Projects
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Meal Tank Exterior Coating - Wichita, KS

COATINGS

UMC completed the exterior coating of two separate meal storage tanks that were approximately 80' tall x 20' diameter. The tanks were experiencing severe spot corrosion on the exterior weld seams that in some areas had resulted in holes in the tank walls. This project was made particularly challenging by the fact that the client would not allow any abrasive blasting or spray-coating to be done on the tanks. UMC prepped the surface of the tanks using industrial degreaser and 5,000 psi water blasting to remove any surface contaminants prior to doing any coating work. After the general surface prep was complete, UMC repaired the metal holes before hand-prepping and spot-priming the corrosion areas. After the corrosion areas were addressed, UMC brush and roll-applied a high-quality silicone alkyd coating to all exterior surfaces of the tanks.  This coating is primarily used on previously painted substrates and provides superior color and gloss retention over conventional alkyd enamels. The tanks were not accessible by using boom lifts or suspended scaffolding which required UMC to erect full scaffolding for each tank. This project resulted in a satisfied client with tanks that will look great and perform well for years to come.


Water Park Blasting & Coating - Liberal, KS

COATINGS

UMC was called upon to perform the abrasive blasting and coating of a water park in Liberal, KS. The water park consisted of four separate concrete pool areas that were experiencing a failure of the existing coating in the form of chalking and flaking. Two of the pools were also experiencing significant leaking through cracks and joints in the concrete. UMC removed the existing coatings and prepped the surface of the concrete by abrasive blasting. Once the blasting was complete, UMC applied an epoxy filler to any cracks in the bare concrete and applied chlorine-resistant caulking to the expansion joints located in the bottom of the pools. Once the pools were leak-proofed, UMC applied three coats of a high-solids polyamide epoxy coating that offers protection against abrasion, immersion, and mild chemical contact. This project was made particularly challenging by the tight timeline in which the work needed to be completed.  UMC was given approximately one month to complete the project so that the water park would be ready to open by Memorial Day weekend. The timeline was met without issue and the client was very pleased with the results of the project.


Process Scale Demo & Install

FACILITY

UMC was called upon to facilitate a series of process improvements at a grain processing facility.  The facility needed to improve their process efficiency to accommodate increased production requirements.  UMC was the Owner’s contractor of choice for this project and immediately got to work on the improvements. UMC began by removing outdated process equipment including an aspirator, cyclone vacuum system, fans, ducting and assorted platforms. Once everything was removed, UMC used a crane to pick and install a new process scale and maintenance platforms that had been custom-fabricated by UMC and galvanized prior to installation. After installing the scale, UMC custom-fabricated spouting to connect the existing grain leg to the newly installed process scale.  UMC then installed spouting from the outlet of the scale onto a new loader which fed a process belt below.  Substantial modifications had to be made in order to fit all of the new equipment onto existing platforms and structural beams were added by UMC to hold the additional weight of the new equipment.  This project was completed on schedule and with zero safety incidents.

 


Process Belt Replacement - Wichita, KS

FACILITY

UMC crews replaced a worn out process belt approximately 700 feet in length on the second floor of a local grain processing facility. In order to complete the project an opening in the ceiling was utilized so that the entire belt could be removed and installed as safely and efficiently as possible. UMC custom fabricated a metal cradle to hold the new 2,200 pound belt, which was moved into position with a crane.  Once the old belt was removed and the new belt spool/cradle was in place, a series of winches and come-a-longs were used to safely install the new belt.  Before re-installing the belt, UMC replaced a handful of worn out liners on the bottom of the belt casing. Finally, the belt and rollers were adjusted and the belt resumed normal operation. This project was made especially challenging due to the tight working quarters where the conveyor was located.  The project was required to be completed during a 3-day plant shutdown, a deadline which UMC met.


