Author: Scott McCarthy

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Video: How Sylmasta formulate WearShield to be the ultimate wear resistant epoxy paste

WearShield Epoxy Paste has an interlocking structure making it super resistant to wear, abrasion and impact damage

In this video, we take a look at the formulation of WearShield Epoxy Paste and explain how its interlocking structure makes the cured material so resistant to wear, abrasion, corrosion and impact damage.

About this Epoxy Paste Video

WearShield Epoxy Paste is used in some of the most abrasive working environments in the world to protect plant equipment and surfaces from damage caused by wear, impact, abrasion and corrosion.

It was originally formulated for the tough requirements of the South American mining industry. The increasing cost of American-made epoxy compounds led a mining company in Chile to approach Sylmasta about formulating an alternative.

The use of WearShield quickly spread across the continent. It is now used worldwide to protect heavy machinery including pumps, ash handling systems, scrubbers, silos, chutes, mineral nozzles, agglomerator drums, trunions and metal castings.

In the above video, we explain how the formulation of WearShield makes it so resistant. The epoxy paste is heavily filled with hard wearing alumina beads in a range of sizes. Large beards protect against bigger particles and little beads against smaller particles.

These beads combined with the high resin content of WearShield create a dense interlocking structure. Once cured, WearShield provides an alumina-reinforced, hardened shell up to 6mm thick for ultimate protection to the original substrate.

The video also shows product testing carried out at Sylmasta HQ. WearShield was applied to a metal demo piece. Once fully cured, it was attacked with an angle grinder for abrasion and impact testing. There was no chipping or fracturing of the cured WearShield.

Two grades of WearShield are available. Standard comes with a work time of between 30 and 60 minutes, a functional cure of 8–12 hours. and a 24-hour full cure.

It is used at higher ambient temperatures or where large amounts of WearShield are being mixed at once, removing the threat of premature curing from the application process.

WearShield Rapid is the fastest-working epoxy wear compound available. It begins to harden in just 10 minutes, significantly reducing system downtime and disruption.

WearShield Epoxy Paste

WearShield is an alumina filled epoxy paste used to protect parts and machinery against impact and wear

WearShield Impact Resistant Epoxy Paste
Alumina bead-filled epoxy paste which forms a toughened layer of protection against impact damage and wear

WearShield Rapid is a fast working alumina filled epoxy paste for making parts and machinery impact resistant

WearShield Rapid 5 Minute Epoxy Paste
Fast working version of WearShield with a three-hour full cure, reducing equipment downtime

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Video: How to use waterproof pipe repair tape to repair a pinhole leak

A demonstration at Sylmasta HQ in the United Kingdom shows how to use Wrap & Seal Pipe Burst Tape to repair a live leak on a stainless steel pipe

This video was filmed during product testing of Wrap & Seal Pipe Burst Tape at Sylmasta HQ and shows how our self-amalgamating waterproof repair tape can seal a leaking pipe even when pressure remains on .

About this Pipe Repair Video

Wrap & Seal Pipe Burst Tape is a self-amalgamating waterproof repair tape capable of sealing online leaks.

It stretches by three times its length when wrapped around a pipe, fusing to form a solid rubber band which creates a high-pressure seal containing pipe content.

This video was filmed during product testing at Sylmasta HQ in the United Kingdom. A 3mm pinhole was drilled into a stainless steel pipe test rig. Pressure was set at 3 bar whilst a Sylmasta technician carried out a live leak repair.

To start the repair, the release film was peeled back from the start of a 50mm x 4m Wrap & Seal Tape and anchored to the side of the leak. One full wrap around the pipe ensured the tape gripped to itself.

It was then wrapped towards the leak whilst being stretched as much as possible, up to the maximum 300 percent. The release film was removed as the application progressed with the tape overlapped by 50 percent per wrap.

Once the leak was reached, Wrap & Seal was applied directly over it with as much stretch as possible. The leak was not chased; even though water was weeping out the side of the repair, wrapping continued to concentrate over the pinhole.

Each layer increased the resistance of the repair, culminating in a thick rubber ridge bonded to the pipe and exerting maximum pressure to seal the pinhole and any potential leak paths.

The application continued until the entire Wrap & Seal was used. Had water still been escaping the pipe after one tape, another would have been applied on top to continue building up the ridge.

Multiple Wrap & Seal fuse to each other in the same way as a single tape amalgamates. Only when the leak is totally sealed should application of Wrap & Seal stop. It is possible to build a repair with pressure resistance up to 30 bar using multiple tapes.

Once the application had been completed, pressure through the test rig was increased to over 5 bar with no visible signs of leakage or any fluctuations.

Repairs made with Wrap & Seal can be reinforced by applying SylWrap HD Pipe Repair Bandage over the tape. SylWrap comes with a fast-working, water-activated resin.

It sets rock hard within minutes as is it is wrapped and smoothed around a pipe, curing to form an impact resistant outer sleeve.

Both Wrap & Seal and SylWrap HD have WRAS approval, meaning they are certified as safe to use on pipes and fittings carrying drinking water.

