Author: Scott McCarthy

Posted on by

Video: How to make a permanent live leak repair to a cast iron pipe pressure resistant to 10 bar

CrackSeal Pipe Sealant and SylWrap HD Pipe Repair Bandage make a permanent live leak repair to a cast iron pipe capable of withstanding up to 10 bar pressure

Sylmasta use CrackSeal Pipe Sealant and SylWrap HD Pipe Repair Bandage to make a live leak repair to a cracked cast iron pipe, which is then successfully tested to withstand up to 10 bar pressure.

About this Pipe Repair Video

This demonstration video was filmed at Sylmasta HQ to test the live leak repair capability and pressure resistance of CrackSeal Pipe Sealant when used to seal a crack in a cast iron pipe.

CrackSeal is a moisture curing pipe sealant used to quickly and easily repair cracks and splits in cast iron waste, drain and soil pipes. It is also effective on other pipe materials, including steel and concrete-lined pipework.

We cut a horizontal split into a test rig and set pressure so that a steady stream of water was leaking through. CrackSeal was then used to repair the damage.

Using a standard sealant gun, we extruded CrackSeal into the crack until it was totally filled. The sealant began to harden almost instantly. It easily contained the live leak and prevented any more water leaking through.

CrackSeal forms a skin in 10 minutes. Before this happened, we worked quickly to smooth it off with a plastic spatula. This helped increase the surface area of the repair and the adhesion between the sealant and the pipe.

After CrackSeal had been applied, the pipe was left for 24 hours. This allowed the sealant to reach maximum properties. We then tested the repair.

Pressure through the rig was steadily increased to 10 bar. No water leaked through and there was no deformation of CrackSeal, indicating a successful repair.

For added reinforcement, we applied a SylWrap HD Pipe Repair Bandage across the entire repair area. SylWrap HD is composite repair wrap with a water activated resin.

It was wrapped and smoothed around the cast iron pipe, curing within minutes to form a rock hard impact resistant sleeve encompassing the leak area.

This made for a stronger repair and a permanent solution with even greater pressure resistance beyond the 10 bar CrackSeal alone had withstood.

CrackSeal and SylWrap HD can be purchased together for making permanent live leak repairs as part of the SylWrap Cast Iron Pipe Repair Kit.

The Kit also includes Superfast Steel Epoxy Putty. Superfast Steel is a fast-working epoxy putty mixed by hand and forced into holes too large to be filled with CrackSeal. It cures to a waterproof, steel-like material in 10 minutes.

Cast Iron Pipe Repair Products

CrackSeal Pipe Sealant seals cracks and splits in cast iron waste, drain and soil pipes

CrackSeal Pipe Sealant
Moisture curing pipe sealant extruded into cracks in cast iron pipework, where it sets almost instantly

SylWrap HD Pipe Repair Bandage is a composite repair wrap used to strengthen and reinforce pipelines to extend their lifespans

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

The SylWrap Cast Iron Pipe Repair Kit seals cracked and leaking cast iron pipework in under 30 minutes

SylWrap Cast Iron Pipe Repair Kit
Contains CrackSeal, Superfast Steel Epoxy Putty and SylWrap HD for fast, permanent cast iron pipe repair

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

Posted on by

Case Study: Worthington Simpson Pump Repair Seals Pinhole Leaks in Casing

Liquid Metal Epoxy Coating used to repair and refurbish a corroded and leaking Worthington Simpson pump

No replacement parts, no problem – repair and refurbishment keeps historic Worthington Simpson Pump operational

The inside of a Worthington Simpson pump head – old enough that replacement parts no longer exist – undergoes repair after the removal of corrosion via shot-blasting left multiple pinhole leaks in the casing.

Case Study Data

Site
Engineering company
Location
Warwickshire, UK
Repair Type
Pump repair
Defect
Pinhole leaks in heavily corroded Worthington Simpson pump head casing

Products Used

Superfast Steel Epoxy Putty Stick
Fast working epoxy putty which cures within 10 minutes for quickly sealing small holes and leaks in metalwork

Liquid Metal Epoxy Coating
Brush applied coating forms a robust metallic surface when painted onto parts and surfaces to shield against corrosion

Case Study PDF

Download

Case Study Details

Worthington Simpson were a British pump manufacturer founded in 1785. They operated independently until merging in 1967 with American companies Wagner Electric and Studebaker Corporation, becoming a subsidiary of Studebaker-Worthington.

