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Maintaining the operational efficiency of pulp and paper facilities is essential, given the industry’s complex processes and harsh operational environments. Key areas such as paper machines, pulp mills, woodyards, finished product warehouses, power and recovery units, and wastewater processing systems each present unique maintenance challenges. Indcon Maintenance offers specialized solutions tailored to address these specific needs, ensuring that every facet of pulp and paper operations remains functional and reliable.

For instance, paper machine pits are continually exposed to water, chemicals, and mechanical vibrations, leading to potential deterioration. Utilizing advanced repair materials that adhere to wet surfaces and cure underwater can effectively restore these areas without significant downtime. Similarly, winder areas endure heavy mechanical loads, causing concrete floors to deteriorate. Implementing rapid-setting repair materials allows for quick resurfacing, minimizing operational disruptions. By focusing on these critical areas, Indcon Maintenance helps these facilities maintain optimal performance and extend the lifespan of their infrastructure.

Paper Machine
Pulp Mill
Woodyard
Finished Product/Warehouse
Power & Recovery
Waste Water Processing

Paper Machine

Keeping your machine running is priority number one. So, when you have planned downtime, you’ve got to make the most of it. You’ll need materials that can be applied while surfaces are still wet. Repairs that can cure under water and gain strength in a few short hours not days. You want the same speed on the dry end. Repairs around the winder, roll conveyors have to cure fast without any residue that could be transferred onto the finished product. Here are a few common applications.

Applications

Resurfacing Pits
Winder Concrete Repairs & Resurfacing
Non-Slip Coating

Resurfacing Pits

The pits beneath paper machines in pulp and paper mills are essential to operations but are highly susceptible to wear and damage. Constant exposure to water, chemicals, and heavy machinery vibrations leads to tile loss, coating failures, and concrete deterioration. Over time, these issues can compromise the structural integrity of the pits and disrupt operations.

Regular resurfacing during scheduled maintenance is critical to preserving these vital components. Advanced repair materials that adhere to wet surfaces and can cure underwater are ideal for these challenging environments. These materials allow for effective repairs without requiring extensive downtime, ensuring minimal disruption to production.

Selecting materials that provide durability and chemical resistance is essential for long-term performance. Properly resurfaced pits can better withstand the harsh conditions of pulp and paper production, extending their lifespan and reducing the frequency of repairs. By addressing damage proactively, mills can maintain operational efficiency and protect critical infrastructure.

Winder Concrete Repairs & Resurfacing

The winder area in pulp and paper mills endures some of the heaviest mechanical and traffic loads in the facility. Constant movement of machinery, forklifts, and heavy materials causes concrete floors in this area to deteriorate over time. Cracking, spalling, and surface damage are common issues, and if left unaddressed, they can lead to safety risks for workers and interruptions in production.

To keep operations running smoothly, regular concrete repairs and resurfacing are essential. Rapid-setting repair materials are particularly effective for winder areas, as they allow for quick application and minimal downtime. Restoring the surface not only improves safety but also helps maintain the performance and longevity of the area under heavy use.

Things to Consider:

Surface Preparation: Choose materials that require minimal surface preparation to save time and labor while ensuring a strong bond.
Curing Time: Fast-curing materials minimize the time needed to reopen the area to traffic, reducing production disruptions.
Durability: Opt for products designed to withstand the impact and abrasion of heavy machinery and high traffic.
Worker Training: Proper application techniques are critical to achieving a long-lasting repair. Ensure your maintenance personnel are trained in using the chosen materials.

By addressing concrete damage early and using the right materials and methods, mills can reduce maintenance costs, enhance worker safety, and minimize downtime in this critical area.

Non-Slip Coating

Safety is a top priority in pulp and paper mills, especially in areas prone to slippery conditions. Wet-end sections, basements, and zones surrounding equipment like size presses are often wet or contaminated with oils, making them dangerous for workers and machinery. Sloped surfaces in these areas can exacerbate the risk of slips and falls, leading to potential injuries and operational disruptions.

Applying non-slip coatings is a proactive way to reduce these hazards. These coatings are specifically designed to provide traction on surfaces exposed to water, oils, or chemicals. Choosing the right non-slip material is essential. Oil-contaminated areas require coatings that can bond effectively under such conditions, while high-traffic zones may need more durable options to withstand constant use by both foot traffic and heavy machinery.

By using non-slip coatings, pulp and paper mills can significantly enhance workplace safety, comply with industry regulations, and maintain smooth operations.