How to calculate the number of Wrap & Seal Tapes needed for a repair

The Sylmasta Wrap & Seal Calculator helps determine the number of tapes needed to repair a live leak up to a specified pressure resistance. Enter the diameter of the pipe in millimetres, water pressure and the size of the hole requiring seal.

A safety factor is a multiple to include a margin of safety. If pipe pressure is 3 bar for example and you want a safety factor of two, the calculate will formulate a repair for 6 bar.

After entering the repair data, selecting the size of Wrap & Seal to be used will determine the number of that specific tape for the application.

Repars to pipes in excess of 150mm diameter using Wrap & Seal PB-50x4m or PB-50x11m should be made in conjuntion with SylPad Pressure Resistance Multiplier.

(Calculations serve as a guide to potential maximum pressure resistance only. Actual pressure resistance depends upon pipe material, condition, hole size, leak type and tension maintained during wrapping.)

Live Leak Pipe Repair Products

Wrap & Seal Pipe Burst Tape is a self-fusing silicone waterproof repair tape used for live leak sealing

Wrap & Seal Pipe Burst Tape
Self-amalgamating waterproof pipe repair which fuses together to form a solid rubber band, sealing live leaks

Wrap & Seal Case Studies


If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Video: How to protect against external corrosion with Liquid Metal Epoxy Coating

Liquid Metal Epoxy Coating being brush applied to carbon steel to show how easy it is to to repair and refubish metalwork attacked by corrosion

This repair video shows how to refurbish rusted metalwork and protect it from future corrosion by using Liquid Metal Epoxy Coating to create a new, hard wearing surface over the weakened original substrate.

About this Epoxy Coating Video

Liquid Metal is a metal-filled epoxy coating used to refurbish and protect metalwork and plastics against corrosion and chemical attack.

It is brush-applied onto pipework, equipment and other surfaces. It sets to form a smooth, metallic, hard-wearing outer shield which acts as a barrier protecting the original substate from attack.

For this demonstration video filmed at Sylmasta HQ, we took a heavily corroded carbon steel industrial barrel and refurbished it using Liquid Metal. The repair strengthened the brittle metalwork and helped prevent future corrosion.

Before application of Liquid Metal, the carbon steel underwent surface preparation. A power brush was used to remove as much rust, grime and remains of previous coatings as possible.

The two parts of Liquid Metal were then easily mixed by pouring the hardener (Part B) straight into the resin (Part A) container. The coating was stirred using a spatula until streak-free and a consistent grey colour.

Liquid Metal was then painted onto the barrell using a brush. Its high initial tack and adhesion enabled it to easily adhere to the steel barrel.

The coating applied was 1mm thick. Liquid Metal has a gel time of 90 minutes and a re-coat time time of between five and eight hours. To speed up the cure, a hot air gun was used evenly across the entire repair.

Once Liquid Metal had cured, the barrell was left with a high gloss, corrosion resistant coating. Additional layers of Liquid Metal could have been painted on, each building up the thickness of the outer shield

In pipe repair applications, Liquid Metal can be further reinforced by overwrapping with SylWrap Pipe Repair Bandage. SylWrap is added whilst Liquid Metal remains tacky. The epoxy coating will then improve adhesion between the pipe and the bandage.

SylWrap will cure within minutes to form a thickened, rock hard, impact-resistant shell around the pipe for even more enhanced protection levels.

This repair method using Liquid Metal and SylWrap is regularly used by water and wastewater companies to refurbish severely weakened pipe bridges.

The expense of removing and replacing such huge structures can otherwise reach six figures and require complex projects which take months to complete.

Liquid Metal and SylWrap in contrast will refurbish many metres of pipe bridge more cost-effectively and in a fraction of the time.

Liquid Metal

Liquid Metal Epoxy Coating is used to repair and protect pipes and other metalwork and structures

Liquid Metal Epxy Coating
Brush-applied epoxy coating forms a smooth, hard-wearing, metallic layer to protect original parts and surfaces

Liquid Metal Case Study

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Complex in UAE Approves SylWrap for Chilled Water System ABS Pipe Repair

An ABS pipe leaking at a joint undergoes repair to show SylWrap is effective in chilled water cooling systems

Keeping cool under pressure – SylWrap passes testing for repair of chilled water system ABS pipe joints

Superfast Aqua PW Epoxy Putty and SylWrap HD Pipe Repair Bandage undergo vigorous pressure testing by an engineering company to receive approval for use sealing ABS pipe joints in a chilled water cooling system at a luxury complex in the UAE.

Case Study Data

Site
Luxury complex
Location
United Arab Emirates
Repair Type
No pressure pipe repair
Defect
Leaking ABS pipe flange in chilled water cooling system

Products Used

Superfast Aqua PW Epoxy Putty Stick
Epoxy putty with specialist high underwater adhesion formulation for sealing pipes when the surface is wet

SylWrap HD Pipe Repair Bandage
Composite wrap cures to form a thickened, reinforced layer which restores pipework integrity

Case Study PDF

Download

Case Study Details

Chilled water and district cooling systems are used throughout the United Arab Emirates to provide an energy efficient method of air conditioning.

