UNIQUE POLYMER SYSTEMS is a leading provider of durable protective solutions for industrial environments. This case study details the successful repair and protection of a concrete substrate used for sulphuric acid containment, utilising UPS 821 FFP FASTFILL PLUG, UPS 909 PP POROUS PRIMER, and UPS 407 EN EPOXY NOVOLAC.

A facility managing sulphuric acid containment faced severe damage to its concrete substrate due to prolonged exposure to 98% concentrated sulphuric acid. The acid had compromised the integrity of the concrete, requiring an urgent and durable solution to restore the surface and protect it from further acid attack.

‍

The challenge was to repair the damaged concrete and apply a protective coating that could withstand the harsh conditions created by concentrated sulphuric acid. The solution needed to ensure long-term durability and protect the substrate from further chemical exposure.

UNIQUE POLYMER SYSTEMS provided a comprehensive repair and protection solution using UPS 821 FFP, UPS 909 PP, and UPS 407 EN. The application process involved the following steps:

Surface Preparation:

- Compressed air was used to "sweat out" oils and other contaminants from the concrete surface.

- The surface was then abraded using hand-held diamond grinders to remove damaged material and create a clean profile for the repair.

Concrete Repair with UPS 821 FFP FASTFILL PLUG

- The damaged sections of the concrete substrate were rebuilt using UPS 821 FFP. This material provided a quick-setting, durable repair to restore the integrity of the concrete. 

Priming with UPS 909 PP POROUS PRIMER

- The entire surface was primed with UPS 909 PP, applied by brush and roller to a wet film thickness of 150 microns. This primer ensured proper adhesion of the subsequent protective coating.

Application of UPS 407 EN EPOXY NOVOLAC

- A stripe coat of UPS 407 EN was applied by brush to all edges and corners for extra protection.

- The entire area was then coated with two layers of UPS 407 EN, applied by brush, roller, and squeegee to achieve a wet film thickness of 400 microns per coat. This final coating provided a robust barrier against sulphuric acid, ensuring long-term protection.

‍

The application of UPS 821 FFP, UPS 909 PP, and UPS 407 EN successfully repaired and protected the sulphuric acid containment area. The durable coating system restored the concrete substrate and provided long-lasting protection against further acid damage, ensuring the safety and integrity of the facility.

This case study highlights the effectiveness of Unique Polymer Systems' repair and protective coatings in safeguarding industrial assets from harsh chemical environments. Our advanced materials and precise application techniques delivered a reliable solution that extended the life of the sulphuric acid containment area.