 minutes. FL20 Primer improves the chemical bonding properties of Flexane 80 Putty. Flexane 80 Putty was then mixed then applied replacing the missing worn rubber.
    • Pump Repair Ceramic Repair / Wearguard™ Fine / Brushable Ceramic 7/14/93 Intermountain Power Services Utility Power Generation Problem: A high solids slurry combination of water and coal ash would cause severe abrasive wear to this bottom ash transfer pump housing. Previous method of repair was to simply replace the pump housing when required. Pump housing replacement cost was estimated to be $30K. Solution: Pump housing was sandblasted to a SSPC-SP5 white metal finish. Complete repair area was then chemically cleaned using Cleaner Blend 300. Ceramic Repair Putty was applied to rebuild wear ring seats, fill holes and repair eroded areas deeper than .125”. Ceramic Repair was allowed to partially cure for 4 hours. Wearguard Fine was applied to a thickness of between 1/2” and 1-1/2” depending on the depth of wear. Acetone was used to smooth and feather Wearguard Fine following gel point. Following a 4 hour partial cure of Wearguard Fine, Brushable Ceramic was applied to a thickness of 30 mils. Brushable Ceramic encapsulated the repaired areas, and provided a protective coating to the remaining exposed edges. Devcon’s repair cost was $1K. Products: Application Date: Customer: Industry: Location 32
    • Location 33 Floor Repair Acid Environment Floor Patch™ - Ultra Quartz™ - EC7000 AR 6-12-99 Alcoa Aluminum Processing Problem: In the processing of aluminum in making cans, high concentrations of acids are used. These acids are contained in large tanks and used in groups in containment areas. These containment areas see “spills” which cause the concrete to be “eaten away” because of chemical attack. This application shows up to 12” deep“trenches” into the concrete which harbors the acid in these pools, attacking the concrete even more. Solution: First, the floor was rinsed multiple times with water to “neutralize” the acid condition of the floor. After, dried Floor Patch was used to fill the large trenches, (12” deep), in the concrete around the tank areas. Before the Floor Patch cures, our chemical resistant Ultra Quartz was used to apply a final ¼” topcoat onto the entire surface for ultimate chemical resistance to the acid. All drains and sloped areas were shaped at this time for good drainage. Then a coating of Epoxy Coat 7000AR (12-15 mils) was applied over the entire containment area for acid resistance. This tank area is now protected for any spills that may occur.
    • Location 34 Conveyor Belt Repair Flexane® 80 Putty 6/8/94 Ash Grove Cement Cement Manufacturing Problem: Conveyor belts would receive extreme impact abrasive wear from processing aggregate. Past repair process was to vulcanize. Vulcanizing was an expensive repair process usually causing long downtime periods. Solution : Complete repair area was roughened using a grinder and wire wheel attachment. Following roughening, surface area was chemically cleaned using Cleaner Blend 300. FL20 Primer was applied and allowed to cure or dry for 15 minutes. Flexane 80 Putty, was mixed and let set up for 30 minutes. Flexane 80 was smoothed and contoured by covering and compressing with a pliable polypropylene sheet. Following functional cure of Flexane 80 Putty, 12 hours, the polypropylene sheet was easily removed.
    • Location 35 Pump Repair Brushable Ceramic 3-15-99 Syncrude, Ft. McMurray Mining Problem: In mines, water feed pumps “wear” because of abrasive particles flowing through the volutes at tremendous speeds, causing wear and abrasion inside the volute and impeller areas. Pump casings are very expensive and instead of “replacing” the volutes, metal-filled epoxies are used to rebuild loose metal. These polymers act as better “wear resistant” finishes on the surface. In this pump, the volute areas had wear up to 1” deep, which had to be filled before a protective coating could be applied. Solution: The volute of the pump casing was sandblasted to an SSPC-SP5 white metal finish. After blasting, the pump was cleaned with our Cleaner Blend 300 to remove all residual abrasive shot from the surface. Then a primer coat of Brushable Ceramic (12-15 mils) was coated on all areas. Immediately after coating with Brushable Ceramic, the large voids (over 1” deep), were filled with Wear Guard High Load. The Brushable Ceramic acts as a primer helping the beaded epoxy adhere better to the surface. Next, Ceramic Repair was used to fill all other voids (under ½” deep). Finally, a topcoat of Brushable Ceramic (12-15mils) was used for a smooth, final chemical resistant finish.
    • Location 36 Pipe Repair Ceramic Repair Putty / Brushable Ceramic 3/30/93 Illinois Metro Water Reclamation Water Treatment Problem: This transition pipe would receive extreme cavitiation and abrasive wear from processing primary sewage water. The wear was so severe that the pipe required immediate replacement. Replacement part was no longer available. Solution: The repair area was sandblasted to a SSPC-SP5 white metal finish. Surface area was then chemically cleaned using Cleaner Blend 300. Ceramic Repair Putty was applied rebuilding the missing metal and cavitated areas deeper than 1/8”. Following a partial cure of Ceramic Repair Putty, (4 hours), Brushable Ceramic was applied to a thickness of 30 mils in two coats brushed at 15 mils each. Brushable Ceramic encapsulated repair areas and provided an abrasion resistant, low co-efficient to friction protective surface coating.
    • Location 37 Coal Crusher Repair Wear Guard™ High Load 3/23/93 N.P.P.D. Sheldon Utility Power Generation Problem: These crusher components including lid and wear plates would receive extreme abrasive wear from processing coal. The wear was so severe that the metal was completely worn through in a number of areas. Previous method of repair was to surface weld worn areas. This repair cost was estimated to be $3K. Solution: Complete repair areas were sandblasted to a SSPC-SP5 white metal finish. Surface area was then chemically cleaned using Cleaner Blend 300. Wear Guard High Load was applied to a thickness of 1/2” replacing worn eroded metal. Wear Guard High Load was smoothed and contoured using acetone as a thinning agent following gel point. Wear Guard High Load provided a long lasting, abrasion resistant protective surface lining. Devcon’s cost was $500.
    • Location 38 Centrifuge Chute Repair Flexane® 80 Putty 2/1/93 City Of Chicago Water Treatment Problem: The steel transition chutes of the centrifuge conveying system would receive extreme abrasive wear. The wear was caused by compressing 3-6% solid through to 28-35% solids. The wear was so severe that the wear plates required immediate replacement. Solution: The wear plates were sandblasted to a SSPC-SP5 white metal finish. Complete surface area was then chemically cleaned using Cleaner Blend 300. FL10 and FL20 Primers were applied and each allowed to cure or dry for 15 minutes. Using both primers will improve adhesion of Flexane 80 Putty from 25 pli. To 50 pli. Flexane 80 Putty was applied to a thickness ranging from 1/2” to 5”. Flexane 80 Putty provided a long lasting, abrasion resistant, and compression resistant protective lining.
    • Location 39 Transformer Oil Leak Repair One Minute™ Epoxy / Fasmetal™ / Flexane® 80 Liquid 5/27/94 BPU Utility Power Distribution Problem: Inspection of this transformer revealed excessive leaking from the flange and fastener areas. The previous method of repair was to de-energize, drain the tank and install new gaskets. De-energizing, draining the tank and installing new gaskets would require a 6 week shutdown. Solution: Complete repair areas were sandblasted to a SSPC-SP5 white metal finish. All active leaks were stopped using One Minute Epoxy and the Mark 5 Application System. Surface areas were then chemically cleaned using Cleaner Blend 300. Fasmetal was applied directly over the One Minute Epoxy to a thickness of .125” and extending beyond by .500”. A mold was manufactured from plywood and generously coated with release agent. Release agent must be used for easy mold removal following full cure of Flexane 80 Liquid. The plywood mold was positioned around the repair area. Flexane 80 Liquid was mixed and poured into the mold. Flexane 80 Liquid flowed evenly, encapsulated the complete repair area. Flexane 80 Liquid provided a flexible (350% elongation), vibration and climate resistant permanent seal. Products: Application Date: Customer: Industry:
    • Location 40 Floor Coating Epoxy Sealer 100 / B-4 Acid Etch 11/29/93 Huffy Sports Manufacturing Building Maintenance Problem: This hazard floor area coating would receive extreme wear from forklift traffic. The previous latex based coating would last only one month. Solution: Complete surface area was pressure washed to remove all loose concrete. Complete area was then etched using B-4 Natural Acid Etch. Etching will create a profile enhancing Epoxy ‘s mechanical bonding properties. Epoxy sealer 100 was then mixed as instructed. American Color pigment was added to the mixed Epoxy Sealer 100. Epoxy Sealer 100 was then applied using a .125” nap paint roller to a thickness of .010”. Epoxy Sealer 100 provided a long lasting, high quality protective coating.
    • Location 41 Pump Impeller Repair Titanium Putty / Brushable Ceramic 26/6/93 Douglas Pump Repair Utility Power Generation Problem: This impeller from a primary water intake pump would receive extreme wear from a combination slurry of sand, soil and water. The previous method of repair was to simply replace when required. Impeller replacement cost was estimated to be $4K. Solution: The impeller was firstly sandblasted to a SSPC-SP5 white metal finish. All surface areas were then chemically cleaned using Cleaner Blend 300. All worn cavitated areas deeper than 1/8” were filled using Titanium Putty. Following a partial cure of Titanium Putty, (2 hours), Brushable Ceramic was applied to a thickness of 30 mils in tow coats at 15 mils each. Brushable Ceramic encapsulated the repair areas, and provided a long lasting, abrasion resistant, low co-efficient to friction protective surface coating. Devcon’s repair cost was $500.
    • Location 42 Coupling Bolt Repair Titanium Putty 1/2/92 Edison Sault Electric Company Utility Power Generation Problem: These coupling bolts used to join the turbine and generator together would receive extreme abrasive wear from the secondary leather coupling. The past repair method was to remanufacture new coupling bolts when required. Solution: Coupling bolts were grooved on a lathe to a depth of 30 mils. Grooving improves mechanical bonding properties of Titanium Putty. Repair area was then chemically cleaned using Cleaner Blend 300. As the coupling bolts rotated slowly on the lathe, Titanium Putty was applied to a thickness 65 mils over the desired dimension. A heat lamp was positioned over the repaired area and the coupling bolt was rotated continually for 1 hour. Rotating eliminates the risk of Titanium Putty sagging. Following a 1 hour cure, Titanium Putty was machined to original coupling bolt specification using carbide tooling.
    • Location 43 Cement Agitator Repair Wear Guard™ Fine Load 9/21/92 Chicago Road Service Cement Manufacturing Problem: The fins or paddles within this portable cement mixer would receive extreme abrasive wear from continually agitating cement. Previous method of repair was to protect fins or paddles by covering with U.H.M.W. This repair procedure was expensive and time consuming. Solution: Repair surfaces were sandblasted to a SSPC-SP5 white metal finish. Expandable metal was tack welded in a raised position 25 mils above the substrate. Tack welding expandable metal above the substrate improved the mechanical bonding properties of Wear Guard Fine Load. Weld slag was removed using a grinder and wire wheel attachment. All surfaces were then chemically cleaned using Cleaner Blend 300. Wear Guard Fine Load was applied using a trowel to a thickness of 1/2”. Wear Guard Fine Load was pressed through the expandable metal forcing complete contact onto the substrate surface. Wear Guard Fine Load was smoothed, contoured and feathered using acetone as a thinning agent following gel point.
    • Location 44 Expansion Joint Repair Fast Cure Rubber Repair Liquid 5/21/96 Wisconsin Tissue Pulp and Paper Manufacturing Problem: Over several years of continual traffic, these expansion joints became deteriorated. As a result of failed expansion joints, spider cracking began. The uneven floor surface caused problems such as difficulty moving wheeled equipment, and forklift load shifting. Solution: Loose, deteriorated concrete was mechanically removed. Remaining concrete was roughened to provide a profile. All surface areas were then chemically cleaned using Cleaner Blend 300. FL20 Primer was applied into the expansion joints and cracks and allowed to cure or dry for 15 minutes. A polypropylene backer was stuffed 3/4” into the expansion joints and cracks. The polypropylene backer will prevent deep migration of Fast Cure Liquid, and reduce the volume required. Fast Cure Rubber Repair Liquid was injected into the damaged or repair areas using Devcon’s Auto Mix Application System. This product is self- leveling and provided a smooth, flexible, (450% elongation), expansion joint seal. Fast Cure Rubber Repair Liquid also provided a functional cure in only 90 minutes, reducing repair downtime.