Water is stored and cooled in a central plant. It is then pumped around buildings, complexes and even entire districts via vast pipe networks operating at between 5 and 7 bar pressure.

Some of these systems provide air conditioning to hundreds of different homes and workplaces from a large-scale plant. The Empower Business Bay plant in Dubai for example serves 188 multi-use buildings and skyscrapers. Future expansion is planned to take that number over 300.

Other leisure complexes and skyscrapers have private chilled water systems, supplying air conditioning for their own facilities. This is the case with the Burj Khalifa, which has 34 kilometres of pipework circulating cooled water around the 830-metre tall building.

Sylmasta were contacted by an engineering company responsible for a private chilled water system at a luxurious complex containing over 500 apartments, a leisure centre, shops, restaurants and a 5-star hotel.

They were looking for a quick and straightforward repair method for sealing any leaking joints in the ABS pipe network which pumped cooled water around the complex. Rapid response time was essential to ensure the efficiency of the air conditioning system.

An engineering company in the UAE build an ABS pipe rig to test SylWrap for the repair of chilled water cooling pipes in the UAE
The engineering company built several ABS pipe test rigs with an intentionally weakened flange end for repair using Superfast Aqua PW and SylWrap HD

To evaluate Sylmasta products, the company built several test rigs with 50mm, 100mm and 150mm ABS pipes. Each rig was one-metre long and connected with stub flange sets and MS end flanges.

One side of the flange ends was made intentionally weak so that it would begin leaking when pressure was increased. The pipe was filled with water through a valve. Once it was full, pressure was applied.

At 4 bar, a leak was noticed at the weakened flange end. The area was instantly cleaned and then sealed using Superfast Aqua PW Epoxy Putty. Aqua PW was chosen for its high underwater adhesion properties, enabling it to bond to the ABS even though the pipe surface was wet.

Enough putty was cut from the stick for application all around the weak flange plate. The putty was kneaded by hand and applied to the pipe whilst still soft. Within 20 minutes, it cured to form a rock-hard, waterproof material permanently bonded to the ABS and covering all leak spots to restore pipeline integrity.

SylWrap HD Pipe Repair Bandage applied to an ABS pipe identical to those found in chilled water cooling systems in UAE
SylWrap HD was wrapped over a 250mm section of pipe either side of where the flange was leaking through

SylWrap HD Pipe Repair Bandage was then wrapped over a 250mm section of the pipe either side of the leak. It cured to create a thickened, impact-resistant sleeve around the leak, further enhancing the seal provided by Superfast Aqua PW.

The repair was left for 90 minutes to reach working strength and then pressure tested. Pressure was gradually increased towards 8 bar, reflecting the maximum the chilled water system at the complex reached.

Throughout each of the three pressure tests to the different sized rigs, the gauge was monitored for any significant drops or irregular fluctuations.

Once 8 bar had been exceeded, the repair was left for 18 hours. When the pipe was inspected again, there were no visible cracks, leaks, deformations or signs of damage.

The repair successfully held over 8 bar pressure for 18 hours

Based on the visual inspection and pressure test results, the engineering company concluded the SylWrap repair to have successfully restored the functionality and integrity of the ABS pipe.

In their report compiled after all 50mm, 100mm and 150mm tests had been completed, the company wrote: “The repair material was applied correctly and adhered well to the pipe surface.”

“The pressure test demonstrated the repair’s ability to withstand the specified pressure without any signs of leakage, failure, or abnormal pressure fluctuations.”

“We therefore consider this repair a suitable solution for any leakage on ABS pipes in chilled water cooling systems.”

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Sylmasta invests in new technology to become word leading epoxy putty stick supplier

Sylmasta are believed to be the only epoxy putty stick supplier based in Europe making their own sticks

Epoxy putty sticks for the global market made in the United Kingdom

Sylmasta have invested heavily in bringing the latest epoxy putty stick manufacturing machinery and technology to our site in the United Kingdom, meaning we are the only supplier currently making its own sticks in Europe.

These sticks are shipped worldwide from our HQ in Sussex, around 50 miles (80 kilometres) south of London. They are supplied under our Superfast brand and are trusted by some of the biggest names in maintenance adhesives.

The benefits of Sylmasta epoxy putty sticks made in the UK

Epoxy putty stick manufacturing was pioneered in the United States. It removed the need for precise measuring and mixing of separate components of resin and hardener by supplying pre-measured portions of each in the correct 1:1 ratio in a single, easy-to-use stick.

But recent global events have highlighted problems with overreliance on the US and Asian markets for importation.

Exports out of Asia were disrupted during the Covid-19 pandemic and its aftermath. In the USA, uncertainty over tariffs has made importing materials for making sticks and exporting the finished product challenging.

Epoxy putty sticks made in the UK by Sylmasta offer numerous advantages. In terms of the sticks themselves, we can provide customised formulations to meet client needs, including adjustments to cure times and colour.

We employ lean manufacturing principles, meaning everything is made to order – guaranteeing fresh product and low minimum order quantities.

