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Application Profile Repair Don’t Replace!. Unique Polymers recently completed a major chemical storage tank refurbishment contract for a major chemical company.

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Application Profile

Repair Don’t Replace!

  • Unique Polymers recently completed a major chemical storage tank refurbishment contract for a major chemical company.

  • The internal surfaces of the tank had been corroded over 15 years of service and had become dangerously thin towards the base of the tank.

  • External and internal corrosion meant that steel plates had to be welded onto the surface of the tank before the entire area could be rebuilt and resurfaced.

  • Due to the high viscosity of the materials stored in the tank a highly abrasive resistant coating was put forward as a long term solution. The customer was expecting to extend the life cycle of the tank by another 5 years.

  • Unique Polymers recommended that the internal surfaces should be rebuilt where required using  UPS105 Metal Repair Paste and then resurfaced with 2 coats of UPS205 Ceramic Repair Fluid.

  • Application Details:

  • The affected area was blast cleaned using angled grit to SA2.5 Swedish Standard, 75 micron profile All surfaces were cleaned using an approved Unique Polymers surface cleaner

  • The uneven surface of the blast cleaned surface was rebuilt using  UPS105 Metal Repair Paste

  • The product was allowed to cure overnight at 20C using heaters in the enclosed area

  • Once the product had reached its minimum over coating time it was coated with UPS205 Ceramic Repair Fluid at a minimum wet film thickness of 350 microns


Application Profile

Repair Don’t Replace!

  • Many UPS distrbutors have been awarded the contracts to refurbish damaged heat exchanger end plates.

  • In this example the heat exchanger had been in operation for over 3 years and during routine inspection had been found to have been severely corroded in certain areas.

  • The UPS Distrbutor was asked to put forward a recommendation to rebuild and protect the end plates.

  • The UPS distrbutor recommended that the area should be blast cleaned and rebuilt using UPS105 Metal Repair Paste and then resurfaced with 2 coats of UPS205 Ceramic Repair Fluid.

  • Once completed the affected area will be protected for many years from erosion and corrosion

  • Application Details

  • The affected area was blast cleaned using angled grit to SA2.5 Swedish Standard, 75 micron profile All surfaces were cleaned using an approved UPS surface cleaner

  • The uneven surface of the blast cleaned end plate was rebuilt using Unioque Polymer Systems UPS105 Metal Repair Paste

  • The product was allowed to cure for 2 hours at 20C using heaters in a tented environment

  • Once the product had reached its minimum over coating time 2 coats of UPS205 Ceramic Repair Fluid were applied at a minimum wet film thickness of 350 microns per coat The repair was completed over two days


Application Profile

Repair Don’t Replace!

  • A UPS Thistlebond Distributor was awarded the contract to refurbish a damaged rudder for a UK based ferry operator.

  • The leading edge of the Rudder had been badly eroded over 4 years of operation and required rebuilding and resurfacing using the UPS Thistlebond Metal and Ceramic Repair Systems.

  • Due to consistent cavitation attack on the metallic substrate the front edge of the rudder had become badly pitted and scarred, UPS Thistelbond recommended that the area should be blast cleaned and resurfaced using TR105 Metal Repair Paste and then coated with 205 Ceramic Repair Fluid.

  • Once completed the affected area will be protected for many years from erosion and corrosion

  • Application Details

  • The affected area was blast cleaned using angled grit to SA2.5 Swedish Standard, 75 micron profile All surfaces were cleaned using an approved THISTLEBOND surface cleaner

  • The uneven surface of the blast cleaned rudder was rebuilt using Thistlebond 105 Metal Repair Paste The product was allowed to cure for 2 hours at 20C using heaters in a tented environment

  •  Once the product had reached its minimum over coating time it was coated with Thistllebond 2025 Ceramic Repair Fluid at a minimum wet film thickness of 350 microns

  • The repair was completed over two days


Application Profile

Repair Don’t Replace!

  • Unique Polymer Systems Distributor has recently completed a major dock gate bearing installation in the UK.

  • As part of a major refurbishment project of over 20 dock gates, UPS Distributor was asked to recommend a product which could be pumped into the void behind the composite bearing.