    • Location 45 Floor Repair Ultra Quartz™ 10/3/95 Rockefeller Boat House Building Maintenance (Marine) Problem: As yachts are moved along the concrete floor to the wooden launch area, the steel casters on the dolly would wear deep grooves into the concrete. This groove would cause extreme difficulty in moving the yacht smoothly and safely. Solution: The complete groove area was roughened mechanically to remove all loose concrete. Repair area was then chemically cleaned using Cleaner Blend 300 to remove all traces of oil, grease and dirt. Ultra Quartz was mixed then applied replacing the worn concrete. Ultra Quartz was smoothed, blended and feather using a cement trowel. Ultra Quartz provided a long lasting, high performance concrete repair.
    • Location 46 Transformer Oil Leak Repair One Minute™ Epoxy / Fasmetal™ / Flexane® 80 Putty 4/3/95 Tucson Electric Power Utility Power Distribution Problem: Weld porosity’s caused seeping oil leaks from this substation transformer. The past repair procedure was to drain the oil from the tank and re-weld. This repair process was expensive and caused long term power outages. Solution: Repair or leak areas were roughened using a grinder. One Minute Epoxy was applied using the Mark 5 Auto Mix System to plug all active leaks. Following confirmation that all oil leaks had been stopped, repair areas were then chemically cleaned using Cleaner Blend 300. Fasmetal was then applied directly over the One Minute Epoxy to a thickness of 1/4, extending beyond the One Minute Epoxy by 3mm. Following Fasmetal’s 1 hour cure, repair areas were primed using both FL10 and FL20 Primers. Each primer was allowed to cure or dry for 15 minutes. Using both primers on metal substrates will improve adhesion from 25 pli to 50 pli. Two primer system is always recommended in wet or outdoor operating conditions. Flexane 80 Putty was applied over the Fasmetal to a thickness of 1/4” extending beyond by 3 inches.. Flexane 80 Putty encapsulated the repair area as a flexible, (350% elongation), vibration and climate resistant permanent seal. Products: Application Date: Customer: Industry:
    • Location 47 Expansion Joint Repair Flexane® 80 Liquid 4/3/95 Barrick Mercur Mine Mining Problem: Cement based products used in the past to seal around chemical storage tanks continued to crack and fail. A seal needed to to be maintained to eliminate chemicals from seeping and contaminating the underground. The seal needed to resist chemicals such as Cyanide and remain flexible to withstand thermal cycling (cold winters and warm summers). Solution: Repair areas were hydroblasted to remove loose concrete and clean contaminates. Cracks and joints were filled using a polypropylene backer. This prevented the Flexane 80 Liquid from migrating deep into the concrete. Crack and joint surfaces were then primed with FL20 Primer. FL20 Primer was allowed to cure or dry for 15 minutes. Flexane 80 Liquid was mixed and transferred into dish soap bottles for ease in dispensing. Following 4 months of service, no failures were visible.
    • Location 48 Anti-Skid Loading Dock/Floor Concrete Sealer, B-4 Etcher 4-9-99 Jergen’s Industrial Supply Machine Shop Problem: Loading dock areas in plants see continuous “wear and tear” from forklifts running back and forth into trucks carrying pallets of material that abrade across the floor. Once these areas become “smooth”, they are dangerously slippery when water gets on the surface. The plant wanted to skid-proof the shipping area in front of the loading bays, which would hold up to heavy forklift traffic, yet coat the floor with an epoxy that could be cleaned up easily everyday and look good. A real dilemma! Solution: The area was degreased with a good cleaner to remove all oil and dirt. The floor was etched with Devcon’s B-4 Etcher in dock area. After the floor was cleaned and dried, a coating of Epoxy Concrete Sealer was rolled onto the surface. Silicone carbide grit was then broad-casted onto the floor. After material cured, backer rod was installed in the expansion/control joints, then a top coat of Epoxy Concrete Sealer (with grey colorant) was rolled over first coat, removing backer rod after coating the area. The finished floor has an epoxy topcoat with silicone carbide underneath for skid proofing that can be easily cleaned.
    • Location 49 Chute Lining Repair Wear Guard™ Fine Load 4/1/95 Canada Cement Lafarge Cement Manufacturing Problem: The flow of water and aggregate mixture feeding into the ball mill would cause extreme wear to these infeed chutes. Past repair procedure was to fabricate and install abrasion resistant plates as a liner. Abrasion resistant plates were expensive and usually required several days to fabricate. Solution: Existing Abrasion resistant plates were removed. Flat expandable metal was tack welded in a raised position 1/8” above the actual substrate. Tack welding expandable metal provided a mechanical bonding surface and offered improved resistance to the impacting of aggregate. Chute was then sandblasted to a SSPC-SP5 white metal finish. Complete repair areas were then chemically cleaned using Cleaner Blend 300. Wear Guard Fine Load was applied to a thickness of 3/4” pressing through the expandable metal, establishing complete contact to the substrate. Wear Guard Fine Load was smoothed, feathered and sculpted using acetone following gel point.
    • Location50 Fan Housing Repair Wear Guard™ Fine Load 4/1/92 Canada Cement Lafarge Cement Manufacturing Problem: Poor fitting ceramic tiles caused severe, uneven wear to this cement fan housing. Ceramic tiles would become loose and break free from the housing substrate. This would cause the fine cement particulate to wear directly through the metal fan housing. Solution: Existing ceramic tiles were removed. Flat expandable metal was tack welded in a raised position 1/8” above the actual substrate. Tack welding expandable metal improved mechanical bonding properties of Wearguard Fine Load. Fan housing was then sandblasted to a SSPC-SP5 white metal finish. Complete repair areas were then chemically cleaned using Cleaner Blend 300. Wear Guard Fine Load was applied at a thickness of 1/2” pressing through the expandable metal, establishing complete contact to the fan housing surface. Wearguard Fine Load was smoothed and sculpted using Acetone. Smoothing Wear Guard Fine Load following gel point helps to reduce leading edges. To provide a smoother surface and protect face areas, Brushable Ceramic was applied to a thickness of 30 mils at two 15 mil coats. Brushable Ceramic was applied following a 4 hour partial cure of the Fine Load.
    • Location 51 Pump Repair Titanium Putty / Wear Guard™ Fine Load 7/1/94 MacMillian Bloedell Pulp and Paper Manufacturing Problem: This fly ash pump would receive extreme wear from processing a slurry of burnt hog fuel (wood chips) and water. The wear was so sever that the pump was replaced every 3 months. Equipment replacement cost was estimated to be $35K. Solution: Complete housing was sandblasted to a SSPC-SP5 white metal finish. Flat expandable metal was tack welded in a raised position .065” above the actual substrate. Tack welding expandable metal improved mechanical bonding properties of Wearguard Fine. The housing was then sandblasted a second time to remove weld slag. The casing was thoroughly cleaned with Cleaner Blend 300. Titanium Putty was applied to the flange area rebuilding the missing metal. Wear Guard Fine Load was applied to the volute to a thickness of 1/2”. Wear Guard Fine Load was pressed through the expandable metal, achieving complete contact to the housing. Wear Guard Fine Load was smoothed, contoured and feathered using acetone as a thinning agent following gel point.
    • Location 52 Floor Coating Floor Patch™ / Ceramic Repair Putty / Epoxy Coat™ 7000 9/9/86 Saint Johns Hospital Building Maintenance Problem: The floor area underneath this large cooking kettle would receive tremendous damage from spalling. The spalling was caused from hot water being discarded down the drain. Solution: Complete surface area was pressure washed to remove all loose concrete. Remaining concrete was roughened using a needle gun. Complete area was then vacuum cleaned. Floor Patch was applied to replace all spalled, damaged concrete. Ceramic Repair Putty was applied to form a slope towards the drain area. Following a partial cure of Ceramic Repair Putty, (4 hours), Epoxy Coat 7000 was applied to a thickness of 8 mils using a 1/8” nap paint roller. Epoxy Coat 7000 provided a long lasting, temperature resistant protective coating. Products: Application Date: Customer: Industry:
    • Location 53 Coal Pipe Elbow Repair Combo Wear™ FC (fast cure) 6/6/96 Delmarva Power and Light Indiana River Plant Utility Power Generation Problem: These pneumatic conveying pipe elbows would receive extreme abrasive wear from processing coal. The wear was so severe that replacement was required every 2 months. Solution: Repair area was sandblasted to a SSPC-SP5 white metal finish. Surface area was then chemically cleaned using Cleaner Blend 300. Brushable Ceramic was applied to a thickness of 10 mils, acting as a primer for Combowear. Following a partial cure of Brushable Ceramic, (2 hours), Combo Wear FC was applied to a thickness of 1/2”. Combo Wear FC provided a long lasting abrasion resistant protective lining to the elbow. Combo Wear FC also provided a functional cure in only 90 minutes, reducing the high cost of downtime.
    • Location 54 Pump Impeller Repair Ceramic Repair Putty / Brushable Ceramic 2/2/91 Associated Electro-Mechanical Utility Power Generation Problem: This diffuser would receive extreme cavitation wear from processing high velocity water. The wear was so sever, that the leading edges of the blades were completely worn away. Previous method of repair was to replacing missing metal by welding. Welding would often cause heat distortion problems. Solution: Complete repair areas were sandblasted to a SSPC-SP5 white metal finish. Surface areas were then chemically cleaned using Cleaner Blend 300. Ceramic Repair Putty was applied to replace missing metal and fill cavitated areas deeper than 1/8”. Following a partial cure of Ceramic Repair Putty, (4 hours), Brushable Ceramic was applied to a thickness of 30 mils in two coats at 15 mils each. Brushable Ceramic provides a long lasting, low co-efficient to friction protective surface coating with outstanding abrasion resistance in a slurry application.
    • Location 55 Water Box Channel Repair Titanium Putty 1/10/91 Baltimore Gas and Electric Utility Power Generation Problem: These water box channels would receive extreme corrosive wear from processing salt water. The wear was so sever that the channel boxes required immediate replacement. Due to equipment age, replacement parts were no longer available. Solution: Complete repair areas were sandblasted to a SSPC-SP5 white metal finish. Surfaces were chemically cleaned using Cleaner Blend 300. Titanium was applied up to 65 mils over original specification or dimension. Following a 6 hour cure of Titanium Putty, the channel was machined back to within original specifications or dimension. Minor imperfections were repaired using Titanium Putty, then re-machined following a 4 hour cure.
    • Location 56 Floor Coating Concrete Primer 1000 / Epoxy Coat™ 7000 AR 5/31/93 Pfizer Minteg Petrochemical Chemical Manufacturing Problem: The secondary containment area in this chemical manufacturing plant required protection from aggressive acid concentrations. The secondary containment area was previously coated, but could not resist concentrations of 10% Sulfuric Acid. Solution: Complete floor surface was roughened using a Blast trak machine and sandblasting. Floor surface was chemically cleaned with an industrial cleaning solution to remove all traces of contaminates, and rinsed thoroughly to neutralize the acidic environment.. Concrete Primer was applied using a notched squeegee, then back rolled using a 1/8” nap roller to a thickness of 6 mils. Following a 4 hour partial cure of Concrete Primer 1000, Epoxy Coat 7000 AR was applied using a notched squeegee, then back rolled using a 1/8” nap roller to a thickness of 12 mils.
    • Location 57 Cyclone Cone Repair Wear Guard™ Fine Load / Ceramic Repair Putty / Brushable Ceramic 2/21/94 Strathcona Paper Pulp and Paper Manufacturing Problem: Cyclone cones would receive extreme abrasive and corrosive wear from a slurry of recycled newspapers, magazines, contaminates, and black liquor. Each cyclone cone replacement cost was $8K. Solution: Complete repair area was sandblasted to a SSPC-SP5 white metal finish. Flat expandable metal was tack welded in a raised position 1/4” above the substrate. Tack welding expandable metal improved epoxy’s mechanical boding properties. Surface areas were then chemically cleaned using Cleaner Blend 300. FL10 Primer was applied and allowed to cure or dry for 15 minutes. FL10 Primer improved chemical bonding properties of epoxy. Wear Guard Fine Load was applied replacing worn missing metal. Ceramic Repair was applied to repair remaining cavitated areas deeper than 1/4”. Following a 4 hour partial cure of Ceramic Repair, Brushable Ceramic was applied to a thickness of 30 mils in two coats (15 mils each). Brushable Ceramic provides a long lasting, abrasion and chemical resistant protective surface coating. Devcon’s repair cost was $550 each cone, excluding labor. Products: Application Date: Customer: Industry:
    • Location 58 Rotary Bark Dryer Repair Brushable Ceramic 12/9/94 Grant Forest Products Corporation Pulp and Paper Manufacturing Problem: Bearing ring inside dimension, and imperfect dryer shell outside dimension of a 15 ft. diameter by 80 ft. long horizontal rotary bark dryer created voids between the mating surfaces. The void spots would cause uneven stress loading and subsequent fatigue cracking. Solution: A 3/16” pocket was machined on the shell side of each positioning wedge. The bearing ring was positioned over the shell. Brushable Ceramic was mixed and heated to 110º F. It was quickly transferred into caulking guns. Brushable Ceramic was injected between the bearing ring and dryer shell. Inspection or bleed holes indicated even dispersion of Brushable Ceramic. Brushable Ceramic provided a more uniform load distribution ultimately extending shell service life.
