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Structural Rehabilitation & Impermeabilization of two structurally deteriorated elevated steel tank silos a the medicinal gas manufacturing plant ACROMAX.
Brief Description of Selective Study Case No. 7:
The age of each of the elevated Carbon Steel Tank Silos was approximately 25 years old. They stored and operated a hot mix solution
of calcium hydroxide and water. Engineering assessment inspections identified many corrosion problems, structural deterioration, and
imperfect and irregular welds on the substrate to be coated.
Subsequently, a wet sandblasting surface preparation was done to generate the anchoring profile and required cleanliness for applying the
coating. All required structural repairs were performed, including removal of imperfect and irregular welds were removed. The Warren Epoxy was sprayed, and the average coating thickness was 1/8” (3 millimeters). Quality Control & Quality Assurance and inspections
were performed and they all passed with outstanding values.
manner, with no safety issues, and within the agreed work schedule with the customer. During the implementation of the project, the plant was able to continue operating at 50% capacity without stopping production. MADERO’s execution of this turnkey Mission Critical Project was a total success.
of calcium hydroxide and water. Engineering assessment inspections identified many corrosion problems, structural deterioration, and
imperfect and irregular welds on the substrate to be coated.
PRODUCT APPLICATION
As part of the surface preparation, high and ultra-high pressure jets of water (Range: 25,000 to 40,000 Psi) were applied to the silo internals for removing deposits of Calcium Hydroxide, which was solidified and strongly adhered to the substrate of the two tanks.Subsequently, a wet sandblasting surface preparation was done to generate the anchoring profile and required cleanliness for applying the
coating. All required structural repairs were performed, including removal of imperfect and irregular welds were removed. The Warren Epoxy was sprayed, and the average coating thickness was 1/8” (3 millimeters). Quality Control & Quality Assurance and inspections
were performed and they all passed with outstanding values.
CONCLUSION
The Impermeabilization and Rehabilitation Project of the two silos were successfully executed in ten (10) days, in a quality and cost-effectivemanner, with no safety issues, and within the agreed work schedule with the customer. During the implementation of the project, the plant was able to continue operating at 50% capacity without stopping production. MADERO’s execution of this turnkey Mission Critical Project was a total success.
Corrosion & Impermeabilization Protection, Structural Rehabilitation/Repair of Semi Deteriorated & Fully Deteriorated Metallic & Concrete
Brief Description of Selective Study Case No. 6:
Process Piping Systems & Component with Rapid Cure, Smart & Durable Engineered Composite Pipe Repair Systems.
Pics. 1 & 2: Composite Structural Rehab/Repair of Fully Deteriorated 12” Dia. Corroded Pipe w/ Pinholes
Pics. 3 & 4: Composite Structural Rehab/Repair of Fully Deteriorated 14” Dia. Corroded Pipe w/ Pinholes
Pics. 5 & 6: Composite Structural Rehab/Repair of Semi Deteriorated 54” Dia. Corroded Pipe w/ 63% Wall Loss
Corrosion Protection Coating Application at Market Center Lift Station’s Atmospheric and Immersion
Brief Description of Selective Study Case No. 5:
Piping Systems at City of Terrell, Texas.
Per owner’s coating specification, Immersion Piping System required application of three layers of Sherwin Williams Macropoxy coating system (i.e. primer, intermediate, and topcoat). Atmospheric Piping System also required first two layers of Sherwin Williams’ Macropoxy coating and Polyurethane topcoat. MADEROs Scope Of Work also included Abrasive Surface Preparation with Dustless Sponge Jet Abrasive System, Quality Control Testing (e.g. Wet Gauge, Holiday, and Adhesion Pull) and Quality Assurance.
Per owner’s coating specification, Immersion Piping System required application of three layers of Sherwin Williams Macropoxy coating system (i.e. primer, intermediate, and topcoat). Atmospheric Piping System also required first two layers of Sherwin Williams’ Macropoxy coating and Polyurethane topcoat. MADEROs Scope Of Work also included Abrasive Surface Preparation with Dustless Sponge Jet Abrasive System, Quality Control Testing (e.g. Wet Gauge, Holiday, and Adhesion Pull) and Quality Assurance.
Major Structural Engineered Rehabilitation & Repair, and Structural Optimization of Fully Deteriorated Buried 96” Diameter Concrete Piping & 4’x4’ Square Concrete Manhole Structures.