Pulp Mill

You’ve got to make pulp to keep the paper machines running. Keeping your process equipment and pulp mill infrastructure in top shape is key. You’ll have annual outages to deal with the big stuff. But, what about those repairs that just can’t wait? If you only have short field days, you’ll need materials that can allow for minimal down time. Check out some common applications below.

Applications

Underwater Epoxy Repair
Acid Proof Grouts
Chemical-Proofing Sumps & Trenches

Underwater Epoxy Repair

Concrete sumps and trenches in pulp mills are exposed to harsh operating conditions, including corrosive chemicals, constant moisture, and abrasive debris. Over time, this exposure leads to cracking, wear, and leaks. These issues need immediate attention to prevent further damage and operational disruption. However, in many cases, a full shutdown of operations isn’t feasible, making timely, underwater repair solutions critical.

Underwater-curing gel epoxies offer a reliable and effective method for sealing leaks and restoring damaged concrete without the need for a complete outage. After cleaning and neutralizing the affected area, these specialized materials bond securely to wet surfaces and cure underwater, ensuring a durable repair even in saturated conditions. For added efficiency, the curing process can be accelerated with heat, allowing the repaired area to return to service faster.

By using these advanced materials, pulp mills can address urgent repairs, maintain operational flow, and delay more extensive maintenance until a scheduled downtime.

Acid Proof Grouts

Sulfuric acid is a critical component in pulp mill processes, but it’s also one of the most aggressive chemicals for infrastructure. At concentrations as high as 98%, sulfuric acid can quickly degrade traditional concrete and cementitious grouts, posing risks to foundations and other structural elements. Protecting these assets requires materials engineered to withstand such extreme chemical exposure.

Polymer concretes and 100% Novolac epoxy-based grouts provide unmatched resistance to high-concentration acids, making them the ideal choice for pulp mills. These materials can be used for grouting applications, thin repairs, or modifying and reinforcing existing foundations. Their versatility extends to incorporating rebar or extending them with gravel to improve strength and longevity.

By using acid-proof grouts, mills can safeguard critical structures against sulfuric acid damage, reducing the need for frequent repairs and ensuring long-term operational reliability.

Chemical-Proofing Sumps & Trenches

Sumps and trenches in pulp mills are subjected to some of the harshest operating environments, with exposure to a combination of acids, caustics, high temperatures, and abrasive materials. These conditions can quickly overwhelm thin-film coatings, leading to concrete saturation, scouring, and ultimately, structural degradation. Maintaining the integrity of these critical areas is essential to ensure smooth operations and prevent costly downtime.

For superior protection, thick polymer concrete systems are the preferred solution. These advanced materials provide enhanced chemical resistance and are designed to handle the high-impact and corrosive conditions common in pulp mills. Unlike thin-film coatings, polymer concrete linings prevent saturation, withstand abrasive forces, and offer long-term durability, making them an excellent choice for protecting trenches and sumps.

By investing in chemical-proofing solutions, pulp mills can extend the lifespan of their infrastructure, reduce maintenance costs, and maintain efficiency in the most demanding environments.

Woodyard

You have to keep your processes in the woodyard in top shape to keep up with the demand for pulp. But the operation is dependent on precise synchronization. Trucks have to continually roll in, railcars need to be emptied, logs have to be moved and chips have to move to the pulp mill. So, having the time to perform routine maintenance is tough enough. Getting to infrastructure repairs seems almost impossible given the day has only 24 hours in it. See if you recognize these applications.

Applications

Truck Dumper Cylinder Base
Rapid Repair of Paved Areas
Abrasion Resistant Linings

Truck Dumper Cylinder Base

Truck dumpers are essential for efficient unloading of logs and chips in woodyards. The hydraulic cylinders that power these dumpers exert significant force on their concrete supports, leading to potential wear and damage over time. A compromised cylinder base can halt operations, causing costly delays.

To ensure rapid and durable repairs:

Concrete Repair: Utilize high-strength, fast-setting concrete repair materials that bond effectively to existing structures, restoring integrity swiftly.
Oil Contamination: If the concrete is saturated with oil, apply an oil-tolerant primer to ensure optimal adhesion of repair materials.
Reinstallation: Secure the hydraulic cylinder base with a fast-setting epoxy grout, facilitating a quick return to operational status.

Implementing these steps minimizes downtime and extends the lifespan of truck dumper systems.