    • Location 59 Exchanger Tube Sheet Repair Retaining Compound / Ceramic Repair / Brushable Ceramic White (Food Grade) 12/12/94 Siftco Canada Incorporated Agriculture Salt Manufacturing Problem: Galvanic corrosion between the tubes and tube sheet resulted in leaking and decreased productivity. Galvanic corrosion was caused by the combination of CuNi tubes, mild steel tube sheet, and a brine solution. Past repair procedure was to seal leaks by welding. Solution: Repair surface was sandblasted to a SSPC-SP5 white metal finish. Because Chlorides were present, therefore a pressure washing and second sandblasting was required. Complete repair area was then chemically cleaned using Cleaner Blend 300. Voids between the tube and tube sheet less than .016” were filled using Devcon’s Retaining Compound. All remaining gaps larger in size, were filled using Ceramic Repair Putty. Ceramic Repair Putty was allowed to partially cure for 4 hours. Brushable Ceramic White, (Food Grade), was mixed and transferred into caulking gun for ease in dispensing. Brushable Ceramic was dispensed and brush applied to a thickness of 30 mils. Brushable Ceramic encapsulated the repair areas and provided a corrosion resistant, low co-efficient to friction protective surface coating. Devcon’s repair extended service life of this exchanger and improved salt production by 2 tons daily. Products: Application Date: Customer: Industry:
    • Location 60 Pump Impeller Repair Ceramic Repair Putty / Brushable Ceramic 9/3/92 Ministry Of The Environment Water Treatment Problem: Primary first stage pump impeller would receive extreme wear from processing raw sewage and other foreign materials. Past pump repair method was to simply replace the worn impeller when required. Impeller cost was estimated to be $5K. Solution: Impeller was sandblasted to a SSPC-SP5 white metal finish. Complete impeller was then chemically cleaned using Cleaner Blend 300. FL10 Primer was applied and allowed to cure or dry for 15 minutes. FL10 Primer improved the chemical bonding properties of the epoxies used. Ceramic Repair Putty was applied to rebuild all worn and cavitated areas deeper than 1/8”. Following a 4 hour partial cure of Ceramic Repair Putty, two 15 mil coatings of Brushable Ceramic were applied. Brushable Ceramic provides an abrasion and chemical resistant, low coefficient to friction protective surface coating. Devcon’s repair cost was $200.
    • Location 61 Ball Valve Repair Ceramic Repair Putty / Brushable Ceramic 9/3/97 Ministry Of The Environment Water Treatment Problem: The ball guides and seat area of the valve were worn by abrasive first stage sewage waste. Two of the four ball guides were completely worn away along with the ball seat. Past repair method was to replace entire valve assembly. Valve assembly replacement cost was estimated to be $22K. Solution: Repair area was dried using a heat gun. Complete repair area was roughened using a drill. The drill bit provided undercuts that were used to establish better mechanical bonding properties for epoxies. The complete repair area was then chemically cleaned using Cleaner Blend 300. Using evidence marks as guides, Ceramic Repair Putty was used to rebuild all worn missing metal. Release agent was applied to the ball then set into it’s operating position. Release agent must be used for easy part separation following cure. Following a partial cure of Ceramic Repair Putty, (4 hours), Brushable Ceramic was applied to a thickness of 30 mils in two 15 mil coats. Brushable Ceramic provides a long lasting, abrasion resistant, low coefficient to friction surface coating. Devcon’s repair cost was $250.
    • Location 62 Grain Inspection Door Repair Titanium Putty / Brushable Ceramic White 8/10/92 Canada Malting Agriculture Grain Terminal Problem: This inspection door would receive extreme abrasive wear from processing grain. The wear was so severe that the grain would quickly wear through the metal. The previous method of repair was to simply replace the inspection door when required. Solution: Complete door assembly was sandblasted to a SSPC-SP5 white metal finish. All surface areas were then chemically cleaned using Cleaner Blend 300. Titanium Putty was applied to rebuild missing or worn metal. Titanium Putty was smoothed and contoured using acetone and a putty knife, following gel point. Brushable Ceramic White (USDA approved) could be applied as a final long lasting, abrasion resistant protective surface coating.
    • Location 63 Conveyor Belt Repair Flexane® 80 Putty 9/10/92 Hemlo Gold Mines Mining Problem: Conveyor belts would receive extreme abrasive wear from processing gold ore. The previous method of repair was to vulcanize whenever possible. Vulcanizing was an expensive repair process, often causing long unscheduled shutdowns. Solution: The complete repair area was roughened using a grinder and wire wheel attachment. Surface area was then chemically cleaned using Cleaner Blend 300. FL20 Primer was applied and allowed to cure or dry for 15 minutes. Flexane 80 Putty was applied, smoothed and contoured using a putty knife. Heat can be applied to speed the cure process. This customer now uses Flexane 80 Putty Fast Cure, (90 minute functional cure), for quick, emergency repairs reducing downtime.
    • Location 64 Feed Bowl Repair Coating Flexane® 80 Putty / Flexane® High Performance Brushable 9/10/92 General Motors of Canada Transportation Automobile Manufacturing Problem: The metal feed bowls at this General Motors manufacturing plant experienced 2 problems. Abrasive wear and unsafe noise levels from processing metal components. Solution: The complete bowl was first sandblasted to a SSPC-SP5 white metal finish. Repair areas were then chemically cleaned using Cleaner Blend 300. Both FL10 and FL20 Primers were applied and each allowed to cure or dry for 15 minutes. Applying both primers will improve adhesion from 25 pli to 50 pli. As the bowl was slowly rotating, Flexane 80 Putty was applied to a thickness of 1/4”. Slowly rotating the bowl assisted in evenly smoothing and contouring Flexane 80 Putty. Following a partial cure, (2 hours), Flexane High Performance Brushable was applied to a thickness of 35 mils. Flexane High Performance Brushable is self leveling and provided the smoothest uniform surface achievable. Heat was applied to speed curing. Products: Application Date: Customer: Industry:
    • Location 65 Stamping Press Alignment Repair Flexane® 80 Liquid 9/10/92 Central Stamping Steel Metal Fabrication Problem: This 200 ton stamping press would misalign after only weeks of operation. Metal shims were used to re-align the press. The metal shims would often move, causing the press to produce a high volume of scrap or rejected finished product. Solution: Complete repair surfaces were roughened to a SSPC- SP5 white metal finish using a grinding machine. All surface areas were then chemically cleaned using Cleaner Blend 300. FL10 Primer was applied and allowed to cure or dry for 15 minutes. Automotive weather stripping was used to dam and hold the Flexane material in position while curing. Flexane 80 Liquid was poured into position to a thickness of 1/2”. Using Flexane 80 Liquid established a tolerance of .0002” inch. This precision could not be achieved or maintained using shims. Flexane’s extremely high compressive strength and flexibility (350% elongation) provided a long lasting solution to this alignment problem.
    • Location 66 Urethane Wear Ring Repair Flexane® 80 liquid 9/10/92 Hemlo Gold Mine Mining Problem: This Urethane wear ring would receive extreme abrasive wear from processing a slurry of gold ore and water. The past repair method was to return to the manufacturer for re-surfacing. This repair procedure was costly and caused extensive downtime. Current repair method cost was $700 each unit. Solution: A wood model was built using a new ring as the mold. The metal ring was sandblasted to a SSPC-SP5 white metal finish. Repair surface was then chemically cleaned using Cleaner Blend 300. Both FL10 and FL20 Primers were applied and each allowed to cure or dry for 15 minutes. Using both primers will improve adhesion from 25 pli to 50 pli. A generous coating of Devcon’s Release Agent was applied to the wood model. Release Agent must be applied for easy removal or separation of molded parts. Flexane 80 Liquid was injected into the mold forming a new urethane surface, bonding to the metal ring. Following full cure of Flexane 80 Liquid, (24 hours), the manufactured part was removed from the mold. Devcon’s repair cost was $25 each unit.
    • Location 67 Door Holding Fixture FL-80 Liquid 2-5-91 Peerless Plastics Automotive Problem: Customer needs to make a holding fixture to hold door panels during the process, so they may attach carpet and handles to doorframe. The holding fixture must not scratch the door, yet be firm and able to hold the door snugly in place while operator attaches their parts. They produce many doors per day. Solution: To form an exact replica of the door for a holding fixture, they first brushed Devcon Liquid Release Agent #19600 over a finished door and then constructed a form out of wood to pour an exact replica of the door. The Flexane will cure within 16 hours. During the curing of the Flexane, a hot air gun is used to disperse all air bubbles on the surface. After curing, they demolded the door from the form, cleaned the edges of Flexane, and now have a holding fixture.
    • Location 68 Paper Machine Component Repair Brushable Ceramic 7/8/93 Temboro Pulp and Paper Pulp and Paper Manufacturing Problem: Critical paper machine components and cover plates would receive extreme corrosion from a combination of water, steam and mild chemicals. The corrosion was so severe that the damaged parts would require frequent replacement. Solution: All repair or coating surfaces were mechanically cleaned and roughened using a needle gun. Surface areas were then chemically cleaned using Cleaner Blend 300. Brushable Ceramic was applied to a thickness of 12 mils in two coats for a smooth holiday free coating. Brushable Ceramic provided a long lasting chemical resistant protective surface coating.
    • Location 69 Floor Coating Floor Grip™ 2/2/91 Opee Chee Agriculture Food Manufacturing Problem: The floor surface around this candy processing machine would become slippery due to wax and gum buildup. The slippery floor area was a high risk concern for employee safety. Solution: The complete area to be coated was cleaned using a Tenant floor scrubbing machine to remove wax and gum buildup. The floor area was then chemically etched 3 times using Devcon’s B-4 Citrus Acid etch. Etching before applying any floor coatings will improve mechanical bonding properties. Floor Grip epoxy component was applied using a notched squeegee, then back rolled using a 1/8” nap paint roller. The silicon carbide granules were broadcast over the applied Floor Grip, then imbedded using a 1/8” nap paint roller.
    • Location 70 Conveyor Belt Repair Flexane® 80 Putty 1/2/91 Domtar Caledonia Pulp and Paper Manufacturing / Wall Board Manufacturing Problem: This conveyor belt would receive extreme wear from processing wall board particulate. The wear was so severe that the belt was worn 1/8” deep into the carcass, and continued for 4 inches wide by 360 feet long! Conveyor belt replacement cost was estimated to $10K. Solution: The complete repair area was roughened using a grinder and wire wheel attachment. Following roughening the surface area was chemically cleaned using Cleaner Blend 300. FL20 Primer was then applied and allowed to cure or dry for 15 minutes. Flexane 80 Putty was then mixed and applied to the repair area. Flexane 80 Putty was smoothed and feathered using a putty knife. To accelerate curing, a heat gun was waved over the completed repair area. Devcon’s repair cost was $3K.
    • Location 71 Ball Mill Cover Repair Wear Guard™ Fine Load, Irathane® 155 01/15/02 South American Copper/Gold mine Mining Problem : Customer had imported used equipment for a their third milling line. The ball mill was very eroded on all surfaces, including these end covers, due to failures in the coating between liner and shell, which allowed leakage of the pulp. Worn areas were rebuilt to original dimensions using Wear Guard Fine Load and the whole surface was coated with Irathane 155 as protection against future potential liner failure. Solution: Surfaces were blasted to white metal (SSPC-SP5.) They were then cleaned using Cleaner Blend 300, and allowed to dry. Eroded areas were rebuilt using Wear Guard Fine Load beaded epoxy. Within 4 hours, surfaces were primed with SA-200 applied with airless spray equipment. This was allowed to cure for three hours, and Irathane 155 was applied with 42:1 ratio airless equipment. Two coats of 155 were applied, for a total DFT of 2.5 mm, to prevent problems in the future.
