Devcon Maintenance and Repair Solutions - Sintemar

Field Application Reports 

Products: 

Application Date: 

Customer: 

Industry: 

Maintenance and 

Repair Solutions 

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


Amusement Parks 

LOCATION REPAIR / REBUILD / MAINTAIN 

122 Cement Floor 

Agriculture 


59 Exchanger Tube Sheet 

62 Inspection Door 

69 Floor Coating 


124 Rubber Rolls 

Automotive 


67 Door Holding Fixture 

Building Maintenance 













128 Expansion Joint 

Cement Manufacturing 


2 Conveying Pipe 

7 Silica Elevator 

8 Fan Housing 

34 Conveyor Belt 

43 Agitator 

49 Chute Lining 

50 Fan Housing 


Coal Preparation 


23 Screw Conveyor Trough 

Construction 



4 Urethane Wheel 

Products: 


Customer: 

Industry: 

Contents 

Machine Shop 


48 Anti-Skid Loading Dock / Floor 



131 Adhere Monitoring Transmitter 

Mining 


9 Filter Plate 


20 Floatation Cell Coating 

21 Ball Mill Shell 

25 Rubber Flange Connector 

28 Pump 


35 Pump 



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 


95 Machine Sump Coating 

Petrochemical 


6 Channel & Pipe Repair 


115 Water Box Cover 

117 Pump 

132 Primary Cooling Water Feed Pump 

133 Hamilton Water-Jet Diffuser


Power Plant 

Processing 

Products: 


Customer: 

Industry: 


26 Rod Mill 

84 Adhere Wood Block Flooring to Metal 


33 Cement Floor Acid Environment0 

Pulp and Paper 



51 Pump 

57 Cyclone Cone 

58 Rotary Bark Dryer 

68 Paper Machine Component Coating 


76 Forklift Paper Clamp 


97 Steel Conveyer Roll Coating 

103 Pulp Grinding Stone 

107 Pump 

116 Pump 

127 Pump Motor Concrete Pad 

138 Auger 

Refinery 


17 Pump Motor Concreter Pad 

Steel Mill 


10 Valve 

65 Stamping Press Alignment 

111 Bearing Housing 

121 Bag House Tube Sheet 

Textile Mill 


24 Heat Exchanger Outer Shell 

Transportation 


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 

Contents 

Utility 


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 


41 Pump Impeller 

42 Coupling Bolt 


53 Coal Pipe Elbow 


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 


91 Valve 

92 Exterior Pipe 


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 


Water Treatment 


22 Concrete 

29 Cone Valve 

30 Agitator 

36 Pipe 

38 Centrifuge Chute 


61 Ball Valve 

96 Pump Coating


Products: 


Customer: 

Industry: 

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..


Products: 


Customer: 

Industry: 

Location 2 

Pipe Repair 

Ceramic Repair Putty / Brushable Ceramic 

3/22/95 

Canada Cement Lafarge 


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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 4 

Urethane Wheel 

Manufacturing 


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.


Products: 


Customer: 

Industry: 

Location 5 

Coal Dust Valve Repair 

Titanium Putty / Brushable Ceramic 

2/15/94 



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.


Products: 


Customer: 

Industry: 

Location 6 

Channel, Valve and 


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.


Products: 


Customer: 

Industry: 

Location 7 

Silica Elevator Repair 

Wear Guard Fine Load 

3/23/96 



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.


Products: 


Customer: 

Industry: 

Location 8 

Fan Housing Repair 

Ceramic Repair Putty 

3/24/96 



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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 12 

Power Pole Repair 

Flexane® 80 Liquid Fast Cure 

3/21/96 

Ontario Hydro 


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.


Products: 


Customer: 

Industry: 

Location 13 

Floor Coating 

Floor Patch / Epoxy Coat 7000 

2/17/95 

Bender Engineering Inc. 


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.


Products: 


Customer: 

Industry: 

Location 14 

Floor Repair 

Floor Patch / Epoxy Coat 7000 

8/5/94 



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


Products: 


Customer: 

Industry: 

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.


Problem: 

Products: 


Customer: 

Industry: 

Location 16 


Floor Patch 

5/12/96 



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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 19 

Conveyor Belt Repair 


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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

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!


Products: 


Customer: 

Industry: 

Location 22 

Concrete Repair 

Floor Patch FC (fast cure) / Flexane® 80 Liquid 

5/14/97 

Central Valley Water 


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.