Rapid Repair of Paved Areas

Woodyard pavements endure heavy loads from trucks and equipment, leading to cracks, spalling, and surface degradation. Damaged paving poses safety hazards and can disrupt the flow of materials. Traditional concrete repairs often require extended curing times, which may not align with operational demands.

To expedite repairs without compromising quality:

Fast-Setting Materials: Employ concrete additives or pre-packaged repair products designed for rapid strength gain, allowing areas to be service-ready sooner.
Strategic Scheduling: Plan repairs during low-traffic periods to minimize operational impact and ensure adequate curing.
Surface Preparation: Properly clean and prepare damaged areas to enhance the bond and longevity of repairs.

By adopting these practices, woodyards can maintain safe and functional paved surfaces with minimal disruption.

Abrasion Resistant Linings

Equipment such as chutes, frames, and hoppers in woodyards are subject to constant abrasion from logs and wood chips, leading to wear that can compromise structural integrity and efficiency. Protecting these components is vital to prevent unexpected failures.

To enhance durability:

Protective Coatings: Apply abrasion-resistant linings to vulnerable surfaces to shield them from wear and extend their service life.
Regular Inspections: Conduct routine checks to identify early signs of wear and address them before they escalate.
Scheduled Maintenance: Plan maintenance activities during scheduled downtimes to implement protective measures without affecting operations.

Implementing abrasion-resistant solutions ensures continuous operation and reduces maintenance costs.

Finished Product/Warehouse

You’ve got a lot invested now that you’ve produced your product. Storing it in a protected space is critical given the potential losses if it’s not sellable. Warehousing operations are more than just a holding area. Finished product has to protected from the elements and that’s not just the weather. There is the constant traffic and the act of moving material to consider.

Applications

Damaged Floor Joints
Expansion Joint Restoration
“Fast Return to Traffic” Pavement Repairs

Damaged Floor Joints

In a finished product warehouse, floor joints are critical to the smooth operation of your facility. These joints endure constant stress from heavy machinery like forklifts and pallet jacks, as well as high foot traffic. Over time, this wear and tear can lead to joint damage, resulting in uneven surfaces that pose risks to both equipment and personnel. Damaged floor joints can disrupt daily operations, causing forklifts to jolt when crossing uneven sections, which may lead to product spills or equipment malfunctions.

The stakes are even higher in warehouses utilizing automated guided vehicles (AGVs), as even minor imperfections in floor joints can cause navigation errors, interrupting the entire workflow. Damaged joints also allow water, debris, and contaminants to infiltrate, potentially compromising the integrity of the floor and increasing maintenance costs over time.

To mitigate these risks, it’s essential to implement a proactive maintenance strategy. Regular inspections can identify early signs of joint deterioration, allowing for timely repairs. High-quality joint fillers and sealants are key to restoring smooth transitions between slabs and protecting the structural integrity of your flooring. By addressing damaged floor joints promptly, you can ensure operational efficiency, enhance workplace safety, and extend the lifespan of your warehouse flooring.

Check out this article for more info.

Expansion Joint Restoration

Expansion joints play a vital role in the structural integrity of a finished product warehouse. These joints allow concrete slabs to expand and contract with temperature changes and load variations, preventing cracks and other structural issues. However, the constant stress of daily operations, combined with exposure to moisture and debris, can lead to deterioration over time. Damaged expansion joints can create uneven surfaces, disrupt equipment operations, and pose safety hazards for employees.

When expansion joints fail, the surrounding concrete can become compromised, leading to more extensive and costly repairs. Additionally, deteriorated joints can allow moisture to seep into the structure, weakening the concrete and accelerating damage. For warehouses storing sensitive products, such as perishable goods or electronics, this moisture intrusion can threaten the integrity of the inventory.

Restoring damaged expansion joints involves removing compromised materials, preparing the area properly, and applying durable, flexible joint fillers designed to withstand heavy traffic and environmental exposure. Regular maintenance of expansion joints not only protects the structural health of your warehouse but also minimizes downtime and operational disruptions. By addressing these issues proactively, you ensure a safer, more efficient working environment while preserving the longevity of your facility.

“Fast Return to Traffic” Pavement Repairs

The paved areas surrounding a finished product warehouse are just as important as the interior for maintaining smooth operations. These surfaces handle heavy truck traffic, forklifts, and other equipment daily, making them susceptible to cracking, spalling, and surface deterioration. Left unaddressed, compromised pavement can lead to safety hazards, operational inefficiencies, and costly repairs.