Water Treatment Plant - Wichita, KS

COATINGS

A local water treatment plant was experiencing coating failure resulting in severe rusting and corrosion on the exterior of three above-ground 36” water lines. In fact, portions of the lines had originally been left uncoated and the bare steel was quickly deteriorating. UMC was called upon to coat the pipes using a three step coating process. UMC began by abrasive blasting the pipe to remove any rust and provide the proper surface profile for coating adhesion. UMC then applied an epoxy base coat followed by a polyurethane top coat that together provide excellent corrosion and rust prevention along with exceptional color retention and UV resistance. This project was made particularly challenging due to the fact that the work had to be done over a fast-flowing channel of water that could not be diverted during the project. UMC’s crew used scaffolding to install a full working platform over the water channel in order to provide access to the pipes and eliminate any safety hazards caused by the flowing water. UMC was able to overcome all challenges involved and complete the project safely and on schedule.

Conveyor Head Section Relocation - Wichita, KS

FACILITY

UMC was called upon by a soybean processing plant to relocate a 4,000 lb. drag conveyor head unit used to process soybeans. The objective of the project was to relocate the conveyor head from the third floor of the plant to the second floor in order to create additional space for machinery on the third floor of the plant. In order complete the project, UMC was able to remove sections of the conveyor casing, shorten the 1,000 lb. chain drag inside the conveyor casing, and remove and re-build the existing catwalk surrounding the conveyor head. The final step required re-fabricating and re-lining the discharge chute installed alongside the conveyor head. To safely lower the conveyor head and chain drag, UMC set up heavy-duty rigging rated to handle the conveyor head load. The project was required to be completed during a 10-day plant shutdown, a deadline which UMC met. During this project, UMC employees utilized their exceptional mechanical and fabrication skills to complete the project. As always, safety was UMC’s top priority on this project and the work was completed on schedule and without incident.


Petroleum Refinery Manhole Rehabilitation - Oklahoma, USA

COATINGS

A petroleum refinery in Oklahoma was experiencing seepage on a 30 inch oily water sewer line. In order to help fix the infiltration the pipe had been rehabilitated by installing CIPP the length of the line. After the pipe-lining was completed UMC was called upon to rehabilitate and epoxy-coat multiple manholes and structures on the newly-lined pipe. UMC began by stopping any points of infiltration in the structures. After the leaks were controlled the cement and brick structures were coated with 250 mils of 100% solids epoxy. The coating was tied-in to the CIPP liner in order to create a monolithic structure that extends the entire length of the rehabilitated sewer line and will provide lasting protection against corrosion and infiltration. The strict safety requirements set forth by the refinery were met and exceeded by UMC for the duration of the project.


Pre-Acidification Tank – Golden, CO

COATINGS

UMC recently completed the interior coating of a 55 ft. x 44 ft. bolted steel tank with approximately 5 mils of spray-applied epoxy primer and approximately 80 mils of spray-applied polyurea topcoat. The tank was experiencing severe corrosion on the center support column, the upper tank walls, and the roof beams. The complete interior of the tank had to be wet- abrasive blasted in order to remove any existing rust or corrosion. This also provided us with the proper profile to ensure that the coating would bond properly to the steel substrate. UMC removed the existing support column and roof beams and replaced them with new beams that we coated off-site prior to beginning the project. After the roof of the tank was coated and the beams were installed, we completed the coating of the walls and the floor of the tank. UMC had to overcome several obstacles in the completion of the tank, including having to race the November weather in order to beat the Colorado freeze due to the sensitive nature of the tank contents. Another challenge was containing the copper slag blast material that was used to the inside of the tank in order to avoid any negative impact on the environment. Safety and quality are of utmost importance here at UMC, and we took every step possible to provide a high quality project that was completed on a tight schedule and without incident.


City of Wichita Treatment Plant 2 Headworks Improvements – Wichita, KS

REHABILITATION

The City of Wichita Public Works and Utilities was experiencing severe erosion in three separate concrete structures at their wastewater treatment facility totaling approximately 5,600 interior square feet. The level of erosion was to the point that, if left untreated, it would jeopardize the structural integrity of the concrete. UMC was called upon by the prime contractor, Dondlinger Construction, to patch and coat the interior of the structures with a four-step cementitious and epoxy coating system that is specifically designed to be highly abrasion resistant. After the concrete surfaces were prepped with abrasive blasting and high-pressure washing, the areas that experienced the highest amounts of erosion were built-back to the original wall dimensions using a cementitious patching material. In addition to the patching, one of the structures had two areas with active ground water leaks that had to be fixed in order for the coating system to be applied properly.  After the leaks were stopped and the cementitious build-back was complete, the next three epoxy coats were hand-applied to create a monolithic epoxy coating that is highly chemical and erosion-resistant. What made this project particularly challenging was that UMC had to complete the work on a very tight schedule due to the city’s high daily cost of bypass pumping that was required to allow UMC to enter the structures. Another challenge was accessing the areas to be coated due to the fact that the structures were 20-30 feet below grade.  As always, safety was UMC’s top priority on this project and the work was completed without incident.