Customers who use Sylmasta as their epoxy putty stick supplier enter a reliable supply chain with reduced lead times and expert technical help readily available for specific applications.bee

A good example of the benefits of Sylmasta epoxy putty sticks comes from 2024, when we produced and shipped a significant quantity of product to a local authority in Canada to repair a leaking underground water main.

Within five days of us receiving the order, the sticks were on-site and ready to be used by engineers in British Columbia.

The Sylmasta epoxy putty stick range

Sylmasta make the following epoxy putty sticks as standard:

  • Steel Stick – Steel filled with a five-minute work time and WRAS approval for use with pipes and fittings carrying drinking water. Sets to a grey, metallic-like colour.
  • Aluminium Stick – Epoxy putty formulated for the repair and bonding of aluminium, other alloys and different types of metalwork. Sets grey with a four-minute work time.
  • Copper Stick – Copper-filled epoxy putty sets to that colour for the rapid repair of copper, brass, bronze and other non-ferrous metals. Has a three-minute work time.
  • Aqua PW Stick – Specialist epoxy putty formulated for very high wet surface and underwater adhesion. Sets white, has a five-minute work time and WRAS approval for use with potable water.
  • Titanium Stick – High temperature epoxy putty with resistance up to 280ºC. It sets to a golden colour, has a 90-minute work time and will bond to most materials operating under extreme heat.
  • Concrete Stick – Concrete-filled epoxy putty which sets grey for the uniform repair of concrete, stone and masonry. Has a quick four-minute work time.
  • Plastic Stick – Plastic-filled epoxy putty which bonds and repairs all major types of plastic, except polyolefins. It comes with a 20-minute work time and sets white.
  • Wood Stick – Wood-filled epoxy putty cures to a material sharing an appearance, hardness and density similar to wood. Has a 15-minute work time, offering a little longer to shape and form the putty.
  • General Purpose Epoxy Putty Stick – Sylmasta AB Original is ceramic-filled, bonds to all materials and comes with a two-hour work time for complex applications requiring longer to handle the putty before curing.

All Sylmasta epoxy putty sticks can be made as standard 200mm diameter sticks or 300mm diameter ‘fat’ sticks.

If you would like to learn more about our epoxy putties or discuss the possibility of having Sylmasta manufacture epoxy putty sticks for your business, please contact Sylmasta via email or on +44 (0)1444 831459

Repairs made using Sylmasta Epoxy Putty

Superfast Steel Epoxy Putty Stick can be used to fill in holes and seal cracks on steel, iron and other ferrous metal

Superfast Steel Epoxy Putty Stick

£12.64 inc. Vat

Steel epoxy putty for sealing cracks and restoring profile to industrial pipes and damage repair of steel, iron, and other ferrous metals

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Superfast Aluminium Stick is an easy-to-use epoxy putty which makes repairs and seals holes in aluminium alloy, other alloys and metalwork

Superfast Aluminium Epoxy Putty Stick

£12.64 inc. Vat

Epoxy putty for the repair and bonding of aluminium and alloys, including sealing radiators, tanks, castings and industrial equipment

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Superfast Copper Epoxy Putty seals leaks and holes in copper pipe and ise used to repair other metals

Superfast Copper Epoxy Putty Stick

£12.64 inc. Vat

Copper epoxy putty for sealing leaks in domestic and small industrial pipes and damage repair of copper and other non-ferrous metals

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Superfast Aqua Potable Water Epoxy Putty Stick makes wet surface repairs which are safe to use on pipe and fittings carrying drinking water

Superfast Aqua Potable Water Epoxy Putty Stick

£12.64 inc. Vat

Specialist wet surface epoxy putty formulated for very high underwater adhesion with a 5 minute cure and WRAS approval for use on pipes

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Superfast Titanium Epoxy Putty Stick is titanium filled for repair and bonding in extreme temperature applications

Superfast Titanium Epoxy Putty Stick

£15.77 inc. Vat

Epoxy putty resistant to 280°C for repairing leaks and damage to pipes and metalwork in environments exposed to extreme temperatures

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Superfast Concrete Epoxy Putty Stick is used to bond broken concrete pieces together in restoration tasks and as a filler in repair applications

Superfast Concrete Epoxy Putty Stick

£12.64 inc. Vat

Concrete epoxy putty for bonding broken concrete and masonry together in repair and restoration tasks and for use as a filler

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Superfast Plastic Epoxy Putty Stick is a semi-flexible epoxy putty which sets white and is used for the bonding and repair of all types of plastic including PVC pipe

Superfast Plastic Epoxy Putty Stick

£12.64 inc. Vat

Plastic epoxy putty which seals holes and cracks in pipes made from all major plastics and bonds broken plastic parts together

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Superfast Wood Epoxy Putty Stick is a wood filled epoxy used as a filler and for bonding in repair tasks

Superfast Wood Epoxy Putty Stick

£12.64 inc. Vat

Wood epoxy putty which is rot resistant and can be sculpted, used as a filler or for bonding wood in repair and restoration tasks

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Sylmasta AB Original Stick supplies super strength epoxy putty with a two-hour work time in an easy-to-use pre-measured stick format

Sylmasta AB Original Epoxy Putty Stick

£15.77 – £266.80 inc. Vat

Pre-formatted, easy-to-use stick of AB Original which removes the need to measure and mix separate components of resin and hardener

View product

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Case Study: Leaking HVAC Cooling Tower Repair at Production Facility in USA

A leaking HVAC cooling tower undergoes repair at a production facility in the USA

Chill out, Sylmasta have got this – leaking cooling tower repair restores efficiency to HVAC system

After several failed repair attempts, a leaking HVAC cooling tower at a production facility is sealed within a matter of hours using a combination of Superfast Aqua PW Epoxy Putty and Industrial Metal Rapid 5 Minute Epoxy Paste.