Products: 


Customer: 

Industry: 

Location 23 

Screw Conveyor Trough 


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.


Products: 


Customer: 

Industry: 

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!


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

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!


Products: 


Customer: 

Industry: 

Location 27 

Scrubber Wet/Dry 

Interface Repair 

Wear Guard Fine Load / Brushable Ceramic 

5/30/95 

Utah Power [Light Hunter Plant] 


Problem: 

Interior wet and dry interface of this Scrubber would receive extreme abrasive and corrosive wear from 

abrasive coal dust, flue gas and H2S04. 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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 29 

Cone Valve Repair 

Wear Resistant Putty 

4/14/97 

Las Vegas Valley Water District 


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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 31 



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: 


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.


Location 32 


Products: Ceramic Repair / Wearguard Fine / 

Application Date: Brushable Ceramic 

Application Customer: Date: 7/14/93 

Customer: Industry: Intermountain Power Services 

Industry: 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: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 34 



6/8/94 

Ash Grove Cement 


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.


Products: 


Customer: 

Industry: 

Location 35 


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.


Products: 


Customer: 

Industry: 

Location 36 



3/30/93 

Illinois Metro Water Reclamation 


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.


Products: 


Customer: 

Industry: 

Location 37 

Coal Crusher Repair 

Wear Guard High Load 

3/23/93 

N.P.P.D. Sheldon 


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.


Products: 


Customer: 

Industry: 

Location 38 

Centrifuge Chute Repair 


2/1/93 

City Of Chicago 


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.


Products: 


Application Customer: Date: 

Customer: Industry: 

Industry: 

Location 39 



One Minute Epoxy / Fasmetal / 


5/27/94 

BPU 


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: 


Customer: 

Industry: 

Location 40 

Floor Coating 

Epoxy Sealer 100 / B-4 Acid Etch 

11/29/93 

Huffy Sports Manufacturing 


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.


Products: 


Customer: 

Industry: 

Location 41 

Pump Impeller Repair 


26/6/93 

Douglas Pump Repair 


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. 



Products: 


Customer: 

Industry: 

Location 42 

Coupling Bolt Repair 

Titanium Putty 

1/2/92 

Edison Sault Electric Company 


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.


Products: 


Customer: 

Industry: 

Location 43 

Cement Agitator Repair 


9/21/92 

Chicago Road Service 


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.


Products: 


Customer: 

Industry: 

Location 44 


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.


Products: 


Customer: 

Industry: 

Location 45 


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 



Products: One Minute Epoxy / Fasmetal / 

Application Date: Flexane® 80 Putty 


Customer: Industry: Tucson Electric Power 

Industry: 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: 


Customer: 

Industry: 

Location 47 



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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 49 

Chute Lining Repair 


4/1/95 



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.


Products: 


Customer: 

Industry: 

Location50 

Fan Housing Repair 


4/1/92 



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.


Products: 


Customer: 

Industry: 

Location 51 


Titanium Putty / Wear Guard Fine Load 

7/1/94 

MacMillian Bloedell 


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.


Products: 




Industry: 

Location 52 

Floor Coating 

Floor Patch / Ceramic Repair Putty / 

Epoxy Coat 7000 

9/9/86 

Saint Johns Hospital 


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: 


Customer: 

Industry: 

Location 53 

Coal Pipe Elbow Repair 

Combo Wear FC (fast cure) 

6/6/96 

Delmarva Power and Light Indiana River Plant 


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.


Products: 


Customer: 

Industry: 

Location 54 



2/2/91 

Associated Electro-Mechanical 


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.


Products: 


Customer: 

Industry: 

Location 55 

Water Box Channel 



1/10/91 

Baltimore Gas and Electric 


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 remachined 

following a 4 hour cure.


Products: 


Customer: 

Industry: 

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 

Products: Wear Guard Fine Load / Ceramic Repair Putty / 



Customer: Industry: Strathcona Paper 

Industry: 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: 


Customer: 

Industry: 

Location 58 

Rotary Bark Dryer 



12/9/94 

Grant Forest Products Corporation 


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.


Products: 




Industry: 

Location 59 

Exchanger Tube Sheet 


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: 


Customer: 

Industry: 

Location 60 



9/3/92 

Ministry Of The Environment 


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. 



Products: 


Customer: 

Industry: 

Location 61 

Ball Valve Repair 


9/3/97 

Ministry Of The Environment 


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.


Products: 


Customer: 

Industry: 

Location 62 

Grain Inspection Door 


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.


