Epoxy Mass Application Service

 

JW Portable Welding & Repairs offers epoxy application services for equipment maintenance repair in construction, manufacturing, utility and marine sectors. We use epoxy resins, so-called epoxy glues, to complement our welding services in areas where welding is impossible, too risky, not desirable, simply too expensive and/or when we want to enhance the metal resistance to rust, abrasion or chemical corrosion.

When you face emergency maintenance repair of equipment components and the part is

  • damaged “beyond recognition” and requires a significant rebuild.
  • damaged in non-accessible to welding spot even if you consider Stick, Mig and Tig welding capabilities.
  • damaged on a significant surface area and the metal has lost its structural properties
  • damaged with many cracks, some pieces broken off and are lost (casts).
  • damaged due to rust, abrasion or chemical corrosion

then it is a good idea to use a specialist to apply the customized epoxy.

In many cases, our welding services are going hand in hand with the epoxy masses. The welding process provides the strength and rigidness and the epoxy mass, ceramic or metal based, forms the actual repair and/or provides protection against abrasion, impact, rust and chemical corrosion.

We also use epoxy resin to increase the properties of the metal surface. Many of our epoxy masses form

  • Abrasion resistance surfaces
  • Temperature resistance surfaces
  • Impact resistance surfaces
  • Chemical corrosion resistance surfaces

In places where welding becomes impractical, too expensive, or simply impossible or when plastic glues do not work anymore on plastics, the epoxy resin application is preferable. Once we choose the epoxy glue to fix our problem, then we have to decide what kind of epoxy we need, the method of surface preparation and cleanup, the method for joint improvement and then the thickness of the epoxy layer we want to achieve. Additionally, we have to consider a position of the repair as well as a temperature of the environment during the epoxy resin application process and, finally, we have to choose application methods.

Bigger and more complex epoxy repairs should be accomplished by trained by manufacturer epoxy specialists who are able to select a proper kind of epoxy pending on density, viscosity, maximum layer thickness, curing time, final hardness, comprehensive strength, tensile strength, flexible strength, temperature resistance and shrinkage. The world of epoxy resin has become more complicated in recent years with a great variety of epoxy products on the market. The epoxy resins we used to apply 5 – 10 years ago are completely different from epoxy resins available right now.

The surface preparation and joint modification methods are, in my opinion, the second most important factors contributing to the success of epoxy repair. The application usually requires an extensive cleanup of surfaces as well as changing the joint to additionally improve the final strength. I personally find, that welder’s skills in surface preparation and joint modification are transferable to the epoxy application process.

The maximum thickness of the epoxy layer depends on the product itself. However, we have to still decide what strength we need and where the maximum thickness should be positioned to achieve the required objective. If the improvements are needed in this regard the specialist has to his/her disposal additional additives improving the strength, temperature resistance and flexibility.

Mixing of the two components properly is a very important task and the mixing process depends on the quantity and the type of the epoxy resin. Once the mixing of the two components is done and the additional additives are added then the pot life starts and the application process begins. The control of the temperature and wind influence the speed of chemical reaction and therefore it determines the useful time of the prepared epoxy resin. We have to remember that the temperature factor relates to the air temperature as well as the surface temperature …and believe me, you should be ready for surprises in this regard.

The application method depends on quantity required, type of epoxy resin as well as application position. The application position is probably the one single factor causing the most problems. The flat or horizontal positions are rather simple to accommodate. The difficulties begin at the vertical position when improperly selected epoxy resin starts dripping down. Then the difficulties become even more challenging if we want to increase the thickness of the epoxy from 1mm to 10mm. The real challenging situation starts with the overhead position or position very close to the overhead position. Such overhead positions demand the most from the epoxy specialist, especially if an additional layer of steel or ceramics has to cover the layer of epoxy resin.

With so many factors to have in mind, it is very easy to make mistake. The mistakes are costly since the product itself is rather expensive and the cleanup after the failed repair takes a long time. In my opinion, proper planning, product knowledge, experience and tricks of the trade make a huge difference for complicated epoxy repairs in the maintenance of equipment in construction, manufacturing, utility, and marine sectors.

“This is truly new century maintenance technology”

 

For further inquiries or to book services please contact:

Darek, @ (519) 872-2662