Damaged pavement can disrupt the flow of goods in and out of the warehouse, slowing down deliveries and increasing turnaround times. Cracks and potholes also pose risks to vehicles and equipment, causing unnecessary wear and tear and potential accidents. Furthermore, water infiltration through damaged pavement can weaken the substrate, leading to further deterioration and increasing repair costs over time.

Repairing compromised pavement requires high-strength, fast-curing materials that can withstand heavy loads and harsh weather conditions. These materials should be applied after thorough surface preparation to ensure a long-lasting bond. For high-traffic areas, additional reinforcement may be needed to extend the lifespan of the repair.

Proactively maintaining paved surfaces reduces the risk of disruptions and protects the infrastructure supporting your warehouse operations. Regular inspections and timely repairs ensure that your facility remains functional, safe, and efficient.

Power & Recovery

If you’re working in maintenance here, you’ve got your work cut out you. The bi-products of your core processes are the worst things for your area’s infrastructure. Whether it’s the salt cake in the recovery boiler or the chemicals in the causticizing process, it’s a tough place for steel and concrete to live. The problem is that there isn’t a cost effective alternative to steel and concrete to support the boiler or move process water to treatment.

However, we do have some proven materials that could help you slow the deterioration and extend the usable life of these areas of your critical infrastructure.

Applications

Concrete & Curb Repair
Trench & Sump Repairs

Concrete & Curb Repair

In recovery boiler areas, concrete floors and curbs are continuously exposed to corrosive by-products like salt cake, leading to rapid deterioration. Traditional protective measures, such as Vinyl Ester (VE) coatings and overlays, often become saturated over time, reducing their effectiveness. Moreover, VE overlays can be cost-prohibitive, especially for extensive applications.

An alternative solution is the application of polymer-modified materials specifically designed for such environments. For instance, Stratarock FRPC is engineered to resist salt cake corrosion and can be applied to horizontal, vertical, and overhead surfaces. Its formulation allows for application on hotter surfaces without flash setting, ensuring a proper bond and long-lasting protection. Utilizing such materials offers a cost-effective and durable method to safeguard concrete structures in recovery boiler areas.

Trench & Sump Repairs

Trenches and sumps in power and recovery facilities handle caustic wastewater, subjecting concrete structures to constant chemical attack. While brick linings provide excellent protection, they are often beyond maintenance budgets. Coatings can serve as a temporary solution; however, they typically require multiple applications and extended curing times, making them impractical during regular operations.

A viable alternative is the use of polymer concrete, particularly those based on Vinyl Ester resins, known for their superior chemical resistance. These materials can be applied in a single step, offering ease of application and rapid return to service. By implementing Vinyl Ester-based polymer concrete, facilities can effectively protect trenches and sumps from caustic degradation, ensuring the longevity of wastewater management systems.

Waste Water Processing

Treating your mill waste water is a critical process. Staying in compliance with local, state and federal requirements is mandatory. This may not seem as important as producing paper, but it is one thing separate from the paper making process that could shut it down.

Applications

Waste Collection System Maintenance
Scouring & Deterioration of Concrete
Fixing a Burst or Leaking Pipe

Waste Collection System Maintenance

The waste collection system in wastewater processing facilities is a critical component of operations, responsible for channeling process wastewater from various areas to treatment facilities. This system often consists of an underground network of pipes and concrete manholes, making it particularly challenging to inspect and maintain. Maintenance tasks frequently require confined space entry and temporary halting of wastewater flow, complicating efforts further.

When left unchecked, the waste collection system can deteriorate over time, particularly the concrete manholes. These structures are exposed to chemical-laden wastewater, which can penetrate and degrade the concrete. Over time, this damage may allow contaminated water to infiltrate the surrounding soil, posing environmental risks and potentially undermining adjacent infrastructure, such as roadways or building foundations.

To address these challenges, regular inspections and preventive maintenance are essential. Applying chemical-resistant coatings and liners to the interiors of manholes can protect the concrete from corrosive substances, ensuring the long-term durability of the system. Promptly repairing minor damage can prevent larger, costlier issues down the line. By prioritizing the integrity of the waste collection system, facilities can minimize environmental impact and ensure the efficient transport of wastewater to treatment areas.