Products: 


Customer: 

Industry: 

Location 63 



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 

Products: Flexane® 80 Putty / 

Application Date: Flexane® High Performance Brushable 


Customer: Industry: General Motors of Canada 

Industry: 

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: 


Customer: 

Industry: 

Location 65 

Stamping Press Alignment 



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.


Products: 


Customer: 

Industry: 

Location 66 

Urethane Wear Ring 


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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 68 

Paper Machine Component 



7/8/93 

Temboro Pulp and Paper 


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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 70 



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: 


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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 72 

Conveyor Belt / Pulley 

Lagging Repair 


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.


Products: 


Customer: 

Industry: 

Location 73 

Floor Coating 

Epoxy Coat 7000 / Safe-T-Grit 

7/2/92 

Kidd Creek Mining 

Mining 

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.


Products: 


Customer: 

Industry: 

Location 74 

Ball Mill Mobile Chute 


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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 76 

Forklift Paper Clamp 



3/1/91 

Provincial Papers 


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.


Products: 


Customer: 

Industry: 

Location 77 

Transformer SF6 Gas 

Leak Repair 

Wear Resistant Liquid 

6/30/95 

PECO Central Shop 


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.


Products: 


Customer: 

Industry: 

Location 79 

Sea Gateway Repair 


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.


Products: 


Customer: 

Industry: 

Location 80 

Head Gate Seal Interface 


Epoxy Concrete Sealer 100 / Titanium Putty 

1/7/91 

Ontario Hydro 


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.


Products: 




Industry: 

Location 81 

Recovery Cyclone Urethane 


Flexane® 80 Putty / 

Flexane® High Performance Brushable 

8/9/91 

Houston Lighting And Power 


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: 


Customer: 

Industry: 

Location 82 



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.


Products: 


Customer: 

Industry: 

Location 83 

Cooler Head Repair 


2/20/92 

Houston Power And Lighting 


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: 


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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 85 

Heat Separator Repair 


12/4/91 

Houston Lighting and Power 


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.


Products: 


Customer: 

Industry: 

Location 86 

Paddle Wheel Shaft / 

Hub Repair 


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.


Products: 




Industry: 

Location 87 

Floor Coating 

Floor Patch Fast Cure / Concrete Primer / 

Epoxy Coat 7000AR 

6/27/95 

Houston Power and Lighting 


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: 


Customer: 

Industry: 

Location 88 



6/10/92 

Houston light and Power 


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.


Products: 


Customer: 

Industry: 

Location 89 



7/24/97 

Houston Power and Light 


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.


Products: 


Customer: 

Industry: 

Location90 


Underwater Repair Putty 

5/12/93 



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.


Products: 


Customer: 

Industry: 

Location 91 



11/18/91 

Houston Lighting and Power 


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.


Products: 


Customer: 

Industry: 

Location 92 

Exterior Pipe Repair 

Flexane® Brushable 

7/10/92 



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 


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.


Products: 


Customer: 

Industry: 

Location 93 

High Voltage Cable 


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.


Problem: 

Products: 


Customer: 

Industry: 

Location 94 

Floor Coating 

Epoxy Coat 6000 NON VOC 

9/13/96 

B.C. Bearing Engineers 


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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 96 


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.


Products: 


Customer: 

Industry: 

Location 97 

Steel Conveyor Roll 


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.


Products: 


Customer: 

Industry: 

Location 98 




4/22/96 

B.C. Hydro 


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 


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.


Products: 


Customer: 

Industry: 

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 

Products: Floor Patch, Epoxy Concrete Sealer, 

Application Date: Flexane® FC Liquid 

Application Customer: Date: 11-18-96 

Customer: Industry: Mutual Manufacturing Company 

Industry: General Manufacturing of Piping 

Problem: 

Passivation tank and concrete pad needs to be coated for chemical protection against H2 SO4 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: 


Customer: 

Industry: 

Location 101 


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.


Products: 


Customer: 

Industry: 

Location 102 

Urethane Bus Bumper 



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.


Products: 


Customer: 

Industry: 

Location 103 

Pulping Stone Repair 


6/19/91 

Lake Superior Paper 


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.


Products: 


Customer: 

Industry: 

Location 104 



29/3/85 

Smith College Power Plant 


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: 


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.


Products: 


Customer: 

Industry: 

Location 105 

Floor Coating 

Epoxy Concrete Sealer 100 / Anti Skid Silica 

6/1/96 

Pilgrim State Hospital 


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.


