Author: Scott McCarthy

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Case Study: Homeowner DIY Repair of 25mm Lead Water Pipe Leaking Inside House Wall

A leaking 25mm vertical lead water supply pipe inside a wall of a house is sealed with a SylWrap Universal Pipe Repair Kit

Behind the wall – a leaking lead pipe repair prevents water damage until future replacement of the system

A homeowner in the United Kingdom makes a DIY repair to a vertical 25mm lead water pipe leaking inside the wall of their house by cutting away the drywall and using a SylWrap Universal Pipe Repair Kit.

Case Study Data

Site
Domestic property
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Leaking 25mm lead water supply pipe inside wall

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating repair tape which fuses to form a solid rubber band capable of sealing leaking lead pipes

SylWrap HD Pipe Repair Bandage
Composite repair wrap reinforced the repair by forming a rock hard, impact resistant sleeve around the pipe

SylWrap Universal Pipe Repair Kit
Wrap & Seal and SylWrap HD can be purchased together in the Universal Pipe Repair Kit

Case Study PDF

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Case Study Details

Homes constructed in the United Kingdom before the 1970s were often built with lead water pipes. Lead was particularly popular for pipework within walls, being malleable enough to shape into long lengths and durable enough to withstand containment.

A homeowner in the south of England noticed discolouration to a white wall close to a window during winter. They initially put it down to condensation and damp from the window.

But when summer arrived and the wall remained wet, they became suspicious of a potential leak. The drywall was removed to access the cavity, where they found a 25mm lead pipe running vertically which was weeping water.

After cutting away the drywall, the homeowner discovered a leaking lead water pipe

Long-term, the homeowner planned to remove the lead pipe because of the associated health risks. But whilst waiting for that to happen, they needed to repair the pipe inside the wall to prevent further water damage.

Water supply through the pipe could be turned off via the property’s external stopcock. Sealing an offline leak would normally mean using a SylWrap Standard Pipe Repair Kit.

However, the softness and oxidised surface of lead means epoxy putty struggles to adhere cohesively to it. Sylmasta therefore always recommend the SylWrap Universal Pipe Repair Kit for sealing lead pipes even when there is no pressure.

The Universal Kit comes with Wrap & Seal Pipe Burst Tape, which can repair lead because it is made from self-amalgamating silicone and bonds to itself more than the substrate.

Despite the space constraints inside the wall, Wrap & Seal was successfully stretched by the maximum three times its length as it was wrapped around the leak area. This enabled it to fuse into a solid rubber band, exerting pressure over the leak to contain pipe content.

Despite the space constraints inside the wall, the lead pipe was successfully repaired using Wrap & Seal and SylWrap HD Bandage

The repair was then overwrapped with a SylWrap HD Pipe Repair Bandage. The water activated resin turned the bandage rock-hard within minutes. It formed an impact resistant protective shell around the pipe for a reinforced repair.

Completing the application took under 20 minutes. Water supply to the house was turned back on and the lead pipe inspected regularly over the next two days for any sign of leakage. It remained bone dry, indicating a successful 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

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Case Study: Rotted Bay Sash Window Frame Repair & Restoration

Rotted bay sash window reframe undergoes repair and restoration using AB Original Epoxy Putty as a filler

Sharing a window on how to seamlessly repair and restore a rotted bay sash frame

A bay sash window frame which had rotted after only eight years due to severe weathering and poor preparation by the installer undergoes repair and restoration by the homeowner using Sylmasta AB Original Epoxy Putty.

Case Study Data

Site
Domestic property
Location
England
Repair Type
Wood repair
Defect
Heavily rotted bay sash window

Products Used

CA3 Penetrating Superglue
Very low viscosity cyanoacrylate superglue stabilises wood by wicking deep into soft damaged fibres and turning them rock hard

Sylmasta AB Original Epoxy Putty
Epoxy putty which is easy to shape and mould when used as a filler to rebuild missing sections of damaged wood

Case Study PDF

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Case Study Details

When installed eight years earlier, the bay sash window was brand new. Thanks to severe weathering and poor preparation by the installer, one sharp corner had become heavily rotted in just eight years.

The rot first softened the wood, then caused cracks to appear before chunks of timber eventually fell away. It left very obvious and unsightly damage visible to all visitors and passers-by.

Wanting to repair the bay sash window, the homeowner contacted Sylmasta for advice. A restoration plan was formulated involving cleaning, stabilising and then rebuilding the damaged corner.

All loose rotted timber was removed from the bay sash window frame as the first stage of repair. Any remaining fragile wood was then stabilised using CAE3 Penetrating Cyanoacrylate Superglue.

The extreme low viscosity of CAE3 makes it as thin as water. This allows CAE3 to penetrate porous surfaces, wick into cracks and flow easily into small and hard-to-access areas.

When CAE3 was applied to the bay sash window corner, it permeated deep into the damaged fibres of the frame. It cured rapidly to turn all wood which had been left soft and fragile by rot into a rock-hard material ready to be rebuilt with epoxy putty.

AB Original Epoxy Putty applied to rebuild and repair the heavily rotted corner of a bay sash window
Once rot had been removed and the remaining wood stabilised, Sylmasta AB Original Epoxy Putty was applied to fill all gaps in the corner

It was decided to use Sylmasta AB Original Epoxy Putty. AB Original was chosen for its two-hour work time, allowing the homeowner to mix, shape and apply the putty carefully without the worry of it curing off quickly.

AB Original was kneaded by hand and applied direct to the frame. It easily adhered to the stabilised wood. Enough putty was added until all the missing wood was filled and replaced, leaving the damaged corner rebuilt.

Epoxy putty smoothed off with a metal spreader during the repair of a rotted bay sash window frame
AB Original was smoothed off with a metal spreader. Once cured, it left a rebuilt corner

Before curing, the putty was smoothed off using a metal spreader and a little water. Once it had fully hardened, it was lightly sanded down and then painted the same white colour as the sash window for a seamless restoration.

Seamless repair of a rotted bay sash window frame completed using Sylmasta AB Original Epoxy Putty
The cured AB Original was painted to seamlessly match the colour of the bay sash window, leaving no signs of any repair

The homeowner had never handled epoxy putty before making the repair. They said afterwards they liked how straightforward an AB Original Stick was to use, simply by cutting off the amount of putty required and mixing by hand.

They also appreciated not having to rush the putty application because of the longer work time, and that AB Original did not sag or lose shape as it was applied to the bay sash window corner.

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 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

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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

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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

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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


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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

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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

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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 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

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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