Scouring & Deterioration of Concrete

Concrete structures in wastewater facilities are constantly exposed to abrasive and corrosive conditions that can lead to significant wear and damage. Wastewater often contains solids such as sand, dirt, and stock material that, when combined with high flow rates, create a scouring effect on concrete surfaces. This type of wear is especially pronounced in areas with bends, turns, or sudden changes in flow direction, where the force of the water intensifies.

If not addressed promptly, scouring can expose the rebar within the concrete, compromising its structural integrity and leading to further deterioration. This not only reduces the lifespan of the infrastructure but also risks operational disruptions and increased maintenance costs.

To combat this issue, repairing damaged concrete with high-strength materials is the first step. Once repairs are completed, applying abrasion-resistant coatings or toppings provides an additional layer of protection. These specialized coatings are designed to withstand the harsh conditions within wastewater facilities, ensuring a durable solution that extends the life of the infrastructure.

Proactively addressing scouring and implementing preventive measures help facilities maintain the efficiency and reliability of their wastewater processing operations while reducing long-term repair costs.

Fixing a Burst or Leaking Pipe

Leaking or burst pipes are common challenges in wastewater facilities, often leading to significant safety hazards and operational inefficiencies. When untreated leaks allow water to accumulate, the resulting moisture creates ideal conditions for algae growth, making surfaces slippery and increasing the risk of accidents for workers. These leaks can also disrupt the flow of wastewater, hindering the overall efficiency of the facility.

Addressing these issues promptly is critical to maintaining safety and operational continuity. Modern pipe repair solutions offer fast, effective methods to fix leaks in various pipe materials and sizes. These products are designed for ease of use, often requiring no specialized training. Repairs can typically be completed in under 30 minutes, even on pressurized pipes, minimizing downtime and disruptions to operations.

Many repair kits come with comprehensive instructions, enabling maintenance teams to efficiently seal leaks and restore pipe functionality. Additionally, advanced repair materials can bond to wet or submerged surfaces, ensuring durability even in challenging environments. By adopting these solutions, facilities can prevent accidents, reduce water loss, and maintain the seamless operation of wastewater processing systems.

Pulp & Paper

Paper Machine

Applications

Resurfacing Pits

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Euclid EucoRepair V100 5 Gallon Pail

Euclid Aquaseal Gel Light Gray 4 Gallon Unit

Winder Concrete Repairs & Resurfacing

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Euclid Versaspeed 100 50lb Bag

Euclid Euco QWIKstitch 21.2oz Dual Cartridge

Non-Slip Coating

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Aquafin Vaportight Coat-SG2 2.2 Gallon Kit

Euclid Duralkote 240 Neutral Base 2 Gallon Kit

Pulp Mill

Applications

Underwater Epoxy Repair

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Euclid Aquaseal Gel Light Gray 4 Gallon Unit

Acid Proof Grouts

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Stratarock Novolac Polymer Concrete

Euclid E3 HCR Epoxy Grout

Chemical-Proofing Sumps & Trenches

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Euclid E3 HCR Epoxy Grout

Stratarock Novolac Polymer Concrete 1 CF Unit

Woodyard

Applications

Truck Dumper Cylinder Base

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Five Star Structural Concrete 50lb Bag

Stratarock Deep Pour Fast Set Epoxy Grout .5 cu ft unit

Aquafin Vaportight Coat-SG2 2.2 Gallon Kit

Rapid Repair of Paved Areas

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Sika SikaQuick 2500 50lb Bag 187589

Abrasion Resistant Linings

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Sylmasta WearShield Rapid 5 Minute Impact Resistant Epoxy Paste 3kg

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Finished Product/Warehouse

Applications

Damaged Floor Joints

Expansion Joint Restoration

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Euclid Euco 456S Mortar .35 CF Kit 038 27

Euclid Euco 700 Joint Filler 2 Gallon Neutral Base

“Fast Return to Traffic” Pavement Repairs

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Perma-Patch Asphalt Patch 60lb

Sika SikaQuick 2500 50lb Bag 187589

Power & Recovery

Applications

Concrete & Curb Repair

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Stratarock FRPC VO, 50lb bag plus liquid additive

Trench & Sump Repairs

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Stratarock Vinyl Ester Polymer Concrete 3 Cubic Foot Unit

Waste Water Processing

Applications

Waste Collection System Maintenance

Scouring & Deterioration of Concrete

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Sylmasta WearShield Rapid 5 Minute Impact Resistant Epoxy Paste 3kg

Fixing a Burst or Leaking Pipe

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