Case Study Data

Site
Production facility
Location
United States
Repair Type
Leak repair
Defect
Leaking cooling tower in HVAC system

Products Used

Superfast Aqua PW Epoxy Putty
Fast working epoxy putty specially formulated for high-strength adhesion to wet and underwater surfaces

Industrial Metal Rapid Epoxy Paste
Epoxy paste with a 60-minute functional cure for quickly rebuilding significant areas of damage

Case Study PDF

Download

Case Study Details

Temperature control at the production facility was provided by a HVAC system. Water which had absorbed heat from inside the building was pumped to a cooling tower located on the roof.

This warmed water was exposed to air inside the tower, leading to heat being rejected into the atmosphere via evaporation. The re-cooled water was then pumped back into the building and the whole process repeated.

After water was seen leaking from the cooling tower, the HVAC system was shut off, and the tower drained and accessed. A long crack was discovered in the floor, with significant amounts of concrete either side having crumbled away.

The floor of the cooling tower was leaking through a hairline crack with severe damage to the concrete either side

With the effectiveness of the HVAC system determined by the amount of water cooled, any loss from the tower through leakage was extremely damaging to efficiency.

The manufacturer of the HVAC system admitted they had never seen a fault like this before. Several repair attempts were made using their normal tried-and-tested methods, but these failed before they contacted a Sylmasta distributor for advice.

Because the tower floor was still saturated with water, Superfast Aqua PW Epoxy Putty was used to fill the crack. Superfast Aqua PW is specially formulated for high underwater adhesion.

Whereas other repair compounds might have struggled to form an effective bond, Aqua PW easily adhered to the wet concrete.

Superfast Aqua PW Epoxy Putty was forced into the crack, forming a rock-hard material in around 20 minutes to seal the leak

After the surface had been prepared via grinding with an abrasive disc, the putty was mixed by hand and forced into the crack. It hardened within 20 minutes, curing to form a solid material which sealed along the entire leak area.

With the leak sealed, attention turned to repairing the significant damage left where the concrete floor had crumbled away, using Industrial Metal Rapid 5 Minute Epoxy Paste.

Industrial Metal Rapid was chosen for its fast 60-minute functional cure time, which would enable the cooling tower to go back into service more quickly than if standard grade Industrial Metal were used.

Industrial Metal Rapid 5 Minute Epoxy Paste rebuilt areas of the floor around the crack where the concrete had crumbled away

The epoxy paste was mixed using a putty knife before being used to rebuild the missing floor around the crack. It filled the damaged area with a smooth, metallic-like material offering excellent corrosion resistance to further enhance the sealing power of Aqua PW.

Within three hours of the leaking cooling tower repair starting, the HVAC system was operating at full efficiency again. Impressed by the ease and speed of the repair, the HVAC manufacturer is now using Sylmasta products for a wider range of applications.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Repair of Underground Clay Drainage Pipe Cracked During Building Work

A cracked underground clay drainage pipe undergoes repair using a SylWrap Standard Pipe Repair Kit

An underground clay pipe repair prevents a home drainage system going to pot

Accidental impact and ground movement during building work left an underground 100mm clay drainage pipe with two cracks requiring repair, one of which was severe enough to almost split the pipe into two separate parts.

Case Study Data

Site
Domestic property
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Two cracks in underground 100mm clay drainage pipe

Products Used

Superfast Steel Epoxy Putty Stick
Fast working steel epoxy putty which sets rock hard inside cracks and holes, sealing leaks

SylWrap HD Pipe Repair Bandage
Composite wrap reinforced the repair with a rock hard sleeve which also helped hold the pipe back together

SylWrap Standard Pipe Repair Kit
Superfast Epoxy and SylWrap HD are supplied together in the Standard Pipe Repair Kit

Case Study PDF

Download

Case Study Details

Clay was a popular material for drainage pipes in the United Kingdom from the early 20th century until the 1970s, when plastic became more widely used due to being easier and cheaper to fabricate and install.

High resistance to corrosion and chemical degradation gives clay extreme durability and longevity, with an estimated lifespan of anywhere between 60 and 100 years. This means many UK homes built before the 1970s are still serviced by working clay pipes.

One weakness of clay pipes, however, is they are susceptible to damage from root ingress and ground movement – which often only becomes obvious when a patch of ground becomes noticeably waterlogged from an underground leak.