  • UPS205 Ceramic Repair Fluid was put forward as a long term, hard wearing adhesive which would be able to bond the bearing to the dock gate, ensure there would be no corrosion to the steel and composite surfaces and would out last the bearings 50 year design life.

  • The project was completed over a 4 day period.

  • Application Details

  • The Bearings were mounted onto the dock gate using UPS200 Ceramic Repair Paste and pre-positioned bolts on each section Three holes were drilled into the bearing at the bottom, middle and top as pumping points Air holes were drilled in certain areas of the bearing to ensure the UPS205 fluid ceramic flowed to cover all parts of the void

  • Using a diaphragm pump UPS200 Ceramic Repair fluid was pumped into the void behind the bearing The product was pumped through the pre-drilled holes, which were then filled as the material worked its way to the top of the bearing Once the product emerged from the top air holes.

  • The fluid ceramic was allowed to cure for 6 hours. The bolts used to fill the pumping points and air holes were taken out and the void was filled using UPS205 Ceramic Repair Fluid Once cured all areas of the bearing surface were abraded using a mechanical grinding disc to ensure a smooth finish


Application Profile

Repair Don’t Replace!

  • One of our distributors has just completed further coating works on Fluid Flow Equipment - Heat Exchangers and Refining Equipment.

  •  Most of these applications were first coated and in some cases repaired in 2005 - using the Engineering Grade Metal Repair (UPS105) and the Ceramics UPS200 and UPS205.

  •  Despite the constant erosion and corrosion capabilities of the fluids involved with these applications - the products have maintained their integrity.


Application Profile

Repair Don’t Replace!

  • Recently one of our distributors carried out a PIPE REPAIR UPS19610 using the UPS product range of PIPWWRAP bandages and UPS19000 STANDARD RESIN & HARDENER unique system.


Application Profile

Repair Don’t Replace!

  • As well as repairing leaking pipes - the Standard Resin & Hardener can be used to PROTECT and REINFORCE:

  • Carbon Steel Piping

  • Steel and Concrete Transitions

  • Concrete Lined Pipes

  • Mortar Lined Pipes

  • Bridge Columns

  • Structural Sign Repair

  • Utility Poles

  • Square Constructed Tanks

  • Round and Oval Tanks

  • Towers

  • Silos

  • Pilings

  • Telephone Poles

  • Pipe Lines

  • Pier Legs

  • Trusses

  • Vessels

  • Leaking Flanges

  • Leaking - Eroded Elbows

  • Underwater Applications

  • The UPS Resin & Hardener System can help maintence engineers to protect these infrastructure items where they are vulnerable to erosion and corrosion (including weatherisation damage) - impact damage and abrasion -

  • The UPS Resin & Hardener System is the BEST ALTERNATIVE TO RECONSTRUCTION!!

  • Can be used for

  • IMMEDIATE REPAIR to leaking pipes and vessel's -

  • Under Pressure with manufacturing schedule

  • Where downtime is costly

  • Where you need to keep up production without stopping the process

  • Where alternatives are either not working effectively or are to "messy"

  • Where you can not use HOT WIELD methods

  • Where you can not use either endless sleeves or wielding of sleeves

  • EXTENDED LIFE IS YOUR EXPECTATION ALONG WITH REDUCED REPAIR COSTS


Application Profile

Repair Don’t Replace!

  • Many companies in today's economic clime are continuing to look for products that will enable them to REPAIR rather than REPLACE their damaged or worn out Plant and Equipment -

  • Unique Polymer Engineering and Maintence Polymers can and do HELP end users to keep vital equipment running smoothly with the minimum of outage and downtime costs whilst also enabling the re-use of the equipment rather than the high expenditure of replacement parts (that are usually more expensive as a spare part that in bought new and attached) -

  • One of the most successful products groups are the UPS Ceramic Range -

  • The Range consists of both Fluid Grade Engineering Ceramic as well as Heavy Duty Wear and Lining Ceramics -

  • Here are some recent examples from one of the UPS exclusive distributors around the world:


Application Profile

Repair Don’t Replace!