    • Location 72 Conveyor Belt / Pulley Lagging Repair Flexane® 80 Putty 4/7/93 Seegmiller Quarry Cement (Sandstone Quarry) Problem: This conveyor belt would receive extreme wear from the impacting of large size aggregate. Mechanical clips were used to temporarily repair torn or worn areas of the belt. The previous method of repair was to vulcanize. Vulcanizing was expensive and would require lengthy unscheduled shut down time. Solution: Complete repair area including the belt and mechanical clips were roughened using a grinding machine and wire wheel attachment. Surfaces were then chemically cleaned using Cleaner Blend 300. Mechanical clips were then primed using FL10 Metal Primer. A second coat of FL20 Rubber Primer was applied over the mechanical clips and rubber following a 15 minute cure of the FL10 Metal Primer. FL10 Metal Primer must cure or dry for 15 minutes before applying a second coat of FL20 Rubber Primer. FL10 Metal Primer is not require for rubber only repairs such as with this pulley lagging. Flexane 80 Putty is mixed and applied over the complete repair area replacing the worn or missing rubber. Flexane 80 Putty is smoothed and feathered using a putty knife.
    • Location 73 Floor Coating Problem: The floor surfaces inside and surrounding this bank of shower stalls would become extremely slippery when wet. Slippery floors were considered an employee health or safety risk. Solution: All coating surfaces were pressure washed with a mild detergent. The floor was left for 4 hours to completely dry. Epoxy Coat 7000 was mixed as per manufacturers instructions. Following a complete mix, Safe-T-Grit (4 lb. unit) was added to each unit of Epoxy Coat 7000. Epoxy Coat 7000 with Safe-T- Grit was applied to a thickness of 8 mils using a 1/8” nap paint roller. Epoxy Coat™ 7000 / Safe-T-Grit™ 7/2/92 Kidd Creek Mining Mining
    • Location 74 Ball Mill Mobile Chute Repair Combo Wear, Flexane® 80 Putty July 2002 South American Copper Mine Mining Problem: The lining of the ball mill mobile chute suffered wear in its bottom area from the rocks, water and pulp that passes through it. This part is hard to rebuild and replacement was the only apparent solution. Solution: Since the surface was well abraded, no additional profile was required, but it needed to be cleaned. The substrate was hydroblasted, dried with compressed air, then wiped down with Cleaner Blend 300. Once the surface was dry, it was primed with UU-66, which dried in 20 minutes. Then a 1” coating of Flexane 80 Putty was applied to the entire worn surface.
    • Location 75 Airport Runway Repair Ultra Quartz™ 7/20/92 Transport Canada Northbay Air Terminal Transportation Air Terminal Problem: The broken concrete on the aprons at this air terminal required immediate repair. Loose concrete could easily damage aircraft engines, windshields and other critical components. Previous method of repair was to apply cold tar to damaged areas. Cold tar offered only a temporary repair often failing after only 3 to 4 months of service. Solution: All loose concrete was mechanically chipped away. Remaining solid concrete was roughened to provide a profile. Repair area was then chemically cleaned using Cleaner Blend 300. Ultra Quartz was applied using a concrete trowel replacing all missing concrete. Acetone was used as a thinning agent to smooth, blend and feather Ultra Quartz following gel point. Customer now uses Floor Patch Fast Cure (90 minute functional cure) to reduce runway downtime.
    • Location 76 Forklift Paper Clamp Repair Flexane® 80 Putty 3/1/91 Provincial Papers Pulp and Paper Manufacturing Problem: Two ton finished paper rolls would receive frequent damage from metal forklift clamps. Damaged rolls would become rejects, requiring expensive reprocessing. Solution: Repair or coating areas were first sandblasted to a SSPC-SP5 white metal finish. Complete surface areas were then chemically cleaned using Cleaner Blend 300. FL10 and FL20 Primers were applied and each allowed to cure or dry for 15 minutes. Applying both primers will improve adhesion from 25 pli to 50pli Flexane 80 Putty was applied in 2 applications to a final thickness of 1/2”. Two application process was used to reduce sagging of Flexane 80 Putty. Flexane 80 Putty provided a flexible cushion surface to the metal clamps.
    • Location 77 Transformer SF6 Gas Leak Repair Wear Resistant Liquid 6/30/95 PECO Central Shop Utility Power Distribution Problem: Over several years of service life, the seals between the ceramic insulator bushing and base would degrade. The failed seal would allow of SF6 gas to leak into the environment. Solution: Complete repair areas were roughened using a grinding machine and wire wheel attachment. Surface areas were then chemically cleaned using Cleaner Blend 300. A cardboard mold was manufactured to position the Wear Resistant Liquid Epoxy. A generous coating of release agent was applied to the cardboard mold. Release agent must be applied for easy part removal. Wear Resistant Liquid was mixed and transferred into simple caulking guns. Wear Resistant Liquid was injected into the mold and seal areas. Following a full cure (24 hours), the mold was easily removed.
    • Location 79 Sea Gateway Repair Titanium Putty 1/6/91 St. Lawrence Seaway Authority Transportation Marine Problem: Over several years of service the gateway metal guide runners received extreme corrosive wear from seawater. The corrosion was so severe that the gate could not move freely up and down the guide runners. The repair procedure being considered was to weld and grind. This was an expensive repair process with a high risk of distorting the guide runners due to the heat generated from welding. Solution: The complete repair area was pressure washed 3 times to remove chlorides. The surface area was then sandblasted to a SSPC-SP5 white metal finish. Following sandblasting, surface area was chemically cleaned using Cleaner Blend 300. A form was manufactured from wood with the radius of the guide runner. Titanium Putty was applied rebuilding all missing metal and forming a new surface. The wood form was used to smooth and contour the Titanium Putty to the shape of the guide runner every 15 feet. Devcon’s repair cost was $2K each gate.
    • Location 80 Head Gate Seal Interface Repair Epoxy Concrete Sealer 100 / Titanium Putty 1/7/91 Ontario Hydro Utility Power Generation Problem: Both the head gate and the metal interface track on the wall received extreme corrosive and cavitation damage. This interface must form an effective seal and prevent water from traveling down the runner. In some areas the metal was worn as much as 1/2”. The previous method of repair was welding the worn areas to rebuild missing metal. Welding had caused heat distortion problems in the past effecting the interface seal. Solution: The entire track area on the wall was sandblasted to a SSPC-SP5 white metal finish. The complete gate area was roughened using a grinder and wire wheel attachment. Epoxy Concrete Sealer 100 was applied as a primer and to seal against water seepage. Epoxy Concrete Sealer 100 can be applied to damp surfaces. Plywood framing was used as a mold on the track side to rebuild the missing metal to original dimension. Release agent was applied to the plywood frame for easy post cure removal. Titanium Putty was applied to the gate and track areas. Titanium Putty was successfully used to rebuild the missing metal and re-establish the seal between the gate and track. Because of the overall cost savings and product performance, Ontario Hydro have specified this procedure for future repairs.
    • Location 81 Recovery Cyclone Urethane Repair Flexane® 80 Putty / Flexane® High Performance Brushable 8/9/91 Houston Lighting And Power Utility Power Generation Problem: Lower vortex area of this recovery cyclone would receive extreme wear to the rubber lining from the abrasion of processing steel grit blast material. Previous repair method was to replace rubber lining or weld patches and plugs to the exterior of the cyclone body. Welding had previously caused rubber distortion problems. Solution: The repair area and existing rubber liner were roughened using a grinder and wire wheel. Complete repair area of the cyclone was chemically cleaned using Cleaner Blend 300. FL10 Primer was applied to all exposed metal surfaces and allowed to dry for 15 minutes. FL20 Primer was applied over the FL10 primed metal as well as all rubber contact surfaces. FL20 Primer was allowed to dry for 15 minutes. Flexane 80 Putty was applied to a thickness of .500” replacing the worn rubber. Following a partial cure of Flexane 80 Putty, (4 hours), Flexane High Performance Brushable was applied to blend the urethane and rubber, and provide a smooth, impact and abrasion resistant protective coating. Products: Application Date: Customer: Industry:
    • Location 82 Conveyor Belt Repair Flexane® 80 Putty 7/9/91 Monroe Hard Wood Pulp and Paper Manufacturing / Lumber Manufacturing Problem: Conveyor belt was repaired by means of splicing. Splicing is often a short term repair, requiring an expensive vulcanizing repair at a later date. Water and dust can contaminate the carcass of the belt causing further damage such as fiber rotting. Solution: Both the mechanical splice and rubber repair area were roughened using a grinder and wire wheel attachment. Complete repair area was chemically cleaned using Cleaner Blend 300. FL10 Primer was applied over the metal mechanical clips. FL10 Primer was cure accelerated using a heat gun. Without the assistance of heat to dry, FL10 Primer must be allowed to dry for 15 minutes. FL20 Primer was applied over the FL10 primed clips, and to all contact areas of the rubber. FL20 Primer was allowed to cure or dry for 15 minutes. Flexane 80 Putty was mixed and applied over the complete repair area. Flexane 80 Putty was used successfully to protect carcass from future damage, and covert a temporary repair to a permanent repair.
    • Location 83 Cooler Head Repair Titanium Putty / Brushable Ceramic 2/20/92 Houston Power And Lighting Utility Power Generation Problem: Over several years of service these cooler heads received extreme corrosive damage from salt water. Past repair method was to simply replace. Replacement cost was estimated to be $6K for each cooler head. Solution: Complete repair areas were sandblasted to a SSPC-SP5 white metal finish. Surfaces were chemically cleaned using Cleaner Blend 300. The center baffle and corroded areas deeper than 1/4” were filled using Titanium Putty. Following a partial cure of Titanium Putty, (2 hours), the first of 3 coats of Brushable Ceramic was applied to a thickness of 20 mils. The second and third coats of Brushable Ceramic were also applied at 20 mils each. Each coat of Brushable Ceramic was allowed to partially cure for 4 hours before re-coating. Brushable Ceramic Blue and Red were both used for easy view of proper and complete coverage. Brushable Ceramic encapsulated repair areas and provided a long lasting, corrosion resistant, low co-efficient to friction protective surface coating. Devcon’s repair cost for each cooler head was $450.
    • Location 84 Adhere Wood Block Flooring to Steel Plating Tile Adhesive 9-9-91 Houston Power & Light Company Power Plant Problem: Rebuilding wood block flooring to adhere blocks to floor. They need an adhesive to bond wood to steel plate. There will be deflection on the surface and large gaps to fill. Solution: First grit-blast steel floor for good surface preparation. Use Tile Adhesive and trowel a 1/4 - 1/2” thick of material onto the steel plate. Set the blocks into the adhesive, and level, using a wooden block; “set” the blocks firmly into the adhesive. Let cure for 24 hours.
    • Location 85 Heat Separator Repair Ceramic Repair Putty / Brushable Ceramic 12/4/91 Houston Lighting and Power Utility Power Generation Problem: This instrumental heat separator would receive extreme corrosive and erosion damage after only a short service life. The previous method of repair was to simply replace when required. Solution: Complete surface areas were first sandblasted to a SSPC-SP5 white metal finish. All repair areas were then chemically cleaned using Cleaner Blend 300. Ceramic Repair Putty was used to rebuild or repair corroded areas deeper than 1/8”. Following a partial cure of Ceramic Repair Putty, (4 hours), Brushable Ceramic was applied to a thickness of 30 mils in two 15 mil coats for a holiday free finish. Brushable Ceramic provides a long lasting, abrasion and corrosion resistant, protective surface coating.
    • Location 86 Paddle Wheel Shaft / Hub Repair Titanium Putty 12/18/95 American Classic Voyages Transportation Marine Problem: The mated or contact areas between the shaft and hub on this steam boat paddle wheel would receive extreme wear from corrosive fretting. The wear was so severe that the metal was worn more than .125”. The previous method of repair was to simply drive wedges between the shaft and hub in an effort to stabilize. Solution: The complete repair areas were first roughened and cleaned using needle guns. All surface areas were then chemically cleaned using Cleaner Blend 300. The hubs were positioned on the shaft using wedges. The hub position was locked using a variety of positioning clamps. Titanium Putty was mixed and transferred into caulking guns. The mixed Titanium Putty was injected between the hub and shaft though injection port holes. Titanium Putty effectively filled all worn contact areas and voids. Titanium Putty has extremely high compressive strength (18,800 P.S.I.), and is non corrosive. An ideal solution for a unique problem saving thousands of dollars. This application is ABS documented and approved.