Brief Description of Selective Study Case No. 4:
using Warren Structural Epoxy for Long Term Useful Operational Life. Asset Owner: City of Fort Worth. The newly Engineered Protective, Structural Rehabilitation & Repair provided full structural integrity plus additional benefits (but not limiting to):
A. Able to withstand all the applicable structural design basis loads of soil and hydro loads.
B. A durable barrier against potential Inflow / Infiltration (I/I) of groundwater and stormwater, and hydrogen sulfide attack.
C. Pipe flow capacity increase due to Warren Epoxy’s Low Coefficient Of Roughness (COF) Vs. Deteriorated Concrete’s High COF.
The following pictures provide a view of their As-Found & As-Left Conditions of the Rehabilitated/Repaired Structures:
B. A durable barrier against potential Inflow / Infiltration (I/I) of groundwater and stormwater, and hydrogen sulfide attack.
C. Pipe flow capacity increase due to Warren Epoxy’s Low Coefficient Of Roughness (COF) Vs. Deteriorated Concrete’s High COF.
The following pictures provide a view of their As-Found & As-Left Conditions of the Rehabilitated/Repaired Structures:
Major Structural Engineered Rehabilitation & Repair of a Structurally Deteriorated Sewer Treatment Plant located at an island in the Gulf of Mexico, Galveston County, Texas.
Brief Description of Selective Study Case No. 3:
In May 2019, MADERO Provided Turnkey Certified Engineering Design / Installation / QA & QC Testing & Inspections of MADERO’s Structural Warren Epoxy Liner on Wastewater Sewer Treatment Tanks (e.g. Clarifier, Aeration Basin, Digester, Chlorine Contact Chambers), Concrete/Brick Manholes, and Metal Pipes & Structural Beams. MADERO also applied Polyurethane Coating in specific atmospheric areas & Performed Inflow & Infiltration (I/I) Structural Repairs.
he plant was constructed around 2014. After five years of operation, its concrete and metal structures had accelerated corrosion & structural deterioration due to the surrounding aggressive marine environment, and hydrogen sulfide attack from processing sewer wastewater. Furthermore, in 2017, the sewer structures were coated with an elastomeric protective coating. After two years of service, the coating was fully deteriorated and delaminating.
In May 2019, MADERO Provided Turnkey Certified Engineering Design / Installation / QA & QC Testing & Inspections of MADERO’s Structural Warren Epoxy Liner on Wastewater Sewer Treatment Tanks (e.g. Clarifier, Aeration Basin, Digester, Chlorine Contact Chambers), Concrete/Brick Manholes, and Metal Pipes & Structural Beams. MADERO also applied Polyurethane Coating in specific atmospheric areas & Performed Inflow & Infiltration (I/I) Structural Repairs.
Major Structural Engineered Rehabilitation & Repair, and Structural Optimization of Fully Deteriorated Stormwater Piping System Stadium
Brief Description of Selective Study Case No. 2:
Uusing Structural Epoxy and High Strength Carbon Reinforced Polymer for Structurally Robust Long Term Useful Operational Life.
Asset Owner: University of Tennessee. The buried Non-Structural Shotcrete Stormwater Piping System segment was located about 60 feet below ground of 100+ years old Neyland Stadium, in Knoxville, Tennessee. The newly Engineered Protective and Structural Composite Piping System provides full structural integrity plus additional benefits (but not limiting to):
a. Able to withstand all the applicable structural design basis loads of soil and hydro loads.
b. High strength Carbon Fiber Reinforced Polymer provides a more robust long-term operating life by protecting the
new composite pipe with resistance to creep rupture and fatigue failure.
c. A durable barrier against potential Inflow / Infiltration (I/I) of groundwater and stormwater.
d. Flow capacity increase due to Warren Epoxy’s Low Coefficient Of Roughness (COF) Vs. Shotcrete’s High COF.
new composite pipe with resistance to creep rupture and fatigue failure.
c. A durable barrier against potential Inflow / Infiltration (I/I) of groundwater and stormwater.
d. Flow capacity increase due to Warren Epoxy’s Low Coefficient Of Roughness (COF) Vs. Shotcrete’s High COF.
Structural Rehabilitation & Impermeabilization of two structurally deteriorated elevated steel tank silos a the medicinal gas manufacturing plant ACROMAX.
Brief Description of Selective Study Case No. 7:
The age of each of the elevated Carbon Steel Tank Silos was approximately 25 years old. They stored and operated a hot mix solution
of calcium hydroxide and water. Engineering assessment inspections identified many corrosion problems, structural deterioration, and
imperfect and irregular welds on the substrate to be coated.