  • PROBLEM:

  • Many ships that have reached over 10 years old will suffer from the BALLAST TANK TRANSFER PIPES becoming corroded, damaged, highly worn surfaces.

  • This PROBLEM requires in most cases that PIPES be REMOVED and REPLACED at a high cost to the ship owner.

  • This process usually has to take place in a DRY DOCK situation which in itself can ADD further to the HIGH COST

  • Description:

  • A ballast tank is a compartment within a boat or ship, that holds water. A vessel may have a single ballast tank near its centre or multiple ballast tanks typically on either side. A large vessel typically will have several ballast tanks including double bottom tanks, wing tanks as well as forepeak and aftpeak tanks. Adding ballast to a vessel lowers its centre of gravity, and increases the draft of the vessel. Increase draft may be required for proper propeller immersion.

  • The COST of this problem area in BALLAST TANK PIPE WORK can vary dramatically BUT will nearly always involve HARD TYPE repair (i.e. PIPE REPLACEMENT) methods or REPLACEMENT that has to be carried out in EXPENSIVE DRY DOCK TIME.

  • Unique Polymers can offer a EXTREMELY COST EFFECTIVE solution to this problem that not only can offer LONG TERM protection but can also be CARRIED OUT WHILST AT SEA - No need for expensive dry dock visits and LOST PROFITABILITY.

  • The REPAIR is QUICK - EFFECTIVE and SIMPLE to carry out by on-board operatives.

  • SOLUTION:

  • The following pictures show a typical BALLAST TANK PIPE repair on board.


Application Profile

Repair Don’t Replace!

  • Dredger Pumps are particularly susceptible to EXTREME DAMAGE to the VOLUTE area and especially at the CUT WATER area of the VOLUTE PUMP CASE.

  •  Centrifugal force tends to PUSH any particles in the fluid being pumped to the OUTSIDE and this causes particular problems to this area.

  •  Dredge pumps are in the forefront of removing sediment from beneath the waterline -

  •  By using the Unique Polymer Range of CERAMIC COATINGS - the distributor has enabled the end user to

  • NOT REPLACE the PUMP unit - at HIGH COST - but to REPAIR and PROTECT the pump units.

  •  This is a SOLUTION to the current economic climate where capital is saved from the maintence budget by the use of LIQUID MAINTENANCE POLYMERS.

  • In this instance THREE polymer products were used: UPS205 UPS240 UPS205

  • UPS205 - ENGINEERING GRADE CERAMIC COATING -

  •  Used to facilitate a smooth flow of the pumped medium over the wetted parts of both IMPELLER and VOLUTE casing and to ADD extra dimension to the UPS240 Repair Solution.

  •  The ALTERNATIVE solution to the problems that this type of fluid flow equipment has is to REPAIR the worn and damaged area. As this is a SPARE PART the COST is EXTREMELY HIGH.

  •  However by using the Unique Polymer range of products - THE ALTERNATIVE LOW COST SOLUTION - the pump can be quickly and effectively repaired AND this also has the ADDED VALUE of ADDING OPERATIONAL LIFE to this equipment.


Application Profile

Repair Don’t Replace!

  • One of our SUCCESSFUL INTERNATIONAL distributors has sent in the following pictures of successful applications that we can share with you -

  • This APPLICATION has been carried out in the face of still competition from many companies.

  • With the worlds wide slow down in the economy - companies are ACTIVELY looking for new and innovative ways that they can not only keep their plants operational BUT also in reducing the HIGH COST of capital equipment replacement. Unique Polymer Systems HAS the products and expertise to help!!

  • These are of APPLICATIONS being carried out with the following Unique Polymer Systems Polymer Products.

  • UPS200 Ceramic Paste

  • UPS205 Ceramic Fluid

  • UPS105 Metal Paste

  • After the proper SURFACE PREPARATION- masking tape is used to protect areas not required to be coated.

  • Corks are used to prevent the repair polymer from entering into the RODS / PIPES -


Application Profile

Repair Don’t Replace!

  • This particular piece of equipment suffers form severe abrasion and erosion and our distributor is engaged in making all the repairs as well as COATING to help prevent further erosion and damage.