Splitter Box Rehabilitation - Golden, CO

COATINGS

UMC was called upon to carry out the coating of a severely deteriorated industrial waste structure with 100% solids epoxy, approximately 1,600 SF. UMC’s crew mobilized and removed four slide gates and their associated assemblies, handrails and catwalks in order to access the interior of the concrete structure. After masking the remaining steel surfaces and bolts, we applied a monolithic coating of epoxy to the complete interior of the structure to protect the surface from corrosion caused by wastewater and to ensure the longevity of the structure. After the coating was fully cured our crew replaced the slide gates, handrails and catwalks. One of the challenges associated with this project was that flow had to be diverted by using plugs on 5 different pipes ranging from 24” to 36”. UMC was able to complete all work safely, on budget and on schedule.


Cooling Line Internal Pipe Repair - Dallas, TX

COATINGS

UMC completed two separate composite repair projects on sections of pipe for this client. The first project consisted of the internal composite repair of 10 LF of 24 inch PVC cooling water line including 2 each 45 degree mitered bends. The cracks around the mitered bends were filled with grout and then the entire area in question was prepped and coated with 100% Solids Epoxy layered with carbon fiber. For the second project, UMC was called upon to find and repair several damaged areas inside a 24 inch diameter PVC cooling water line. UMC was able to locate the damaged areas in the pipe by CCTV and pressure testing of four separate 24 inch cooling lines. Once UMC was able to determine which areas were damaged and causing leakage, we were able to prep and coat the surface with 100% Solids Epoxy layered with carbon fiber. After the repairs were completed and the epoxy was cured-out, the line in question was once again pressure tested to ensure that the repair was effective.  Both of these projects required stringent lockout-tag out and confined space entry procedures due to the location of the pipes. UMC was able to carry out all work efficiently and without incident.


Manhole Replacement - Larned, KS

Utilities

The city of Larned contacted UMC upon discovery of a collapsed sanitary sewer manhole.  Due to high levels of H²S gas the concrete manhole had been corroded from the inside out and the surrounding soil pressure caused a collapse.  UMC was hired to stabilize the existing manhole while a new precast concrete manhole was manufactured.  Once the new manhole was delivered on site UMC managed the bypass pumping operation and the installation of the new manhole. The new manhole was coated with 100% solids epoxy and an inside drop was installed to prevent further corrosion caused by sewer gases.

Academy Water and Sanitation District – Colorado Springs, CO

COATINGS

Three water vaults under residential streets were showing signs of infiltration and the manager of Academy Water and Sanitation District felt that epoxy coating was the answer. Utility Maintenance Contractors was able to coat the vaults with 125 mils of 100% solids epoxy and ensure that the vaults would not be subject to further infiltration problems. Work was performed during winter months and offered challenges with bringing the concrete structures to an acceptable temperature for coating. Residents were not impacted by UMC’s work area and all coating work was completed on schedule and at budget.


AGCO Corporations – Hesston, KS

MAINTENANCE

AGCO has been a long standing client of ours. UMC has been providing industrial cleaning and maintenance services on a scheduled and emergency basis. Their paint department is where the majority of our services are utilized. An average crew of 4 to 8 workers has the task of cleaning out AGCO’s large paint pits with the use of vactor trucks. This work also requires a fair amount of sweat and hard labor from each worker. We are proud to be the cleaning and maintenance contractor AGCO has selected.