A homeowner was carrying out building works when an area of their garden began suffering from this problem. After digging down, they discovered a dislodged 100mm clay pipe with two areas of significant damage.

The first and most severe was a crack next to a junction almost splitting the pipe into separate parts. The junction and uneven surface meant it would not be possible to reassemble the pipe using a repair clamp.

The clay pipe had a significant crack next to a junction with a smaller hairline crack along its top

Across the top of the pipe was a hairline crack, representing the second damaged area. There was no pressure and the homeowner was keen to avoid the cost and disruption which would come with replacing the pipe.

They therefore used a SYL-412-NP SylWrap Standard Pipe Repair Kit to seal the leaks and attach the pipe back together. Before the repair, enough room was dug out underneath the pipe to allow clearance for it to be wrapped.

The two cracks were then filled with Superfast Steel Epoxy Putty. Enough putty was first mixed by hand to cover the hairline crack. It was then pushed firmly down across the top of the pipe, curing within five minutes to form a rock hard material covering the leak.

Superfast Steel Epoxy Putty used to repair cracks in an underground clay drainage pipe
Superfast Steel was used to seal the two cracks in the pipe

For the larger crack, more putty was mixed and forced into the gap between the two sections of pipe. Once it had set, Superfast Steel bridged the crack with a watertight material bonded to both pieces.

The pipe was then overwrapped with SylWrap HD Pipe Repair Bandage. The fast-working resin in SylWrap HD was activated with water and the bandage wrapped along the entire length of the exposed pipe.

SylWrap HD cured to form a rock-hard, impact resistant protective shell. It reinforced the repair and helped hold the two broken pieces of clay pipe back together.

SylWrap HD Pipe Repair Bandage applied to an underground clay drainage pipe to reinforce the line after it cracked
The pipe was overwrapped with a SylWrap HD Bandage to complete the repair

The homeowner said afterwards that the repair worked perfectly and that the product was great. Completing the repair took under 30 minutes and cost less than £50, representing a huge saving compared with removing the pipe and installing a replacement.

With many clay pipes installed before the 1970s now beginning to reach the end of their natural lifespan, repairs such as this are set to become more common in the UK over the coming years.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: SylWrap Leak Repair Passes ASME PCC-2 402-III Qualification Standard

Superfast Aqua PW Epoxy Putty and SylWrap HD Pipe Repair Bandage are successfully tested to be ASME PCC-2 402-III compliant

Leak repair made using Sylmasta products withstands 30 bar pressure in qualification tests for ASME PCC-2 402-III

Superfast Aqua PW Epoxy Putty and SylWrap HD Pipe Repair Bandage make a leak repair qualified to ASME PCC-2 Appendix 402-III – Validation for Repair of Leaking Component by withstanding 30 bar pressure in multiple tests.

Case Study Data

Site
Sylmasta HQ
Location
United Kingdom
Repair Type
Leak repair
Defect
25mm hole in 110mm diameter carbon steel pipe

Products Used

Superfast Aqua PW Epoxy Putty
Fast working epoxy putty which bonds to wet surfaces with WRAS approval for sealing holes and cracks in pipes

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to reinforce pipework with a thickened, impact resistant sleeve

Case Study PDF

Download

Case Study Details

ASME PCC-2 Appendix 402-III – Validation for Repair of Leaking Component is a test which assesses the ability of a composite pipe repair system for sealing leaking pipes, tanks and vessels containing non-hazardous fluids operating below 10 bar.

To qualify for ASME PCC-2 402-III, a repair must successfully seal a leaking pipe which has been fully breached, restore pressure-retaining capability to the line and show it will not degrade or be compromised over time under service conditions.

It is a standard widely used across many industries – such as water utilities – to give confidence that repairs on the public supply network will be strong and long-lasting.

ASME PCC-2 402-III is also applicable to other industries where high-pressure water pipes are used – such as desalination plants and cooling systems at oil refineries, power stations and food and beverage production.

Testing took place at Sylmasta HQ in the United Kingdom. A 25mm hole was cut into a 110mm diameter carbon steel pipe. The leak needed to be sealed before being subjected to three separate pressure tests up to 30 bar.

A 25mm hole was cut into a steel pipe for testing

Superfast Aqua PW Epoxy Putty was used to plug the hole in the pipe. To improve adhesion, the pipe was abraded first. This removed any traces of rust, dirt or grime. It also created a textured surface for the repair to grip onto.

The putty was mixed by hand and formed into a disc around 75mm in diameter, ensuring total coverage of the leak. It was placed over the hole and pushed firmly down onto the pipe for maximum contact.

Superfast Aqua PW seals a 25mm hole in a carbon steel pipe to qualify for ASME PCC-2 401-III standard
Superfast Aqua PW Epoxy Putty was formed into a disc and fixed over the hole

At the edges, the putty was smoothed off using a little water to remove any step from the surface. It was allowed to cure for around 10 minutes until gelled but not hardened.

SylWrap HD Pipe Repair Bandage was then used to reinforce Superfast Aqua PW. The composite repair wrap was activated with water and applied over an area approximately 225mm, with the leak at its centre.