Subsequently, a wet sandblasting surface preparation was done to generate the anchoring profile and required cleanliness for applying the
coating. All required structural repairs were performed, including removal of imperfect and irregular welds were removed. The Warren Epoxy was sprayed, and the average coating thickness was 1/8” (3 millimeters). Quality Control & Quality Assurance and inspections
were performed and they all passed with outstanding values.
manner, with no safety issues, and within the agreed work schedule with the customer. During the implementation of the project, the plant was able to continue operating at 50% capacity without stopping production. MADERO’s execution of this turnkey Mission Critical Project was a total success.
of calcium hydroxide and water. Engineering assessment inspections identified many corrosion problems, structural deterioration, and
imperfect and irregular welds on the substrate to be coated.
PRODUCT APPLICATION
As part of the surface preparation, high and ultra-high pressure jets of water (Range: 25,000 to 40,000 Psi) were applied to the silo internals for removing deposits of Calcium Hydroxide, which was solidified and strongly adhered to the substrate of the two tanks.Subsequently, a wet sandblasting surface preparation was done to generate the anchoring profile and required cleanliness for applying the
coating. All required structural repairs were performed, including removal of imperfect and irregular welds were removed. The Warren Epoxy was sprayed, and the average coating thickness was 1/8” (3 millimeters). Quality Control & Quality Assurance and inspections
were performed and they all passed with outstanding values.
CONCLUSION
The Impermeabilization and Rehabilitation Project of the two silos were successfully executed in ten (10) days, in a quality and cost-effectivemanner, with no safety issues, and within the agreed work schedule with the customer. During the implementation of the project, the plant was able to continue operating at 50% capacity without stopping production. MADERO’s execution of this turnkey Mission Critical Project was a total success.
Corrosion & Impermeabilization Protection, Structural Rehabilitation/Repair of Semi Deteriorated & Fully Deteriorated Metallic & Concrete
Brief Description of Selective Study Case No. 6:
Process Piping Systems & Component with Rapid Cure, Smart & Durable Engineered Composite Pipe Repair Systems.
Pics. 1 & 2: Composite Structural Rehab/Repair of Fully Deteriorated 12” Dia. Corroded Pipe w/ Pinholes
Pics. 3 & 4: Composite Structural Rehab/Repair of Fully Deteriorated 14” Dia. Corroded Pipe w/ Pinholes
Pics. 5 & 6: Composite Structural Rehab/Repair of Semi Deteriorated 54” Dia. Corroded Pipe w/ 63% Wall Loss
Corrosion Protection Coating Application at Market Center Lift Station’s Atmospheric and Immersion
Brief Description of Selective Study Case No. 5:
Piping Systems at City of Terrell, Texas.
Per owner’s coating specification, Immersion Piping System required application of three layers of Sherwin Williams Macropoxy coating system (i.e. primer, intermediate, and topcoat). Atmospheric Piping System also required first two layers of Sherwin Williams’ Macropoxy coating and Polyurethane topcoat. MADEROs Scope Of Work also included Abrasive Surface Preparation with Dustless Sponge Jet Abrasive System, Quality Control Testing (e.g. Wet Gauge, Holiday, and Adhesion Pull) and Quality Assurance.
Per owner’s coating specification, Immersion Piping System required application of three layers of Sherwin Williams Macropoxy coating system (i.e. primer, intermediate, and topcoat). Atmospheric Piping System also required first two layers of Sherwin Williams’ Macropoxy coating and Polyurethane topcoat. MADEROs Scope Of Work also included Abrasive Surface Preparation with Dustless Sponge Jet Abrasive System, Quality Control Testing (e.g. Wet Gauge, Holiday, and Adhesion Pull) and Quality Assurance.
Major Structural Engineered Rehabilitation & Repair, and Structural Optimization of Fully Deteriorated Buried 96” Diameter Concrete Piping & 4’x4’ Square Concrete Manhole Structures.
Brief Description of Selective Study Case No. 4:
using Warren Structural Epoxy for Long Term Useful Operational Life. Asset Owner: City of Fort Worth. The newly Engineered Protective, Structural Rehabilitation & Repair provided full structural integrity plus additional benefits (but not limiting to):
A. Able to withstand all the applicable structural design basis loads of soil and hydro loads.
B. A durable barrier against potential Inflow / Infiltration (I/I) of groundwater and stormwater, and hydrogen sulfide attack.