In their heyday, Worthington Simpson supplied pumps for most municipal waterworks throughout Great Britain. They later worked with the Royal Air Force and the Royal Navy.

The demise of Worthington Simpson has made getting hold of replacement parts for older pumps virtually impossible. Repair and refurbishment is therefore the only option to keep systems operational.

GEM Integrated Solutions are an electrical and mechanical engineering company in the United Kingdom specialising in motor and pump repair.

They were asked by the owner of a now-obsolete Worthington Simpson pump to refurbish the corroded pump head, for which spare parts no longer exist.

The pump was disassembled so that the inside of the head could be shot-blasted to remove all traces of rust, dirt and grime. But when the pump was then pressure tested after the repair, it was found to be leaking.

Heavily corroded inside of an old Worthington Simpson pump before repair and refurbishment with Liquid Metal Epoxy Coating
Heavy corrosion was removed from the inside pump head via shot-blasting

Shot-blasting had turned the head porous by creating several pinholes in the casing, through which water sprayed out in small volumes when the pump was pressurised. This was not something which GEM had experienced before.

An attempt to patch weld over a pinhole was unsuccessful, leaving GEM needing an alternative method to seal the casing and successfully complete the Worthington Simpson pump repair for their client.

They used two 114g Superfast Steel Epoxy Putty Sticks to fill all pinholes in the pump. Small amounts of epoxy putty were cut from the stick, mixed by hand and then pushed flat onto the casing over every pinhole.

Within 10 minutes of application, Superfast Steel cured to form a rock-hard material covering all leaks. No water could now escape the pump.

Liquid Metal Epoxy Coating applied to a Worthington Simpson pump to repair casing damaged by pinhole leaks and corrosion
After shot-blasting left pinhole leaks, the pump was sealed with Superfast Steel before being reinforced with three layers of Liquid Metal

Liquid Metal Epoxy Coating was then used to completely seal the casing and give the metalwork inside robust protection against future corrosion, extending the lifespan of the pump.

Three coatings of Liquid Metal were painted onto the casing. Once cured, this provided a 3mm thick reinforced metallic layer which covered the pump interior.

Worthington Simpson pump reassembled after repair using Sylmasta products
GEM’s client were delighted with both the fully working pump and that its lifespan had been significantly extended thanks to the protection provided by Liquid Metal

Fluid inside the pump was now fully contained and with the original metalwork shielded from water contact by Liquid Metal, it will now be many years before the inside casing shows any sign of corrosion again – much to the delight of the client.

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

Posted on by

Case Study: Cast Iron Waste Pipe U-Bend Crack Repair Above Hospital Corridor

A cast iron pipe U-bend with a hairline crack at a UK hospital is sealed with a SylWrap Drain & Waste Pipe Repair Kit

Ladder-top repair stops leaking cast iron waste pipe driving hospital staff around the U-bend

From the top of a ladder, a maintenance worker makes a repair in under 15 minutes to a hairline crack in a cast iron waste pipe U-bend within a cramped roof space above a hospital corridor.

Case Study Data

Site
Hospital
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Hairline crack in cast iron waste pipe U-bend

Products Used

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

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to create a reinforced sleeve around pipework

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


Download

Case Study Details

Damp patches were noticed in ceiling tiles above a busy corridor in the hospital. A maintenance worker climbed up a ladder, removed the tiles and accessed the roof space above to investigate.

They found a complex network of cast iron pipework. One of these pipes came down through the ceiling, into a U-bend followed by a 90-degree elbow before connecting with two other waste pipes via a Y-joint.

The problem was found to be a hairline crack across the U-bend located directly above the Y-joint. Wastewater was seeping through this crack, corroding the three pipes at the Y-joint where they met below and dripping further down to discolour and damage the ceiling tiles.

Hairline crack in a cast iron pipe U-bend through which wastewater was leaking at a UK hospital before undergoing repair
After accessing the roof space, a hairline crack was discovered in a cast iron pipe U-bend

To replace the cracked U-bend, every pipe connected to it – including the Y-joint – would have needed to be removed to gain enough access.

The cash-strapped NHS trust responsible for the hospital could not afford the cost of effectively taking the entire system out of operation.

Research by the maintenance team led them to the SylWrap Drain & Waste Pipe Repair Kit, which is already used by several NHS trusts in England for making fast, straightforward and cost-effective repairs to leaking cast iron and plastic pipework on their estates.