    • Location 87 Floor Coating Floor Patch™ Fast Cure / Concrete Primer / Epoxy Coat™ 7000AR 6/27/95 Houston Power and Lighting Utility Power Generation Problem: This secondary containment area required repairs to cracks caused by thermal cycling and erosion. The erosion was accelerated by the occasional spilling or leaking of beach from the storage tanks. Solution: Complete floor and wall surfaces were first pressure washed to remove contaminates. Floor and wall areas were then etched using Devcon’s B-4 Citrus Acid Etch. All cracks were repaired and sealed with Devcon’s Floor Patch Fast Cure, (90 minute functional cure). Following a 1 hour partial cure of Floor Patch Fast Cure, Concrete Primer was applied to a thickness of 8 mils. Following a partial cure, (4 hours), a final coat of Epoxy Coat 7000AR (Acid Resistant) was applied to a thickness of 16 mils. Devcon’s Epoxy Coat 7000AR withstands aggressive chemical operating environments. Products: Application Date: Customer: Industry:
    • Location 88 Valve Repair Ceramic Repair Putty / Brushable Ceramic 6/10/92 Houston light and Power Utility Power Generation Problem: Over several years of service this gate valve would receive extreme damage from abrasive and corrosive wear. The wear was so severe that the valve seal had failed resulting in leakage. The previous method of repair was to simply replace the complete valve when required. Solution: The complete valve was first pressure washed three times to remove all traces of chlorides. Following adequate removal of chlorides, the complete valve was sandblasted to a SSPC-SP5 white metal finish. All surface areas were then chemically cleaned using Cleaner Blend 300. A wood template was used to re-dimension worn missing metal on the valve body. The wood template was generously coated with Devcon’s Release Agent. Release agent must be used for easy template or part removal. Worn metal over 1/8” deep was rebuilt using Ceramic Repair Putty. Following a partial cure of Ceramic Repair Putty, (4 hours), Brushable Ceramic was applied to a thickness of 20 mils. A second coat of Brushable Ceramic was applied, at 20 mils. The 2 coats of Brushable Ceramic encapsulated the repair areas and provided a long lasting, corrosion resistant, low co-efficient to friction protective surface coating.
    • Location 89 Valve Repair Ceramic Repair Putty / Brushable Ceramic 7/24/97 Houston Power and Light Utility Power Generation Problem: This valve require the replacement specialty size gate. To reduce costs, the gate was fabricated from mild steel. Mild steel would corrode and erode quickly due to salt water operation conditions. A protective or preventative maintenance coating was required. Solution: Complete valve assembly was sandblasted to a SSPC-SP5 white metal finish. Surface areas were then chemically cleaned using Cleaner Blend 300. Cavitated, eroded areas deeper than 1/8” on the valve body were filled or repaired using Ceramic Repair Putty. Following a partial cure of Ceramic Repair Putty, (4 hours), Brushable Ceramic Red was applied to the valve body and gate to a thickness of 15 mils. Following a partial cure of Brushable Ceramic Red, (4 hours), a second coat of Brushable Ceramic Blue was applied, at 15 mils. Two coats of Brushable Ceramic provides a long lasting, abrasion and corrosion resistant, low co-efficient to friction, protective surface coating.
    • Location90 Pump Impeller Repair Underwater Repair Putty 5/12/93 Houston Power and Light Utility Power Generation Problem: This stainless steel water circulation pump impeller received extreme cavitation from processing high velocity cooling water. The pump could not be removed from it’s operating position. This required the repair be completed in wet conditions and in an overhead position. Solution: The damaged areas on the impeller blades were roughened by hand using a wire brush. Complete repair areas were then pressure washed with distilled water. Surface area was then chemically cleaned using Cleaner Blend 300. Underwater Repair Putty was applied to damaged areas, covered with pliable plastic paper, and compressed or formed. The plastic paper protected the Underwater Repair Putty from being eroded by the continual flow of water while curing. Following a 2 hour cure of Underwater Repair Putty, the plastic was easily peeled away.
    • Location 91 Valve Repair Ceramic Repair Putty / Brushable Ceramic 11/18/91 Houston Lighting and Power Utility Power Generation Problem: This primary intake water butterfly valve would receive extreme abrasive and corrosive wear. The wear was so severe that the valve would leak. Previous method of repair was to simply replace when required. The valve replacement cost was estimated to be $40K. Solution: The complete valve assembly was sandblasted to a SSPC-SP5 white metal finish. All repair surfaces were then chemically cleaned using Cleaner Blend 300. Ceramic Repair Putty was applied to rebuild missing metal on the valve body and gate deeper than 1/8”. Following a partial cure of Ceramic repair Putty, (4 hours), Brushable Ceramic was applied to a thickness of 30 mils in two coats 15 mil each coat.. Brushable Ceramic provides a long lasting, corrosion and abrasion resistant, low co-efficient to friction protective surface coating. Devcon’s repair cost was $1.5K.
    • Location 92 Exterior Pipe Repair Flexane® Brushable 7/10/92 Houston Power and Light Utility Power Generation Problem: The exterior surfaces of these condensate pipes would receive extreme corrosion due to aggressive operating conditions. The corrosion was minimal but required immediate preventative action. The previously used protective coating was epoxy in chemistry would crack and fail due to thermal cycling. Solution: Complete coating surfaces were sandblasted to a SSPC-SP5 white metal finish. Surface areas were then chemically cleaned using Cleaner Blend 300. Both FL10 and FL20 Primers were applied and each allowed to cure or dry for 15 minutes. Using both primers will improve adhesion of Flexane Brushable from 25 pli to 50 pli. Flexane Brushable was applied in 2 stages. Each coat was applied to a thickness of 30 mils. The first coat was allowed to partially cure for 4 hours before re-coating. Flexane Brushable provided a long lasting, flexible, (350% elongation), protective surface coating that was resistant to thermal cycling.
    • Location 93 High Voltage Cable Repair Cable Cast 9/21/96 R & W Cable Underground Mining Problem: These high voltage cables will arc and “ground out” when electric digging shovels pierce through the rubber protective jacket of the cable. These cables carries 1KV to 5KV of electricity. This rubber jacket acts as an insulator and must be M.S.H.A. approved and flame resistant. Solution: The complete repair area was roughened using a small belt sander. Surface area was then chemically cleaned using Cleaner Blend 300. FL20 Primer was applied and allowed to cure or dry for 15 minutes. A polypropylene mold jacket was clamped into position surrounding the repair area. Injection funnels were placed into the injection ports on the polypropylene mold jacket. Cable Cast (8 minute pot life),was injected into the mold using Devcon’s Auto Mix Application System. Following a 16 hours functional cure, the mold jacket was removed. Cable Cast provided a long lasting,flame retardant, M.S.H.A., abrasion resistant, cable jacket repair accepted in the underground mining industry.
    • Location 94 Floor Coating Epoxy Coat™ 6000 NON VOC 9/13/96 B.C. Bearing Engineers Building Maintenance Problem: New warehouse addition required protective coating to maintain floor integrity and reduce dust. Solution: Complete surface was first roughened to create a profile using a Blas-Trac machine. Surface was then vacuum cleaned to remove all dust. Floor Patch was applied to repair pot holes and chips from newly poured concrete. Epoxy Coat 6000 was applied using a 1/8” nap paint roller to a thickness of 8 mils. A second coat was applied to a thickness of 8 mils due to the absorption of the first coat into the porous concrete floor. The finish product was a 10-12 mils tough warehouse floor.
    • Location 95 Sump Repair B-4 Etcher, Epoxy Concrete Sealer 11-25-96 Link Belt Contractor OEM Contractor Equipment Problem: The milling machine’s sump has corroded over time. The customer needed to line the interior of the concrete sump area of the milling machine. The concrete has been compromised and cutting fluids are leaking from sump area. This poses environmental concerns. Solution: Degrease sump area with high pressure washer. Etch concrete with B-4 Etcher #13500. Pour Epoxy Concrete Sealer into sump area and back roll vertical surfaces. The epoxy will penetrate concrete and fill all voids, leaving a smooth non-porous surface. Water soluble cutting fluids will not penetrate the coating, therefore sealing sump area.
    • Location 96 Pump Repair Brushable Ceramic, Red & Blue September 1996 Bayou Yokley Pumping Station Water Treatment Plant Problem: A Worthington KN-62 Pump had worn metal areas that needed to be coated for chemical/abrasion attack to the metal surfaces. Solution: Pump casing is abrade with Washington Mills Blastite 36 BT, then solvent-cleaned with Cleaner Blend 300, (#19510). The blasting is performed to a Nace 1 Standard, or SSPC 10 White Metal Finish. Pump was coated immediately after blasting to ensure ultimate adhesion to the surface. Then two coats of Brushable Ceramic were applied 12-15 mils each and cured for 24 hours. A good chemical resistant finish was achieved.
    • Location 97 Steel Conveyor Roll Repair Floor Grip™ 9/2/96 MacMillan Bloedel Pulp and Paper Manufacturing Saw Mill Problem: Steel rolls used to convey lumber would become slippery when wet. The conveying of lumber and overall manufacturing process would slow considerably in wet operating conditions. Solution: Steel rolls were roughened using a grinder and wire wheel attachment. Following roughening complete coating areas were chemically cleaned using Cleaner Blend 300. Floor Grip epoxy component was mixed and applied to a thickness of 16 mils, using a paint brush. Floor Grip silicon carbide granules were sprinkled using a spaghetti strainer/ seed sower. Floor Grip silicon carbide granule were pressed into the epoxy mixture by “back rolling” using a 1/8” nap paint roller. Floor Grip provided an slip resistant coating improving the process of conveying limber in wet operating conditions.
    • Location 98 Transformer Oil Leak Repair Flexane® 80 Putty 4/22/96 B.C. Hydro Utility Power Distribution Problem: Over several years of service, existing caulking sealant would harden and crack compromising the seals on this Step Down Transformer Tap Changer. Water and moisture would seep into the transformer causing a catastrophic failure, often exploding. Step Down Transformer replacement cost was $8K. Solution: Seal areas were roughened to remove existing caulking material and paint. Repair areas were then chemically cleaned using Cleaner Blend 300. Both FL10 and FL20 Primers were applied and each allowed to cure or dry for 15 minutes. Using both primers will improve Flexane adhesion from 25 pli to 50 pli. Two primer system is always recommended for metal substrates in wet or outdoor operating conditions. Flexane 80 Putty was applied and smoothed forming a new seal. Flexane 80 Putty will remain flexible, (350% elongation), while providing a vibration and climate resistant seal. GoJo hand cleaner was used to smooth and sculpt Flexane 80 Putty following gel point. Re-sealing cost using Devcon materials totaled $250.
    • Location 99 Hydraulic Hose Repair Flexane® Fast Cure Repair Putty 7/10/96 J. H. Service Company Limited Mining Problem: The high pressure hydraulic hose systems in this long wall mining operation receive extreme surface wear and gouging. This application is a non structural repair used to prevent premature replacement of expensive hydraulic hose systems due to surface abrasion. Solution: The complete repair area was firstly roughened using a belt sander. After roughening, repair area was chemically cleaned using Cleaner Blend 300. FL20 Primer was applied and allowed to cure or dry for 15 minutes. Flexane Fast Cure Repair Putty is dispensed and applied to the repair area using Devcon’s Auto Mix Application System. Fast Cure was sculpted and smoothed using a putty knife. Flexane 80 Putty Fast Cure (90 minute functional cure), provided a long lasting, abrasion resistant repair.