C. Pipe flow capacity increase due to Warren Epoxy’s Low Coefficient Of Roughness (COF) Vs. Deteriorated Concrete’s High COF.
The following pictures provide a view of their As-Found & As-Left Conditions of the Rehabilitated/Repaired Structures:
B. A durable barrier against potential Inflow / Infiltration (I/I) of groundwater and stormwater, and hydrogen sulfide attack.
C. Pipe flow capacity increase due to Warren Epoxy’s Low Coefficient Of Roughness (COF) Vs. Deteriorated Concrete’s High COF.
The following pictures provide a view of their As-Found & As-Left Conditions of the Rehabilitated/Repaired Structures:
Major Structural Engineered Rehabilitation & Repair of a Structurally Deteriorated Sewer Treatment Plant located at an island in the Gulf of Mexico, Galveston County, Texas.
Brief Description of Selective Study Case No. 3:
In May 2019, MADERO Provided Turnkey Certified Engineering Design / Installation / QA & QC Testing & Inspections of MADERO’s Structural Warren Epoxy Liner on Wastewater Sewer Treatment Tanks (e.g. Clarifier, Aeration Basin, Digester, Chlorine Contact Chambers), Concrete/Brick Manholes, and Metal Pipes & Structural Beams. MADERO also applied Polyurethane Coating in specific atmospheric areas & Performed Inflow & Infiltration (I/I) Structural Repairs.
he plant was constructed around 2014. After five years of operation, its concrete and metal structures had accelerated corrosion & structural deterioration due to the surrounding aggressive marine environment, and hydrogen sulfide attack from processing sewer wastewater. Furthermore, in 2017, the sewer structures were coated with an elastomeric protective coating. After two years of service, the coating was fully deteriorated and delaminating.
In May 2019, MADERO Provided Turnkey Certified Engineering Design / Installation / QA & QC Testing & Inspections of MADERO’s Structural Warren Epoxy Liner on Wastewater Sewer Treatment Tanks (e.g. Clarifier, Aeration Basin, Digester, Chlorine Contact Chambers), Concrete/Brick Manholes, and Metal Pipes & Structural Beams. MADERO also applied Polyurethane Coating in specific atmospheric areas & Performed Inflow & Infiltration (I/I) Structural Repairs.
Major Structural Engineered Rehabilitation & Repair, and Structural Optimization of Fully Deteriorated Stormwater Piping System Stadium
Brief Description of Selective Study Case No. 2:
Uusing Structural Epoxy and High Strength Carbon Reinforced Polymer for Structurally Robust Long Term Useful Operational Life.
Asset Owner: University of Tennessee. The buried Non-Structural Shotcrete Stormwater Piping System segment was located about 60 feet below ground of 100+ years old Neyland Stadium, in Knoxville, Tennessee. The newly Engineered Protective and Structural Composite Piping System provides full structural integrity plus additional benefits (but not limiting to):
a. Able to withstand all the applicable structural design basis loads of soil and hydro loads.
b. High strength Carbon Fiber Reinforced Polymer provides a more robust long-term operating life by protecting the
new composite pipe with resistance to creep rupture and fatigue failure.
c. A durable barrier against potential Inflow / Infiltration (I/I) of groundwater and stormwater.
d. Flow capacity increase due to Warren Epoxy’s Low Coefficient Of Roughness (COF) Vs. Shotcrete’s High COF.
new composite pipe with resistance to creep rupture and fatigue failure.
c. A durable barrier against potential Inflow / Infiltration (I/I) of groundwater and stormwater.
d. Flow capacity increase due to Warren Epoxy’s Low Coefficient Of Roughness (COF) Vs. Shotcrete’s High COF.
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We believe architecture and design are critically important to addressing the most pressing challenges of our time.
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We believe architecture and design are critically important to addressing the most pressing challenges of our time.
Ernest Smith
Construction Worker
Great experience and impressive product. It was a very professional and technically competent job from the whole team.
Thomas Smith
CEO & Engineer
We believe architecture and design are critically important to addressing the most pressing challenges of our time.
Monica Smith
CEO & Architect
We believe architecture and design are critically important to addressing the most pressing challenges of our time.
Ernest Smith
Construction Worker
Great experience and impressive product. It was a very professional and technically competent job from the whole team.
Thomas Smith
CEO & Engineer
We believe architecture and design are critically important to addressing the most pressing challenges of our time.
Monica Smith
CEO & Architect
We believe architecture and design are critically important to addressing the most pressing challenges of our time.
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Great experience and impressive product. It was a very professional and technically competent job from the whole team.