As SylWrap HD was wrapped and smoothed over the putty, it helped force Superfast Aqua PW further into the hole for a more effective seal. SylWrap HD set rock hard within minutes, curing to form a thick, rock hard, impact-resistant sleeve around the pipe.

SylWrap HD reinforced the pipe with a rock hard, impact resistant sleeve

The repair was left for 24 hours to achieve maximum properties before pressure testing. This involved increasing pressure through the pipe at a steady rate for more than 30 seconds until 30 bar was reached.

After 60 seconds of the pipe being pressurised at 30 bar, the repair was inspected for any visible leakage. This test was carried out on three separate occasions.

With no leak or defect detected during any of the three pressure tests, repairs made using Superfast Epoxy Putty and SylWrap HD are qualified to meet ASME PCC-2 402-III standard.

A SylWrap Pipe Repair withstands 30 bar pressure to be qualified for ASME PCC-2 401-III - Validation for Repair of Leaking Component
The repair was pressure tested three times, withstanding 30 bar on each occasion

In addition to qualifying for ASME PCC-2-402-III, Superfast Aqua PW and SylWrap HD both have WRAS approval – meaning they are certified as safe for use on pipes and fittings carrying drinking water.

For repairs to be fully ASME PCC-2 402-III compliant, installers must undergo training and certification on using Sylmasta products for leaking pipe repair. To find out more, please email sales@sylmasta.com

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: SylWrap Pipe Repair Passes ASME PCC-2 401-III Qualification Standard

Industrial Metal and SylWrap HD Bandage pass PCC-2 401-III qualification testing in a repair on a high temperature steel pipe

Composite pipe repair using Sylmasta products exceeds 309.6 bar pressure resistance to qualify for ASME PCC-2 401-III

SylWrap HD Pipe Repair Bandage and Industrial Metal Epoxy Paste make a repair independently witnessed and verified as passing ASME PCC-2 Appendix 401-III – Short Term Spool Survival standard by exceeding 309.6 bar pressure resistance.

Case Study Data

Site
Test site
Location
United Kingdom
Repair Type
Composite pipe repair pressure test
Defect
Carbon steel pipe machined back to 1mm outer wall thickness

Products Used

Industrial Metal Epoxy Paste
Metal filled epoxy paste used to strengthen pipelines by rebuilding weakened outer walls back towards original thickness

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to reinforce pipework with a thickened, impact resistant sleeve

Case Study PDF

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Case Study Details

ASME PCC-2 Appendix 401-III – Short Term Spool Survival is a test which assesses the ability of a composite pipe repair system to restore the integrity of a weakened pipeline back to the strength of the original pipe.

Industries like oil and gas, chemical processing and power generation where high pressure systems and hazardous pipe content are present require pipe repairs to be ASME PCC-2 401-III compliant.

To qualify Sylmasta HD Pipe Repair Bandage and Industrial Metal for ASME PCC-2 401-III standard repairs, Sylmasta carried out a test independently witnessed and verified by a UKAS registered company.

A steel pipe spool similar to the type of pipe found in high temperature applications was fabricated for the test

The test was performed on an ASTM A106 Grade B pipe spool. This type of carbon steel pipe is often used in high temperature environments such as steam and gas lines.

A defect was machined into the spool to reduce wall thickness down to 1mm, accounting for an 86 percent weakening of the pipe.

An defect was machined into the pipe, reducing wall thickness down to 1mm

Based on the measured yield strength of the pipe, diameter and original wall thickness, the repair needed to withstand 309.6 bar of pressure to pass the test and certify the materials as PCC-2 401-III compliant.

Before the repair, a flap wheel was used to clean the area back to bare metal. The whole area was then thoroughly cleaned using a solvent degreaser to remove any remaining traces of foreign substances.

Industrial Metal Epoxy Paste was used to fill in the defect. It rebuilt the pipe wall back towards original thickness, and acted as a load transfer medium between the pipe spool and SylWrap HD.

Industrial Metal is applied to a pipe during successful testing to make an ASME PCC-2 401-III standard repair
Industrial Metal filled the defect in the pipe, rebuilding the degraded pipe wall back towards original thickness

The two parts were mixed together until turning a uniform grey colour. Industrial Metal was then applied using a putty knife, ensuring maximum contact between the spool and the epoxy paste.

Industrial Metal was allowed to fully set before the flap wheel was used to smooth the cured material and the area around surrounding it, followed by further cleaning with degreaser.

Industrial Metal Epoxy Paste used to successfully repair a pipe to ASME PCC-2 401-III standard
Once Industrial Metal had fully set, the cured material and area surrounding it were smoothed off and cleaned

The Sylmasta Pipe Refurbishment Calculator helped determine the size and number of SylWrap HD Pipe Repair Bandage needed to reinforce the repair so it became strong enough to hold 309.6 bar pressure.

SylWrap HD Pipe Repair Bandage used to successfully repair a pipe to ASME PCC-2 401-III standard
Five SYL633HD Bandages were used over the defect

Five SYL633HD Bandages were used for the repair. The fast working, water activated resin began to cure within minutes to form a rock-hard, impact resistant shell.