    • Location 100 Tank Coating Floor Patch™, Epoxy Concrete Sealer, Flexane® FC Liquid 11-18-96 Mutual Manufacturing Company General Manufacturing of Piping Problem: Passivation tank and concrete pad needs to be coated for chemical protection against H 2 SO 4 in slight concentrations in water. They previously used rubber linings in the tank, but the process is very costly. Solution: First they blasted off all existing rubber liner in the containment area and rinsed thoroughly several times and neutralized the concrete. All worn concrete areas were regrouted with Floor Patch. Then Epoxy Concrete Sealer was used (8-10 mils thick) to coat entire containment area. Flexane Fast Cure #15050 was next injected into the control joints to seal the joints, and a second coat of Epoxy Sealer was used for the final coat. This tank is now a sealed chemical resistant liner which will not leak any liquid into the environment. Products: Application Date: Customer: Industry:
    • Location 101 Floor Repair Floor Patch™ Fast Cure / Flexane ® Fast Cure Liquid 8/23/96 Certified Foods Agriculture Food Processing Problem: Over several years of service, water contamination and traffic have caused the concrete to become spalled and eroded. Corrosion has also caused the handrail to become dislodged from the concrete. Solution: Loose concrete was removed using a grinder and wire wheel attachment. Solid concrete was then roughened. Forms were manufactured from metal and placed into position around the repair areas. Duct tape was used to hold the forms in place. Devcon’s Release Agent was applied to the forms for easy removal following partial cure of Floor Patch Fast Cure. Release agent must be used for easy part or form removal. An oversized metal pipe extension was positioned around the existing rail. Wood wedges were positioned to center the rail within the pipe extension. Floor Patch Fast Cure, (90 minute functional cure), was applied to rebuild missing concrete. Following a partial cure of Floor Patch fast Cure, (15 minutes), the metal forms were removed. FL10 Primer was applied to the metal rail and pipe. Flexane 80 Liquid Fast Cure, (90 minute functional cure), was injected as a flexible filler between the pipe and rail. Flexane 80 Liquid will remain flexible, (350% elongation), while resisting freeze thaw cycles caused by seasonal weather changes.
    • Location 102 Urethane Bus Bumper Repair Flexane® 80 Putty 7/16/96 Quebec City Transit Transportation Public Transit Problem: These urethane bus bumpers would receive damage from minor traffic accidents. The bumpers were frequently replaced at cost of $1.5K each. The customers objective was to repair bumpers rather than replace, reducing maintenance costs and extending the bumpers service life. Solution: Repair areas were roughened and gouged using a grinding machine and coarse sanding disc. All surface areas were then chemically cleaned using Cleaner Blend 300. FL20 Primer was applied and allowed to cure or dry for 15 minutes. Flexane 80 Putty was applied covering or coating the complete repair area. Following a 24 hour cure of the Flexane 80 Putty, the repair area was sanded using a very fine sanding disc. Bumpers were then repainted and installed back on the bus. Devcon’s repair cost was $150.
    • Location 103 Pulping Stone Repair Titanium Putty / Brushable Ceramic 6/19/91 Lake Superior Paper Pulp and Paper Manufacturing Problem: The exposed unprotected areas on the sides and edges of this pulp grinding stone would receive extreme wear from wood chips, water and steam. Replacement of the pulp grinding stone was estimated to be 35K. Solution: Repair areas were roughened to 5 mil profile using a grinder and wire wheel attachment. Repair surfaces were chemically cleaned using Cleaner Blend 300. Titanium Putty was mixed and applied to a thickness of 1/4” filling all voids and missing metal. Following a partial cure of Titanium Putty, (2 hours), Brushable Ceramic was and applied to a thickness of 30 mils in two 15 mil coats.encapsulating the complete repair area, and providing a long lasting, abrasion resistant protective coating. Devcon’s repair cost was $800.
    • Location 104 Pump Repair Titanium Putty 29/3/85 Smith College Power Plant Utility Power Generation Problem: The stuffing box area of this Bell and Gosset pump would receive extreme wear from a slurry combination of water and fly ash. Previous method of repair was to grind damaged areas and rebuild with gasket or packing material. Solution: Complete repair areas were sandblasted to a SSPC-SP5 white metal finish. Surfaces were chemically cleaned using Cleaner Blend 300. Small holes were drilled in stategical positions to establish a mechanical bond and anchor Titanium Putty. A dummy shaft was machined and used as a mold to shape bearing seat areas. Titanium Putty was mixed and applied to repair areas. The dummy shaft was coated generously with Devcon’s Release Agent and placed into position. Release agent must be applied for ease in part or mold separation. Following a full cure of Titanium Putty, (24 hours), the dummy shaft was removed.Repair areas were then lightly sanded to remove leading edges. Pump was assembled and returned to service.
    • Location 105 Floor Coating Epoxy Concrete Sealer 100 / Anti Skid Silica 6/1/96 Pilgrim State Hospital Building Maintenance Problem: Shower stalls within this hospital used abrasive tape in an effort to provide a safe non skid floor surface. The abrasive tape would usually peel off within only a few weeks. Solution: Floor surface was mechanically roughened to remove all traces of abrasive tape and provide a profile for epoxy coating. Complete floor surface was chemically cleaned using Cleaner Blend 300. Epoxy Sealer was then premixed. Anti Skid Silica was added to the mixed Epoxy Sealer. Epoxy Sealer with Anti Skid Silica was applied to a thickness of 10-12 mils. Epoxy Concrete Sealer provided a clear, water resistant, non skid surface to these shower stalls.
    • Location 106 Man Hole Seal Repair Flexane® 80 Putty 9/13/86 Con Edison Utility Power Distribution Problem: Over several years of service, these transformer man hole covers would become distorted from the constant weight of passing vehicles. This distortion caused rattling noise and structural problems. Solution: Complete repair area was roughened using a grinder and wire wheel attachment. The surface areas were chemically cleaned using Cleaner Blend 300. Both FL10 and FL20 primers were applied and each allowed to cure or dry for 15 minutes. Flexane 80 Putty was applied to a thickness of 1/4”. Cellophane was used as a release agent covering the applied Flexane. The manhole was repositioned compressing and forming the new seal between the manhole and the manhole seating area. Following full cure of the Flexane 80 Putty, (24 hours), the manhole was lifted and the cellophane removed.
    • Location 107 Pump Repair Titanium Putty / Ceramic Repair / Brushable Ceramic 9/10/85 Southwest Forest Products Pulp and Paper Manufacturing Problem: Exposure to pulp, H 2 SO 4, and caustic soda would cause severe abrasive and corrosive damage to the interior of this Ingersol Rand pump casing. The previous method of repair was to simply replace the complete unit when required. Replacement cost was estimated to be 20K. Solution: The complete interior of the casing was sandblasted to a SSPC-SP5 white metal finish. All repair surfaces were chemically cleaned using Cleaner Blend 300. A template was manufactured from wood and positioned to resize bearing seat areas. Original evidence markings were used as a guide when manufacturing the template. Devcon’s Release agent was applied generously onto the template. Release Agent must be used for easy removal or separation of templates. Titanium Putty was applied to damaged bearing seat areas rebuilding the missing metal. Ceramic Repair Putty was applied to all corroded areas deeper than 1/4”. Following partial cure of Titanium Putty and Ceramic Repair Putty, (4 hours), Brushable Ceramic was applied to a thickness of 30 mils. Brushable Ceramic encapsulated the repair areas and provided a long lasting, chemical and abrasion resistant, low co-efficiency to friction surface. Devcon’s repair cost was $2K. Products: Application Date: Customer: Industry:
    • Location 108 Tank Repair Wear Guard ™ Fine Load 6/6/92 New York State Gas and Electric Utility Power Generation Problem: The inlet areas of this tank would receive extreme wear from a combination slurry of fly ash and water. The wear was so severe the complete unit required replacement annually. Replacement cost was estimated to be $9K. Solution: Complete interior of tank was sandblasted to a SSPC-SP5 white metal finish. Following sandblasting the complete repair area was then chemically cleaned using Cleaner Blend 300. Wearguard Fine Load was applied to worn areas rebuilding the missing metal. Wearguard was smoothed and sculpted using acetone following gel point. Devcon repair was $1K.
    • Location 109 Bearing Race Repair Plastic Steel® Liquid / Plastic Steel® Putty 9/1/83 Stephens Adamson Incorporated Transportation Heavy Duty Equipment Manufacturing Problem: This large bearing race support or mating structure required repairs to rebuild worn missing metal. The new bearing required precision leveling when repositioned. The past repair procedure was to weld and machine to required dimension. This repair procedure was costly, caused heat distortion damage, and created lengthy equipment downtime. Solution: The new bearing was generously coated with Devcon’s Paste Release Agent. Release Agent must be used for easy part separation or removal. The bearing was positioned and leveled using jack bolts. A metal strip was tack welded around the perimeter to contain Plastic Steel Liquid and prevent migration while curing. Plastic Steel Liquid was pumped between the surfaces using a Grayco manual pump. Following full cure, (24 hours), the bearing was separated from the support or mating surface using jacks. Any remaining voids, imperfections, or pinholes were filled using Plastic Steel Putty then lightly sanded.
    • Location 110 Pump Repair Titanium Putty / Brushable Ceramic 6/1/82 NY State Gas and Electric, Seneca Lake Plant Utility Power Generation Problem: Over several years of service this pump casing would receive extreme wear and cavitation from processing primary cooling water. The cavitation and wear was so severe that the pump was operating at 50% efficiency. Previous method of repair was to replace complete pump casing at a cost of $60K. Solution: Complete surface area was sandblasted to a SSPC-SP5 white metal finish. All repair areas were then chemically cleaned using Cleaner Blend 300. Titanium Putty was mixed and applied filling all cavitated and worn areas deeper than .125”. Following a partial cure of Titanium Putty, (4 hours), Brushable Ceramic was applied to a thickness of 30 mils. Brushable Ceramic encapsulated the repair areas and provided a long lasting, abrasion and chemical resistant, low co-efficient to friction surface coating. Devcon’s repair cost was $1K.
    • Location 111 Bearing Housing Repair Titanium Putty 1/1/90 Bethlehem Steel Steel Manufacturing Problem: This gear box bearing housing would receive wear from vibration and contaminates between the bearing and bearing housing. The wear was so severe that the output shaft would rotate miss-aligned. The previous method of repair was to replace the bearing housing when required. Solution: Repair area or bore was grooved using a carbide threading insert to a .005” profile. Cutting a profile will improve the mechanical bonding properties of Titanium Putty. Surface area was then chemically cleaned using Cleaner Blend 300. Titanium Putty was applied to a thickness of .065” over the desired finished dimension. A heat lamp was positioned to speed curing while the housing was slowly rotated continually for 90 minutes. Slowly rotating will eliminate any risk of sagging while Titanium Putty cures. Following a 90 minute cure, Titanium Putty was machined to original housing specifications. Devcon’s repair cost was $100.00.
    • Location 112 Pump Repair Titanium Putty / Ceramic Repair Putty / Brushable Ceramic 6/1/90 Pennsylvania Electric Company Utility Power Generation Problem: This multi-stage cooling pump would receive extreme abrasive and cavitation wear to the spicket fits, hub area, flange and casing. The wear was so severe the pump efficiency was reduced by 50%. The previous method of repair was to simply replace when required. Replacement cost was estimated to be 28K. Solution: Complete repair areas were sandblasted to a SSPC-SP5 white metal finish. All surfaces were chemically cleaned using Cleaner Blend 300. Titanium Putty was applied to the spicket fits to replace or rebuild missing metal. Titanium was smoothed and contoured using Acetone and a putty knife following gel point. Titanium Putty was also used in the same way to rebuild missing metal on the hub and flange areas. Ceramic Repair Putty was applied to cavitated areas deeper than 1/4”. Following a partial cure of Ceramic Repair Putty and Titanium Putty, (4 hours), Brushable Ceramic was applied to a thickness of 30 mils in two 15 mils coats. Brushable Ceramic provides a long lasting, low co-efficient to friction, protective surface coating. Products: Application Date: Customer: Industry:
    • Location 113 Exhauster Fan Repair Titanium Putty / Brushable Ceramic 6/1/90 Pennsylvania Power and Light Utility Power Generation Problem: This exhauster fan would receive extreme corrosive and abrasive wear at the bore or inlet from a combination of fly ash, flume steam and sulfuric acid. The wear was so severe that a new ring needed to be fabricated, welded into position, and then machine to specification. Solution: The complete bore or inlet area was sandblasted to a SSPC-SP5 white metal finish. The surface area was chemically cleaned using Cleaner Blend 300. Titanium Putty was applied to all eroded areas greater than 1/8” deep. Following a partial cure of Titanium Putty, (2 hours), Brushable Ceramic was applied to a thickness of 25 mils. Following a partial cure of Brushable Ceramic, (4 hours), a second coat was applied, again to a thickness of 25”mils. Brushable Ceramic encapsulated repair areas and provided a long lasting, abrasion and corrosion resistant, protective surface coating.