City of Laramie, Wyoming – Simon Contractors – Laramie, WY

COATINGS

Simon Contractors was in the process of installing a new road and all associated utilities when they discovered that the waste water piping material was too flexible to form a water tight seal at the manholes. They contacted Utility Maintenance Contractors for a solution to the infiltration problems on 12 manholes. With UMC’s quick mobilization and production rate, the contractor was saved 10's of thousands of dollars in bypass costs. Installation of 250 mils of 100% solids epoxy solved their infiltration problems and the project was completed at cost and on schedule.


City of Park City - Park City, KS

UTILITIES

UMC was low bidder on a remove/replace of a heavily deteriorated brick sanitary manhole, approx. 17’ deep. Bypass for this project was self-performed and approved by the city. The immediate challenge associated with this project was the close proximity of our planned excavation to existing communications and power lines. Coordination with AT&T and Westar was required to complete this job. A precast concrete manhole was installed and this job was completed without any interference to resident’s sewer services.


Colorado Springs Utilities – Colorado Springs, CO

COATINGS

Colorado Springs Utilities was having serious infiltration issues with a manhole next to one of its lift stations. This particular manhole housed a pressurized pipe with flow meters that had been covered by surcharged ground water to the point that the utility was unable to attach sensors to read the flow on the pipe. CSU contacted UMC to mitigate the infiltration and bring the manhole back to a functional state. Infiltration at the pipe penetration was constantly flowing and required hydrophilic grout to seal the leaks from the outside. Our crew mobilized and injected the grout allowing the manhole to be dried for application of the epoxy. After masking the pipe and meters in the manhole, a monolithic coating of epoxy was applied to ensure the manhole would remain dry and functional. This procedure was performed in a single day with no digging required and no interruption of service to the district or end users.


Conifer Marketplace – Conifer, CO

COATINGS

Utility Maintenance Contractors, LLC was contacted by the property management company for a small shopping center in Conifer, CO with complaints of infiltration in one of the wastewater manholes on their property. Another contractor had previously tried to stop the infiltration at the bench with some cementitious product which resulted in relocating the infiltration point to an area near the invert at the pipe penetration. UMC mobilized and was able to inject hydrophilic grout through the barrel section of the manhole to eliminate the infiltration in that area. Knowing the budget constraints of a small mountain shopping center, we proceeded to coat the bottom portion of the manhole to eliminate the chance of further spread of infiltration. Total time from the first date of contact to project completion was less than two weeks with all coating work happening in one day and no disruption of service or impact to the owner.


Containment Wall Rehabilitation – Wichita, KS

REHABILITATION

Through a relationship with a local concrete contractor UMC was made aware of some concrete corrosion at one of Wichita's processing facilities. The damage was described as chemical corrosion of concrete containment walls around two chemical tanks. Once a site visit was conducted it was determined that 100% solids epoxy and a mortar build-back material would be an adequate solution. The mortar was used to build-back the profile of the concrete walls where the corrosion was the most severe. With the possibility of more exposure to chemicals 100% solids epoxy was used to topcoat all repaired surfaced.


Dam Diversion Gates Replacement – Arkansas River

FACILITY

Wildcat Construction subcontracted the removal of existing gates and fabrication/installation of replacement gates to UMC. There were three areas with significant damage to concrete which was rehabilitated to prevent further issue. For the gate work a local welder/fabricator was brought on to help complete this work. The challenges of this project were mostly the design and fabrication of new gates to match the existing gates which were built more than 30 years ago. The river bed was pure sand so maneuvering equipment did take some patience. Project was completed on time and on budget.


Denver Metro Wastewater Reclamation District - Denver, CO

COATINGS

UMC was subcontracted by Wildcat Construction Colorado to complete the epoxy lining portion of the “Par 1136 - Diversion Structure Rehab” project. This work included the epoxy lining of moderately to heavily deteriorated concrete diversion structures, approx. 14,000 SF. One of the difficulties that this project presented was that not all of the structures could have their flows diverted while the coating work needed to be done. With a lot of planning UMC was able to safely complete all work on schedule.


Kansas Fence - Bushton KS

Utilities

UMC was hired by Kansas Fence to perform hydro-excavation for the installation of fence posts near a natural gas plant.  Due to the risk of hitting utilities using conventional excavation, hydro-excavation is the preferred method.  We have different sized vactor-truck units to accommodate all of our clients needs.