Once SylWrap HD had set, the pipe spool was pressure tested by a UK-based specialist using calibrated and certified pressure gauges. The results were recorded using a data logger.

SylWrap HD undergoing pressure testing to qualify for PCC-2 pipe repair
The pipe spool was pressure tested using calibrated and certified pressure gauges with results recorded on a data logger

The repair exceeded the 309.6 bar required to pass PCC-2 401-III, eventually failing when pressure reached 310.29 bar and water began leaking through the edges.

The repair exceeded the 309.6 bar required to meet PCC-2 401-III, failing when pressure reached 310.29 bar

With the test signed off as a success, composite pipe repairs using SylWrap HD and Industrial Metal are qualified to meet ASME PCC-2 401-III standard.

To determine the quantity of Sylmasta materials needed to make a composite pipe repair conforming to PCC-2 401-III standard, please use the ASME PCC-2 Compliant Repair Calculator below.

The calculator serves only as a guide. Judgement should be made on the exact repair based upon all conditions. Please contact Sylmasta for more information or if you need help with a specific application.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: 150mm Cast Iron Soil Pipe Repair Leaking in Hospital Roof Space

A cast iron soil pipe leaking wastewater above a hospital ward undergoes repair using CrackSeal Sealant

30 minute operation to repair a cast iron soil pipe leaking wastewater above a hospital ward

A 150mm cast iron soil pipe leaking through a two-metre horizontal crack undergoes repair in a confined roof space by a hospital maintenance team, preventing a potentially dangerous escape of wastewater into the ward below.

Case Study Data

Site
Hospital
Location
United Kingdom
Repair Type
Leak Repair
Defect
Two-metre crack in cast iron soil pipe

Products Used

CrackSeal Pipe Sealant
Sealant extruded directly into cracks in cast iron pipework, where it hardens almost instantly to seal the leak

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to reinforce pipework with an impact resistant sleeve

SylWrap Drain & Waste Pipe Repair Kit
Specialist Kit containing products for repairing low-pressure cast iron and plastic waste, sewer and drain pipes

Case Study PDF

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Case Study Details

The cast iron soil pipe was part of the wastewater system installed when the hospital building was constructed in the early 1960s. It was located in a confined roof space, surrounded by other pipework, ducting and electrical cables.

Water starting to drip from a roof above a ward alerted the hospital to a problem. The maintenance team accessed the loft space and discovered a significant horizontal crack approximately two-metres long in the cast iron pipe through which wastewater was leaking.

A two-metre long crack in a cast iron soil pipe before undergoing repair using a SylWrap Drain & Waste Pipe Repair Kit
Wastewater was leaking through a two-metre long crack in the cast iron soil pipe

Leaking pipes in hospitals were a hot topic at the time of the repair. Freedom of information requests submitted to NHS trusts as part of a national newspaper investigation showed hospitals in England recorded 456 sewage leaks into wards, maternity units and A&E departments over the previous 12 months.

Only 55 trusts out of more than 100 in England responded to the requests, meaning the true scale of the problem was certain to be much worse. Hospital trusts were therefore under scrutiny for how they responded to and managed leaks.

For this reason, the hospital kept a SylWrap Drain & Waste Pipe Repair Kit on-site, containing everything needed to permanently seal all types of drain, waste and soil pipes throughout its estate.

The cracked cast iron soil pipe could therefore be repaired instantly by the maintenance team; preventing water damage to the hospital building, limiting disruption to patients and staff and avoiding the sorts of dangerous leaks reported by other NHS trusts.

Using a standard sealant gun, CrackSeal Cast Iron Pipe Sealant was extruded directly into the crack along its entire two-metre length until it was totally filled.

CrackSeal is a specialist high-performance moisture curing sealant specifically formulated for sealing cracks and longitudinal splits. It is effective on wet surfaces and where water is leaking through at minimal pressure.

CrackSeal Cast Iron Pipe Sealant extruded into a soil pipe in a repair made at a hospital
CrackSeal Pipe Sealant was extruded directly into the crack, hardening inside it almost instantly

For this particular application, CrackSeal offered a faster repair than wrapping over the entire crack with Wrap & Seal Pipe Burst Tape – the other sealing material in the Drain & Waste Kit capable of wet surface repair.

As CrackSeal was extruded, it hardened instantly inside the crack. It formed a skin within 10 minutes, after which the cast iron soil pipe was reinforced with SylWrap HD Pipe Repair Bandage.

Two SYL633HD SylWrap Bandages were used. The resin in the bandage was activated with water and SylWrap applied around an area of the pipe just over two metres; encompassing the crack and giving the repair additional coverage either side.

The repair was completed by wrapping SylWrap HD along the entire length of the pipe for added strength and reinforcement

Once cured, SylWrap formed a rock-hard, impact resistant shell around the pipe. From discovering the leaking pipe to completion of the repair, the entire application was completed in 30 minutes.

Had a Drain & Waste Kit not been available to the hospital, the cast iron pipe would have continued to leak wastewater until a repair solution was found – a process could have taken days.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com