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 appropriate 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 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 the 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.
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, 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, in order to allow UMC to enter the structures. Another challenge was accessing the areas in need of coating, 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.
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.