    • Location 114 Coal Pulverizer Repair Wear Guard ™High Temp 8/12/97 Pennsylvania Power and Light Utility Power Generation Problem: This pulverizer would receive extreme wear from the abrasion of pulverizing or crushing coal prior to being fed to the boilers. The wear was so severe that the metal was completely worn through. Previous method of repair was to weld or replace missing metal with AR plates. Solution: Repair area was roughened to a SSPC-SP5 white metal finish using a grinding machine. Gouges were ground into the metal to improve mechanical bonding properties of Wearguard High Temp.. All surface areas were chemically cleaned using Cleaner Blend 300. Wear Guard High Temp was applied to rebuild or replace missing metal. Wear Guard was smoothed, contoured and feathered using acetone as a thinning agent. Acetone should be used only after gel point or stiffening of Wear Guard High Temp.
    • Location 115 Water Box Cover Repair Ceramic Repair Putty / Brushable Ceramic 6/1/90 Sun Oil Company Petrochemical Gasoline Manufacturing Problem: These heat exchanger water box covers would receive extreme corrosion, cavitation and erosion after only a short service life. The previous method of repair was to simply replace when required. Replacement cost was estimated to be several thousand dollars. Solution: Complete surface area was sandblasted to a SSPC-SP5 white metal finish. All surfaces were then chemically cleaned using Cleaner Blend 300. Ceramic Repair Putty was applied to all cavitated or eroded areas deeper than 1/8”. Following a partial cure of Ceramic Repair Putty, (4 hours), Brushable Ceramic Red was applied to a thickness of .025”. Following a partial cure of Brushable Ceramic Red, (4 hours), a second coat of Brushable Ceramic Blue was applied, again to a thickness of 25 mils. Brushable Ceramic encapsulated the repair areas and provided a long lasting, abrasion and corrosion resistant, low co-efficient to friction protective surface coating. Devcon’s repair cost was$ 200 each cover.
    • Location 116 Pump Repair Titanium Putty / Ceramic Repair Putty / Brushable Ceramic 3/4/93 Eurocan Pulp Pulp and Paper Manufacturing Problem: After only a short service life this Bingham pump casing would received extreme abrasive and cavitation wear from processing wet pulp stock. The wear was so severe that the pump would require replacement every 3 years. Pump replacement cost was estimated at $60K. Solution: Complete pump casing was sandblasted to a SP5 white metal finish. Expandable metal was tack welded to areas of extreme wear. Expandable metal improved mechanical bonding properties of Titanium Putty. Welding slag was cleaned using a grinding machine. Surfaces were chemically cleaned using Cleaner Blend 300. A thin 10 mil coating of Brushable Ceramic was applied as a primer to thoroughly wet out the pump surface area. Titanium Putty was applied to rebuild all areas of extreme wear and wear ring seat areas. Ceramic Repair Putty was applied to cavitated areas deeper than 1/8”. Following a partial cure of Ceramic Repair Putty, (4 hours), Brushable Ceramic was applied to a thickness of 30 mils in two 15 mil coats.. Brushable Ceramic provides a long lasting, abrasion and chemical resistant, low co-efficient to friction protective surface coating. Devcon’s repair cost was $4K. Products: Application Date: Customer: Industry:
    • Location 117 Pump Repair Combowear FC (fast cure) 1/16/96 Florida Plating Petrochemical Gypsum Manufacturing Problem: This Hazelton Pump would receive extreme abrasive wear from processing gypsum rock. The wear was so severe that the pump efficiency was reduced to 40%. The previous method of repair was to simply replace when required. Pump replacement cost was estimated to be $25K. Solution: Complete volute of the pump casing was sandblasted to a SSPC-SP5 white metal finish. Expandable metal was tack welded in a raised position .065” inch above the actual substrate. Welding slag was removed using a wire brush. Tack welding expandable metal improved mechanical bonding properties of Combowear FC. All contact surfaces were then chemically cleaned using Cleaner Blend 300. Combowear FC was applied to a thickness of 1/2” rebuilding the missing metal. Combowear FC was smoothed and contoured using acetone as a thinning agent following gel point. Combowear FC provided a fast curing, (90 minute functional cure), long lasting, abrasion resistant protective lining. Devcon’s repair cost was $2K.
    • Location 118 Valve Gate Repair Titanium Putty / Brushable Ceramic / Flexane® 80 Putty 1/19/97 Houston Light and Power Utility Power Generation Problem: This 1.5 meter cooling system valve would receive extreme abrasive wear from a slurry of sand and water. The wear was concentrated on the valve body seal area and the on the edges of the valve gate. The wear was so severe that the valve no longer sealed due to a 1/2” gap between the gate and seal. The previous method of repair was to simply replace when required. Valve replacement cost was estimated to be $45K. Solution: Complete valve assembly was sandblasted to a SSPC-SP5 white metal finish. All surfaces were then chemically cleaned using Cleaner Blend 300. Titanium Putty was applied to the valve gate edges rebuilding the missing eroded metal. Following a partial cure of Titanium Putty, (2 hours), Brushable Ceramic was applied to a thickness of 25 mils. Following a partial cure of Brushable Ceramic, (4 hours), a second coat of Brushable Ceramic Red was applied, again to a thickness of 25 mils . Titanium Putty was applied to the seal support area rebuilding the missing eroded metal. Following a partial cure of Titanium Putty, (2 hours), both FL10 and FL20 Primers were applied and each allowed to cure or dry for 15 minutes. Using both primers improved bonding properties of Flexane 80 Putty from 25 pli to 50 pli.. Flexane 80 Putty was applied to replace the worn missing rubber seal. Vaseline was applied to the gate as a release agent, and then closed. Closing the gate compressed the uncured Flexane 80 Putty, forming a new urethane seal. Following a full cure of the Flexane 80 Putty, (24 hours), the gate was opened. All remaining exposed metal was coated with a final coat of Brushable Ceramic. Brushable Ceramic encapsulated repair areas and provided an abrasion and corrosion resistant, low co-efficient to friction protective coating. Devcon’s repair cost was $3K.
    • Location 119 Lining Victaulic® Elbows Flexane® 80 Liquid & Putty June 2002 South American Copper Mine Mining Problem: These Victaulic ® brand elbows came from the supplier without a lining. They wear quickly in mining applications, such as mineral pulp transport lines, and need a lining to withstand the abrasion. The lining available from the OEM is very expensive, more than the original elbow! Solution: The ends of the elbow were milled 2mm and deburred. The metal substrate was grit blasted and cleaned with Cleaner Blend 300, and primed with SA-200 primer. When this was dry, UU-66 primer was applied and allowed to dry. The entire interior surface was then coated with Devcon Flexane 80 putty and liquid.
    • Location 120 Coal Diversion Gate Repair Flexane® 80 Putty 9/20/91 Linatex Corporation Mining Problem: These metal gates used to divert minerals for classification would receive extreme abrasive wear. The previous method of repair was to attached hardened plate or ceramic tiles to the gates. Attaching hardened plate added significant weight and the ceramic tiles would often break due to impact abrasion. Solution: The complete surface area of the metal gate was sandblasted to a SSPC-SP5 white metal finish. Surface area was then chemically cleaned using Cleaner Blend 300. Both FL10 and FL20 Primer were applied to the metal gate surface area and each allowed to cure or dry for 15 minutes. Applying both primers will improve adhesion of Flexane from 25 pli to 50 pli. Flexane 80 Putty was applied on the metal gate to a thickness of 1/8”. Urethane sheets, (.750” thick), were fabricated to cover the metal gates. Urethane sheet contact surfaces were roughened and chemically cleaned using Cleaner Blend 300. RU80 Urethane Primer was applied to the urethane covers and allowed to cure or dry for 15 minutes. A thin coat of Flexane Brushable was applied to the urethane covers to completely wet out the surface. The urethane sheets were positioned and compressed into place. Flexane 80 Putty provided a long lasting, flexible bond of the urethane sheets to the metal gates.
    • Location 121 Bag House Tube Sheet Repair Plastic Steel® Putty 6/33/93 U.S. Steel Edgar Thompson Plant Steel Manufacturing Problem: Over months of service the weld seams, and tube sheet joints would wear from processing or filtering lime and dry dust particulate. The wear was so severe that air and material leakage occurred. Past repair procedure was to weld or reseal with RTV sealant. Both past repair procedures were time consuming and offered poor performance. Solution: Repair areas were first roughened to a SSPC-SP5 white metal finish using a grinding machine. Following roughening, all repair areas were chemically cleaned using Cleaner Blend 300. Plastic Steel Putty was mixed and applied as a filler to all worn metal areas on both the floor and wall seams. Following a partial cure of Plastic Steel Putty, (2 hours), Plastic steel Liquid was applied using a paint brush to lock in Plastic Steel Putty and to seal all potential pin holes. This repair process reduced downtime by 6 days. The overall cost savings using Devcon’s repair was estimated at $10K.
    • Location 122 Concrete Floor Repair Floor Patch™ FC, Flexane ® FC Liquid July 2003 Walt Disney World Amusement Park Problem: Concrete in a heavily traveled area cracking and falling apart due to heavy traffic and wear. The expansion joint also needed to be repaired. Solution: Damaged concrete was chiseled out, squaring the edges for a locked, “feathered edge”. Floor Patch FC was used as the area needed to be back in service quickly. Floor Patch FC was mixed/applied into area and troweled smoothly. The expansion joint was cleaned out to a minimum ½” depth and FL-20 Primer was applied in a thin, uniformed coating along the entire expansion joint. This was followed using a portable air tank and a 400ml pneumatic applicator, (4:1 ratio) with a Flexane FC liquid cartridge, and a 400ml mix nozzle. A uniform self-leveling bead was applied and allowed to level until the filled expansion joint was just below the concrete surface for a smooth transition for vehicles traveling across this joint.
    • Location 123 Floor Coating Flexane® 80 Liquid / Concrete Primer / Epoxy Concrete Sealer 100 7/29/96 Linkbelt Construction Building Maintenance Problem: This waste chemical storage room required protection from mild chemicals such as glycol, oils and solvents. The storage room floor had not been previously coated and had a number of expansion joint cracks. Chemicals could possibly seep through the floor and contaminate the groundwater. Solution: Complete floor area was acid etched using Devcon’s B-4 Citrus Acid Etch. Once the floor had completely dried the floor was vacuum cleaned. All expansion joint cracks were filled using Flexane 80 Liquid Fast Cure (90 minute functional cure). Flexane 80 Liquid Fast Cure will remain flexible, (350% Elongation), and cushion concrete movement due to thermal cycling. Following a 2 hour cure of Flexane 80 liquid Fast Cure, Concrete Primer was applied to a thickness of 5 mils using a 1/8” nap paint roller. Following a partial cure, (4 hours), Epoxy Sealer was applied to a thickness of 12 mils using a 1/8” nap paint roller. Products: Application Date: Customer: Industry:
    • Location 124 Rubber Roll Repair Flexane ® Belt Repair Kit June 2003 Circle C Equipment Agriculture Problem: Farmers use rubber rolls to flatten hay in order to speed up the drying process of the hay. Occasionally rocks will tear apart sections of these rolls reducing their effectiveness to dry the hay. Resurfacing the roll with new rubber has an estimated cost of $1,500, besides enormous “downtime” as the farmer must send the roll to the shop to be resurfaced. This “do-it-yourself” system would allow the farmer to repair the roll the same day. Solution: Devcon’s Flexane Belt Repair Kit is a complete “do-it-yourself” system that a farmer can repair the rolls themselves. All repair areas were sandblasted or abraded using a wire brush. Next, Cleaner Blend 300 was applied to the metal roll to thoroughly clean all contaminants. FL-10 is used to prime the metal roll while FL-20 is used to prime areas that will come in contact with the existing rubber surface. Flexane 80 Putty is then applied to the roll core building up to the existing roll. Grooves are then made in the Flexane 80 prior to setting up to match the existing rubber roll. Farmers now repair their rubber rolls in 24 hours! Devcon’s repair cost per roll is $100. While sending them out for repair averages $1,500. A major cost savings for the farmer.
    • Location 125 Broom Box Chute Coating Flexane® High Performance Brushable 8/4/92 Norfolk and Southern Railroad Transportation Rail Problem: These Broom Box Chutes would receive extreme corrosion and impact abrasion wear from processing limestone particulate. The wear was so excessive that the chute required replacement annually. Solution: Complete repair or coating area was sandblasted to a SSPC-SP5 white metal finish. Surfaces were then chemically cleaned using Cleaner Blend 300. Both FL10 and FL20 Primers were applied and each allowed to cure or dry for 15 minutes. Using both primers will improve mechanical adhesion of Flexane High Performance Brushable from 25 pli to 50 pli.. Flexane High Performance Brushable was applied to a thickness of 25 mils. Flexane High Performance Brushable provided a long lasting, impact resistant protective surface lining.
