Alex-James Pulp and Paper 20100422

5/21/2018 Alex-James Pulp and Paper 20100422

1/15

Location 20Flotation Cell Repair

Brushable Ceramic and Ultra Quartz

January 1998

Noranda Mine (Brunswick Mine Division)Mining

Volume: 30,000 sq.ft

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 t

steel surfaces rather quickly once abrasion starts! The floor of the Floatation Cell sees the sediment of

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 a

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 durab

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.


2/15

Location 100Tank Coating

Floor Patch, Epoxy Concrete Sealer,

Flexane FC Liquid

11-18-96Mutual Manufacturing Company

General Manufacturing of Piping

50,000 sq.ftProblem:Passivation tank and concrete pad needs to be coated for chemical protection against H2SO4in 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 tim

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 f

the final coat. This tank is now a sealed chemical resistant liner which will not leak any liquid into the

environment.

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3/15

Location 57Cyclone Cone Repair

Wear Guard Fine Load / Ceramic Repair Putty

Brushable Ceramic

2/21/94Strathcona Paper

Pulp and Paper Manufacturing

Problem:Cyclone cones would receive extreme abrasive and corrosive wear from a slurry of recycled newspaper

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 tac

welded in a raised position 1/4 above the substrate. Tack welding expandable metal improved epoxys

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. Ceram

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.

Devcons repair cost was $550 each cone, excluding labor.

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4/15

Location 44Expansion Joint Repair

Fast Cure Rubber Repair Liquid

5/21/96

Wisconsin TissuePulp 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 provid

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 de

migration of Fast Cure Liquid, and reduce the volume required. Fast Cure Rubber Repair Liquid was

injected into the damaged or repair areas using Devcons Auto Mix Application System. This product i

self- leveling and provided a smooth, flexible, (450% elongation), expansion joint seal. Fast Cure Rubb

Repair Liquid also provided a functional cure in only 90 minutes, reducing repair downtime.


5/15

Location 58Rotary Bark DryerRepairBrushable Ceramic

12/9/94

Grant Forest Products CorporationPulp 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 110 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.


6/15

Location 68

Paper Machine ComponentRepairBrushable Ceramic

7/8/93

Temboro Pulp and PaperPulp 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.


7/15

Location 70Conveyor Belt Repair

Flexane 80 Putty

1/2/91

Domtar CaledoniaPulp and Paper Manufacturing /

Wall Board Manufacturing

Problem:This conveyor belt would receive extreme wear from processing wall board particulate. The wear was s

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. Devcons repair cost was $3K.


8/15

Location 80

Head Gate Seal InterfaceRepairEpoxy Concrete Sealer 100/ Titanium Putty

1/7/91

Ontario HydroUtility 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. I

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 applie

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.


9/15

Location 82Conveyor Belt Repair

Flexane 80 Putty

7/9/91

Monroe Hard WoodPulp 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 th

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.


10/15

Location 107Pump Repair

Titanium Putty / Ceramic Repair /

Brushable Ceramic

9/10/85Southwest Forest Products


Problem:Exposure to pulp, H2SO4,and caustic soda would cause severe abrasive and corrosive damage to theinterior 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 repairsurfaces were chemically cleaned using Cleaner Blend 300. A template was manufactured from woodand positioned to resize bearing seat areas. Original evidence markings were used as a guide whenmanufacturing the template. Devcons Release agent was applied generously onto the template. ReleaseAgent must be used for easy removal or separation of templates. Titanium Putty was applied to damagebearing seat areas rebuilding the missing metal. Ceramic Repair Putty was applied to all corroded areasdeeper 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 repairareas and provided a long lasting, chemical and abrasion resistant, low co-efficiency to friction surfaceDevcons repair cost was $2K.

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11/15

Location 116Pump Repair

Titanium Putty / Ceramic Repair Putty /

Brushable Ceramic

3/4/93Eurocan Pulp


Problem:After only a short service life this Bingham pump casing would received extreme abrasive and cavitatio

wear from processing wet pulp stock. The wear was so severe that the pump would require replacemen

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 t

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 o

Ceramic Repair Putty, (4 hours), Brushable Ceramic was applied to a thickness of 30 mils in two 15 mi

coats.. Brushable Ceramic provides a long lasting, abrasion and chemical resistant, low co-efficient tofriction protective surface coating. Devcons repair cost was $4K.

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12/15

Location 127

Concrete Pump Pad Repair

Floor Patch

8/4/92

Laurel MaintenancePulp and Paper Manufacturing

Problem:Over several years of service, this pump pads 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 poo

chemical resistance.

Solution:The concrete surface was sandblasted to remove loose concrete and provide a rough profile. Devcons

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 o

Floor Patch (24 hours), the pump mounting fasteners were tightened.


13/15

Location 87

Floor CoatingFloor Patch Fast Cure / Concrete Primer /

Epoxy Coat 7000AR

6/27/95Houston 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 Devcons B-4 Citrus Acid Etch. All cracks were repaired and sealed with

Devcons 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.

Devcons Epoxy Coat 7000AR withstands aggressive chemical operating environments.

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14/15

Location 138Auger Repair

Wear Guard Fine Load 300

January 2004

Co-Gen II, LLCPulp Paper/Wood Products

Problem:Augers are precise pieces of equipment that needs to be within specification in thickness and height totransfer the materials it was intended. The company saw that hard-facing the augers saw only a 14months life expectancy and thy wanted more! The flights of the auger wear over time from abrasion ofthe material against the flight walls. In this application , the customer hard-faced welded one auger acoated a similar auger with Devcons Wear Guard Fine Load 300Both augers went into service for 13 month to determine what method worked the best! As can be seenfrom the photos, the auger with Devcon shows virtually no wear! Measurements taken indicate howwell 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 numberare in millimeters with nominal flight thickness being 5/8 or 16mm. These numbers show the wearover the past thirteen months

Hard-face welded f l ights: 14mm 13mm 9mm 10mm

Devcon coated flights: 22mm 20mm 21mm (22mm is slightly less than 7/8

Devcons 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 haveapproximately 12 months of additional service before wearing out. Wear Guard has doubled the life ofthe 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 inservice with Devcons Wear Guard Fine Load 300.


15/15

Location 103Pulping Stone Repair

Titanium Putty / Brushable Ceramic

6/19/91

Lake Superior PaperPulp 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. Devcons repair cost was $800.

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Alex-James Pulp and Paper 20100422