All the products in the Drain & Waste Kit are lightweight enough to be applied from the top of a ladder. The repair started by using CrackSeal Pipe Sealant to fill the crack in the U-bend.

Using a standard sealant gun, CrackSeal was extruded directly into the crack. As a moisture curing sealant, it began to harden almost instantly. Within 10 minutes, it had formed a skin to leave the pipe fully sealed.

CrackSeal was then reinforced using SylWrap HD Pipe Repair Bandage. Although the U-bend was a difficult geometry to wrap the bandage around, the worker managed to apply it effectively.

The resin in SylWrap was activated using water and the bandage wrapped and smoothed around the U-bend. Once the U-bend was covered, wrapping continued vertically to cocoon the entire repair area.

Cast iron pipe U-bend with hairline crack undergoes repair at a UK hospital with SylWrap Pipe Repair Bandage
The crack was sealed with CrackSeal and then reinforced with SylWrap HD, despite the lack of space left by the complex network of pipes in the roof

SylWrap set rock-hard within minutes of application, providing the entire leak area with an impact-resistant protective sleeve capable of containing any future leaks should the weakened U-bend become breached in future.

The worker completed the cast iron U-bend repair in under 15 minutes and with little disruption to the hospital, other than the corridor being out of use whilst they were up the ladder.

With the Drain & Waste Pipe Repair Kit containing enough products to seal multiple cracks and holes in different types of pipework, the hospital now have CrackSeal, Superfast Steel Epoxy Putty, SplitFill Epoxy Adhesive and SylWrap HD Bandages on-site in an easy-to-store case for use when future leaks occur.

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

Posted on by

Video: How to permanently fix a threaded pipe joint whilst water is leaking through

A leaking threaded pipe joint is sealed in a live repair capable of withstanding up to 10 bar pressure

After a client contacted Sylmasta needing to fix a threaded pipe joint with pressure on, we formulated and filmed this six-stage repair method which withstood up to 10 bar when tested afterwards.

About this Pipe Repair Video

Sylmasta were approached by a client requiring help with a complex repair. They had a leaking threaded joint on a pipe which could not be totally isolated.

Any repair needed to be effective whilst water continued to leak though. It also had to withstand fluctuations up to 10 bar when the system was fully pressurised. A basic repair using plumber’s tape would be nowhere near strong enough.

We constructed a test rig replicating the pipe in question and formulated a six-stage repair method to permanently fix the threaded joint. The repair was filmed and instructional captions added to provide visual training for the client.

First, a sufficient amount of Superfast Steel Epoxy Putty to cover the threaded joint around the entire pipe diameter was mixed by hand and placed to one side.

One 25mm x 2m Wrap & Seal Pipe Burst Tape was wrapped next to the thread until enough layers had been built to create a rubber ridge level with the female fitting.

The mixed Superfast Steel was then rolled out, formed into a sausage shape and applied into the gap between the Wrap & Seal ridge and female fitting, directly over the threaded joint.

More Wrap & Seal was added to the repair, initially over the first application of tape. Wrapping then continued over the Superfast Steel sausage, forcing the epoxy putty into the threaded joint.

The repair was next smoothed by hand, helping to push any remaining Superfast Steel into leaking thread. One 50mm x 4m Wrap & Seal was then applied directly over the threaded joint. This increased the strength of the repair, its pressure resistance and created a total seal.

After the application of tape had been completed, the repair was left for one hour to allow Superfast Steel to cure and Wrap & Seal to be in. Pressure was then increased through the pipe up to 10 bar. There were no signs of leakage or deformation of the repair.

Although the client was not working with drinking water, both Wrap & Seal and Superfast Steel are WRAS approved – meaning this repair method could be used to seal leaking threads on pipes carrying potable water.

Pipe Repair Products

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
Fast-working epoxy putty forced into leaks whilst soft before curing to form a rock hard material

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 repair tape which fuses together to form a solid rubber band, sealing leaks and removing step from joints

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

Posted on by

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

Posted on by

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

Posted on by

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

Posted on by

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 rigorous 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

Posted on by

Sylmasta invests in new technology to become world 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

View product
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

View product
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

View product
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

View product
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

View product
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

View product
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

View product
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

View product
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

Price range: £15.77 through £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

Posted on by

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