    • Location 127 Concrete Pump Pad Repair Floor Patch™ 8/4/92 Laurel Maintenance Pulp and Paper Manufacturing Problem: Over several years of service, this pump pad’s concrete would become loose and eroded from a combination of vibration and chemical leakage from the pump. The previous method of repair was to pour new concrete. Newly poured concrete could not achieve good bond strength and also provided poor chemical resistance. Solution: The concrete surface was sandblasted to remove loose concrete and provide a rough profile. Devcon’s Release agent was generously applied to the pump mounting base for easy removal or separation. Release agent must be used for easy part or mold separation. Floor Patch was applied onto the worn concrete. The pump mounting base was set and leveled on top of the uncured Floor Patch. Fasteners were pushed through the the pump mounting base into the uncured Floor Patch. Following a full cure of Floor Patch (24 hours), the pump mounting fasteners were tightened.
    • Fast Cure Rubber Repair Liquid 8/4/97 Laurel Maintenance Building Maintenance Problem: The current expansion joints within this floor system received corrosive wear from chemical attack. Previous repair method was to fill worn areas with a caulking material. Caulking material offered poor chemical resistance to H 2 S0 4 and was prone to cracking, ultimately compromising the seal. Solution: Complete repair area was sandblasted to remove loose concrete and provide a roughened surface. A polypropylene backer was stuffed into the expansion joints. The polypropylene backer prevented deep migration of Flexane 80 Liquid, reducing the amount required. FL20 Primer was applied to the interior of the expansion joint and allowed to cure or dry for 15 minutes. Flexane 80 Liquid fast Cure, (90 minute functional cure), was injected using Devcon’s Automatic Mixing Application System. Flexane 80 Liquid’s viscosity allowed the urethane material to self level forming a smooth even flexible, (350% elongation), seal. Location 128 Expansion Joint Repair
    • Location 129 SAG Mill Feed Chute Side Rail Sealing High Performance Backing Compound March 2002 South American Gold/Copper Mine Mining Problem: Rocks would fall into the side rails of the SAG mill feed chute, preventing movement of the chute. A way to seal off the area was required to stop the damage. Solution: The whole cavity was cleaned with compressed air followed by Cleaner Blend 300. It was then filled with High Performance Backing Compound. The problem was solved economically and quickly. Rigorous substrate preparation was unnecessary for this type of application.
    • Location 130 Transformer Oil Leak Repair One Minute™ Epoxy / Fasmetal™ / Flexane® 80 Putty 3/16/96 Alabama Power Utility Power Distribution Problem: Transformers often develop leaks in a variety of areas such as radiator fins, flanges, circuit breakers, valves, and fastener assemblies. The leak on this radiator fin is so severe that oil coolant levels would drop, resulting in a catastrophic failure of this transformer. Previous method of repair was to drain coolant oil and replace complete radiator assembly. Solution: One Minute Epoxy is compressed onto the leak area by hand using a polypropylene sheet. (Inserting a machine screw to slow the leak prior to applying One Minute Epoxy is advised.) Once the leak has stopped, the complete repair area was roughened to aSSPC-SP5 white metal finish using a wire bush. Repair area was then chemically cleaned using Cleaner Blend 300. Fasmetal was applied to a thickness of 1/8” over the One Minute Epoxy extending 5mm beyond the One Minute Epoxy. Following a partial cure of Fasmetal, (1 hour), FL10 and FL20 Primers were applied and each allowed to cure or dry for 15 minutes. Using both primers will improve adhesion of Flexane 80 Putty from 25 pli to 50 pli. Flexane 80 Putty was applied to a thickness of 1/2” ,extending beyond the Fasmetal by 2 inches. Flexane 80 Putty provided a long lasting, flexible, (350% elongation), final seal that is resistant to vibration and thermal cycling. Following full cure, (24 hours), Flexane 80 putty was then painted. Products: Application Date: Customer: Industry:
    • Location 131 Adhesive Mounting of Transmitter 5-Minute® Epoxy 8-24-99 Marine Biology Problem: Marine biologists use transmitters to track marine life in order to monitor the animal’s life in the Gulf of Alaska. They need an adhesive to bond fiberglass mesh attached to a transmitter to the seal’s skin without damage to the animal. Solution: 5-Minute Epoxy was used to adhere fiberglass to the skin, and then “smoothed” out in a thin film around the fiberglass mesh for a smooth finish.
    • Location 132 Primary Cooling Water Feed Pumps Ceramic Repair Putty / Brushable Ceramic 4/15/98 Flakecoat Singapore SPC Singapore Petrochemical Problem: After only 3 years of service, these Primary Cooling Water Feed Pumps would become severely corroded and eroded. Previous solution was to replace when necessary. Complete system replacement cost was estimated in excess of 100KUS each. Solution: Complete surface areas were sandblasted to a SP5 white metal finish creating a 3-5 ml. profile. Repair and coating areas were then chemically cleaned using Cleaner Conditioner 300. Corroded, eroded areas deeper than 1/4” were filled using Ceramic Repair Putty. Following a partial cure of Ceramic Repair Putty, (4 hours), Brushable Ceramic Red was applied to a thickness of 15 ml. encapsulating repair areas and providing a primer coat sealing all surface areas. Brushable Ceramic Red was sanded following a complete cure of 24 hours. A second application of Brushable Ceramic Blue was applied providing a smooth, corrosion resistant, long lasting, low co-efficient to friction protective surface coating.
    • Location 133 Hamilton Water-Jet Diffuser Repair Titanium Putty / Brushable Ceramic 3/23/99 Flakecoat Singapore Petrochemical Problem: The surface areas, specifically the leading edges of the fins became severely corroded after several year of service. The previous method of repair was to simply replace when required. Replacement costs were estimated to be several thousands of dollars. Solution: Repair surfaces were first sandblasted to a SP5 white metal finish. Complete surface areas were then chemically cleaned using Cleaner Conditioner 300. Worn damaged fins were repaired using Titanium Putty. Corroded, eroded areas deeper than 1/4” were filled using Titanium Putty. Following a partial cure time of 6 hours, Titanium Putty was sanded to a smooth finish. Brushable Ceramic Red was then applied to a thickness of 15ml. Following a partial cure of Brushable Ceramic Red (4 hours), a second coat of Brushable Ceramic Blue was applied to a thickness of 25 ml. Brushable Ceramic provided a smooth, corrosion resistant, long lasting co-efficient to friction protective surface coating.
    • Location 134 Milling Line Equipment Grouting High Performance Backing Compound March 2002 South American Copper/Gold mine Mining Problem: Installation of the equipment in a new milling line, requries precision grouting. The material used needs to support tremendous weight, vibration and the adverse operating conditions of a mine. Cementitious grouts are an inferior option compared to a polymeric compound. Solution: Devcon’s High Performance Backing Compound was chosen to level the baseplates of the bearing housings, motors, and gear boxes of the SAG and ball mills. Its chemical, oil and compression resistance, and self-leveling quality, make it an excellent grouting material.
    • Location 135 Copper Concentrate Elbow Lining Wear Guard™ Fine Load January 2002 South American Copper/Gold Mine Mining Problem: Elbows in the concentrate transport system wear excessively and had to be changed frequently. Solution: The interior of the elbows was given a profile using a grinder. It was then chemically cleaned using Devcon Cleaner Blend 300. Subsequently, Wear Guard Fine Load was applied with a spatula. This lining at least doubles the duration of the elbow in service, reducing maintenance and downtime costs.
    • Location 136 Pump Liner Repair Flexane® 80 Liquid & Putty, Irathane® 155HS May 2002 South American Copper Mine Mining Problem: These Warman ® pump rubber liners suffer a lot of wear because of the severe operating conditions in mineral pulp. The cost of replacement is extremely high. Solution: The surface of the liners was hydroblasted to give it a good profile for the repairs and to decontaminate it. Then it was cleaned with Devcon Cleaner Blend 300. UU-66 primer was applied and allowed to dry. Then Flexane Putty and Liquid were used to rebuild the worn geometry of the liner. Once this repair cured, the substrate was again primed with UU-66 and 4 mm of Irathane 155HS polyurethane was applied to even out the surface and give it greater abrasion resistance.
    • Location 138 Auger Repair Wear Guard™ Fine Load 300 January 2004 Co-Gen II, LLC Pulp Paper/Wood Products Problem: Augers are precise pieces of equipment that needs to be within specification in thickness and height to transfer the materials it was intended. The company saw that “hard-facing” the augers saw only a 14 months life expectancy and thy wanted more! The flights of the auger wear over time from abrasion of the material against the flight walls. In this application , the customer “hard-faced” welded one auger and coated a similar auger with Devcon’s Wear Guard Fine Load 300 Both augers went into service for 13 month to determine what method worked the best! As can be seen from the photos, the auger with Devcon shows virtually no wear! Measurements taken indicate how well the Devcon product has performed over hard-face welding. Solution: Starting at the drive end the numbers below show the wear of the four flights on the auger,. All numbers are in millimeters with nominal flight thickness being 5/8” or 16mm. These numbers show the wear over the past thirteen months Hard-face welded flights: 14mm 13mm 9mm 10mm Devcon coated flights: 22mm 20mm 21mm (22mm is slightly less than 7/8”) Devcon’s Wear Guard High Load 300 has proven itself to be superior in extending the life of the auger. After determining the remaining wear of the flights the Devcon coated auger would still have approximately 12 months of additional service before wearing out. Wear Guard has doubled the life of the auger! Besides the extended wearing qualities of Wear Guard Fine Load the cost to coat the augers were $1044 [with 45 minutes labor to coat] compared to hard-facing which was $694/each [with 5-7 hours to coat]. The total savings to coat all 12 augurs were $25,000! All new augers will be coated before allowed in service with Devcon’s Wear Guard Fine Load 300.
    • Location 139 Ball Mill Repair Devcon® Irathane® 155 01/15/02 South American Copper/Gold mine Mining Problem: The customer had purchased a used milling line. The ball mill in the system was very worn on all surfaces, including the covers. This was due to defects in the internal coating, which allowed leakage of the pulp between liner and shell. The customer needed to restore worn dimensions to original condition, and prevent future problems. and used Wear Guard™ Fine Load on all worn areas. The whole surface was then coated with Irathane 155 as protection against possible future liner failure. Solution: Complete surface was blasted to white metal (SSPC-SP5). Surface was then cleaned with Cleaner Blend 300. When the surface was dry, eroded areas were repaired with Wear Guard Fine Load. Within 4 hours, the substrate was primed with SA-200 applied with airless spray equipment. This was allowed to dry for 3 hours, when Irathane 155 was applied, using 42:1 ratio airless equipment. Two coats of 155 were applied, achieving a total DFT of 2.5 mm. Repairs were made and future damage prevented, using two Devcon systems.
    • Location 140 Ball Mill Trunnion Repair and Lining Combo Wear, Flexane® 80 Putty July 2002 South American Copper Mine Mining Problem: The ball mill suffered extreme wear in the trunnion liner feed area, and in the area where it joins the mill. This wear threatened to endanger the system, since if the trunnion liner should be perforated, process water and pulp would enter the chamber between the liner and the trunnion, leading to critical wear and equipment shutdown. Solution: The trunnion liner and joint area with the mill was grit blasted and cleaned with Cleaner Blend 300. Devcon Combo Wear FC beaded epoxy was mixed and applied 6-10 mm thick with a trowel. This was allowed to cure for 40 minutes, after which Flexane 80 Putty was applied in a 6mm coat. This was allowed to cure for a few hours and the mill was put back in operation.
    • Location 141 Conveyor Belt Diverter Lining Tile Adhesive, Ferro Ceramic Tiles March 2002 South American Copper/Gold mine Mining Problem: The customer installed a system in the milling line in which one conveyor belt feeds 3 different chutes. A diverter distributes the material, including rocks up to 2” diameter, to the desired chute. Solution: Given the potential for abrasion of the diverter, Ferro brand ceramic tiles (100x150 mm x ½” thick) were applied for protection. The substrate (metal plate) was blasted to white metal and cleaned with Cleaner Blend 300. Devcon Tile Adhesive was spread onto the diverter, in a 1/8” thick coat. The tiles were then placed onto the adhesive, which is very resistant to abrasion and impact.