Mennonite Housing Rehabilitation Services, Inc. – Wichita, KS

UTILITIES

UMC was contracted in to install approx. 500 linear feet of concrete storm sewer pipe and all associated inlet boxes and rain leaders for a new housing development project. All work was self-performed and passed all final inspections. Part way through the project an additional manhole was added to the scope of work due to existing communication equipment which could not be moved. This manhole was located in the middle of a residential street and required traffic control and street closure to complete the work safely.


Reconstruction of Stage One Flocculators – Wichita, KS

FACILITY

City of Wichita put this project out for competitive bid and UMC was the low bid. Project overview was the labor and equipment to safely remove existing flocculator paddles and shafts, replace shafts with new ones provided by the City and reattach paddles once the City had finished repairing them. The difficulty with this project was safely handling the weight of the solid steel shafts. Use of a boom truck was needed in order to raise and lower shafts into flocculator basin. Only minor challenges arose during the project but UMC and City employees were able to overcome them and complete the project.


Sand Creek Interceptor – HDR Constructors, Inc. Denver, CO

COATINGS

UMC was contacted by HDR Constructors, Inc. for coating of a newly constructed diversion structure and some repair work to manholes damaged during the clean-up of Sand Creek after the fall flooding of 2013. Metro Wastewater Reclamation District is the owner of the interceptor that parallels Sand Creek in this particular area, and MWRD requires Warren Environmental Epoxy as one of the few products approved for use on their waste water infrastructure. A couple of the damaged manholes had been previously coated with 100% solids epoxy and required repair at the joints. HDR also contracted UMC to coat the new lids and risers added to raise the structures out of the Creek. On the first mobilization it was determined that the required 28 day cure time had not passed for one of the structure lids. HDR asked that UMC come back again after the proper cure of the concrete to perform that work in addition to another 3 manholes requiring coating.


Sanitary Sewer Maintenance/Inspection – St. Mary’s, KS

MAINTENANCE

UMC was low bidder on an annual sanitary sewer cleaning and CCTV inspection contract. This project included approx. 24,000 linear feet of pipe each year. Our experienced employees have been able to provide quality services and continue to keep the city satisfied with our work.


Southwest Suburban Denver Water and Sanitation District - Denver, CO

COATINGS

Utility Maintenance Contractors was contracted by SEH Engineers and SWSDWSD to eliminate infiltration on 15 of the district’s manholes. The structural condition of the manholes was acceptable so after proper surface preparation, UMC spray applied 125 mils of 100% solids epoxy to the manhole barrel section, bench and invert for a completely sealed manhole. We were able to utilize flow-through plugs instead of a bypass system to keep costs to the owner down. All traffic control, ROW permitting, and water use permitting for the ~2,500 SF total of coated surfaces was obtained by UMC prior to the start of coating operations. This effort minimized the required efforts of time and energy on the part of the owner and the engineer, and the project was completed safely, ahead of schedule, and on budget.


Sugar Creek Packing Co. – Frontenac, KS

COATINGS

This project arose when Wildcat Construction Company, Inc. was installing new sewer line and manholes and the originally specified manhole lining had failed. UMC was brought in to assess the failure and come up with a solution. After an on-site inspection it was determined that the original lining could be completely removed and monolithic epoxy lining could be applied. Using this method also allowed UMC to coat all of the exposed piping for corrosion protection.


Truck Parts – Wichita, KS

COATINGS

UMC has completed two separate epoxy lining projects for this client. Both projects consisted of rehabilitation of concrete oil/grease troughs located in their building. High pressure water was used to properly clean the surface before epoxy coating.


Western Farmers Power Corp. – Mooreland, OK

UTILITIES

Layne subcontracted the installation of two 16 inch diameter gate valves located on Western Farmers Power Corp. grounds to UMC. We were selected based upon our experience with valve installation and ability to handle asbestos pipe and its disposal. A small crew was mobilized to assist Layne in completing this project. All materials and excavation was provided by others, labor and supervision were the only responsibilities UMC had. Both installations were successful and completed ahead of schedule.


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