Products: 


Customer: 

Industry: 

Location 106 

Man Hole Seal Repair 


9/13/86 

Con Edison 


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 


Products: Titanium Putty / Ceramic Repair / 



Customer: Industry: Southwest Forest Products 


Problem: 

Exposure to pulp, H2SO4, 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: 


Customer: 

Industry: 

Location 108 

Tank Repair 


6/6/92 

New York State Gas and Electric 


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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 110 



6/1/82 

NY State Gas and Electric, Seneca Lake Plant 


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.


Products: 


Customer: 

Industry: 

Location 111 

Bearing Housing Repair 


1/1/90 

Bethlehem Steel 


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 


Products: Titanium Putty / Ceramic Repair Putty / 



Customer: Industry: Pennsylvania Electric Company 

Industry: 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: 


Customer: 

Industry: 

Location 113 

Exhauster Fan Repair 


6/1/90 

Pennsylvania Power and Light 


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.


Products: 


Customer: 

Industry: 

Location 114 

Coal Pulverizer Repair 

Wear Guard High Temp 

8/12/97 

Pennsylvania Power and Light 


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.


Products: 


Customer: 

Industry: 

Location 115 

Water Box Cover Repair 


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 


Products: Titanium Putty / Ceramic Repair Putty / 



Customer: Industry: Eurocan Pulp 


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 coefficient 

to friction protective surface coating. Devcon’s repair cost was $4K.


Products: 


Customer: 

Industry: 

Location 117 


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.


Products: 


Customer: 

Industry: 

Location 118 

Valve Gate Repair 

Titanium Putty / Brushable Ceramic / 


1/19/97 

Houston Light and Power 


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.


Products: 


Customer: 

Industry: 

Location 119 

Lining Victaulic® Elbows 

Flexane® 80 Liquid & Putty 

June 2002 


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.


Products: 


Customer: 

Industry: 

Location 120 

Coal Diversion Gate Repair 


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.


Products: 


Customer: 

Industry: 

Location 121 

Bag House Tube Sheet 


Plastic Steel® Putty 

6/33/93 

U.S. Steel Edgar Thompson Plant 


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.


Products: 


Customer: 

Industry: 

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 

Products: Flexane® 80 Liquid / Concrete Primer / 

Application Date: Epoxy Concrete Sealer 100 


Customer: Industry: Linkbelt Construction 

Industry: 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: 


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.


Products: 


Customer: 

Industry: 

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 


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.


Products: 


Customer: 

Industry: 

Location 127 

Concrete Pump Pad Repair 

Floor Patch 

8/4/92 

Laurel Maintenance 


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.


Products: 


Customer: 

Industry: 

Location 128 


Fast Cure Rubber Repair Liquid 

8/4/97 

Laurel 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 H2S04 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.


Products: 


Customer: 

Industry: 

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 



Products: One Minute Epoxy / Fasmetal / 

Application Date: Flexane® 80 Putty 


Customer: Industry: Alabama Power 

Industry: 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: 


Customer: 

Industry: 

Location 131 

Adhesive Mounting of 

Transmitter 

5-Minute® Epoxy 

8-24-99 


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.


Products: 


Customer: 

Industry: 

Location 132 

Primary Cooling Water Feed 

Pumps 


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.


Products: 


Customer: 

Industry: 

Location 133 

Hamilton Water-Jet 

Diffuser Repair 


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.


Products: 


Customer: 

Industry: 

Location 134 

Milling Line Equipment 

Grouting 

High Performance Backing Compound 

March 2002 


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.


Products: 


Customer: 

Industry: 

Location 135 

Copper Concentrate 

Elbow Lining 


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.


Products: 


Customer: 

Industry: 

Location 136 

Pump Liner Repair 

Flexane® 80 Liquid & Putty, Irathane® 155HS 

May 2002 


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.


Products: 


Customer: 

Industry: 

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.


Products: 


Customer: 

Industry: 

Location 139 

Ball Mill Repair 

Devcon® Irathane® 155 

01/15/02 


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.


Products: 


Customer: 

Industry: 

Location 140 

Ball Mill Trunnion 

Repair and Lining 

Combo Wear, Flexane® 80 Putty 

July 2002 


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.


Products: 


Customer: 

Industry: 

Location 141 

Conveyor Belt Diverter 

Lining 

Tile Adhesive, Ferro Ceramic Tiles 

March 2002 


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.

Devcon Maintenance and Repair Solutions - Sintemar

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