  • This equipment is called a BAR SCREEN -- and suffers from extreme abrasion due to the operating process -

  • The Repairs were carried out with the UPS105 Metal Repair product.

  • All the equipment was then coated with our CERAMIC UPS200 / 205 RANGE of HARD COATINGS.

  • The Unique Polymer Range of MAINTENANCE POLYMERS can be used for rebuilding and resurfacing components operating in the most aggressive industrial environments, which are subject to erosion and corrosion damage.

  •  Can be used in the majority of Fluid Flow environments to protect against erosion and corrosion:

  • Pumps & Valves

  • Condenser Tube Sheets

  • Heat Exchangers

  • Pipes, Chutes & Hoppers

  • Impellers and Propellers

  • Tanks and Valves

  • Bow Thrusters and Rudders

  • The UPS polymer does NOT sag or slump during application. Contains NO SOLVENTS, Has good LOW TEMPERATURE cure properties, unaffected by most industrial chemicals, OUTSTANDING Impact and Abrasion Resistance, excellent adhesion to Metal Surfaces, approve for use with drinking water (WRC & DWI approved UK) 


Application Profile

Repair Don’t Replace!

  • Fluid Flow Equipment suffers from erosion from day one  in operation. This erosion will compromise the efficiency of the PUMP and increase the amount of energy required to power the unit.

  •  Even WEAR resistant materials will eventually wear away. The ABRASIVE PARTICLES in erosive applications will wear away the protective oxide layer and subsequently wear away the base material. If temperature and chemicals are also part of the application - then the wear can be significantly accelerated.

  •  If this cost is them multiplied by the number of pump units within the facility - increase in power consumption can be significant.

  •  With the added problem of CORROSION in the cases of ABRASIVE applications - this can also add to the burden of the PUMP MOTOR.

  •  This cause and effect problem can mean that the PUMP VOLUTE and IMPELLER being replaced on a regular basis.

  •  To COMBAT these difficulties - there are a series of HARD CERAMIC ENGINEERING GRADE PRODUCTS available.

  • UPS200- CERAMIC CARBIDE WEARING COMPOUND / Ideal for REPAIRING erosion/corrosion damage on all types of FLUID FLOW equipment

  • UPS205- ABRASION RESISTANT CERAMIC CARBIDE FLUID - Ideal for prevention erosion/corrosion damage on all types of fluid flow equipment.

  • UPS240 - Extreme abrasion resistant heavy duty lining material for use in highly abrasive situations in all fluid flow equipment.

  • Products Used UPS200 – UPS205 – UPS105 – UPS240


Application Profile

Repair Don’t Replace!

  • Many problems can occur and lie in wait for unsuspecting industrial accounts when the pipe carrying production fluids start to leak without any notice

  • This happens when the pipes are covered / protected by lagging systems that HIDE the condition of the underlying PIPE.

  •  Moisture can ingress through the lagging and start interacting with the pipe metallurgy and can cause pitting and rusting that can eventually turn into leakage paths through the pipes.

  • As the lagging material covers the pipe in total - no visual warning can be seen of this impending serious problem.

  • Unplanned leakage and pipe breakdown can in most cases cause major disruption in the plant process and its ability to function in either manufacturing or service supply.

  • To elevate this problem - there has been developed a WATER BASED - SINGLE COMPONENT - Elastic property polymer UPSTTLG that combined with UPSTTLG Reinforcing Sheet can offer total protection against under lagging corrosion and at the same time offer some abrasion and impact damage protection for the lagging covering the pipe.

  • The UPSTTLG product is a HIGH PERFORMANCE polymeric coating designed to encapsulate and protect all types of pipe insulation materials and dangerous asbestos fibre from exposure to the air.

  •  Is designed to offer MAXIMUM PROTECTION against UNDER INSULATION CORROSION in the most aggressive of environments. Is a colour stable and flame retardant product that supplies optimum levels of adhesion, impact resistance and durability in all types of weather.

  • Remains FLEXIBLE at temperatures of -30'C t0 160'C.

  •  Is extremely easy to use, and promotes excellent resistance to fungal and algal growth.


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