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Case Study: Burst Underground Water Main is Repaired After 15 Years of Leaking

A live repair carried out on a water main which had been leaking for the previous 15 years

Repairing the unrepairable – Sylmasta devise a live leak repair method for a burst underground water main which had been leaking for 15 years

For 15 years, no contractor, maintenance company or water board had been able to find a repair method for a burst 400mm carbon steel underground water main. That was until Sylmasta devised a successful live leak repair method which was effective inside an hour.

Case Study Data


Site
Underground Water Main
Location
United Kingdom
Repair Type
Live leak pipe repair
Defect
Split 400mm carbon steel water main

Products Used


Wrap & Seal Pipe Burst Tape
Multiple Wrap & Seal Pipe Burst Tapes were used to provide a pressure resistant repair to the live leak

SylWrap HD Pipe Repair Bandage
SylWrap HD was overwrapped to offer an impact resistant layer over the Wrap & Seal

SylWrap Universal Pipe Repair Kit
All the products used in the repair are available as part of the SylWrap Universal Pipe Repair Kit for fixing live leaks

SylWrap Pipe Repair Contractor Case
A Contractor Case containing enough products to make up to six live leak pipe repairs was recommended to the contractor for conveniently fixing future bursts and leaks

Case Study PDF


Case Study Review


The large split across the diameter of the 400mm underground carbon steel water main had been considered unrepairable for 15 years for several reasons. The normal method for fixing a pipe on the underground water network would be to use a hefty pipe repair clamp, but that was not possible due to the severely confined space the main was located in.

Only a single contractor could access the water main at any one time and there was no room for any heavy equipment, including a clamp. This also made replacement impossible without digging up the area surrounding the water main.

The importance of the water main to the network meant that shutting off flow to carry out work was impractical. The only solution therefore was to find a way to carry out a live leak repair in a restricted space which could be effective even when water pressure could not be turned off – something which had proven elusive until Sylmasta were consulted.

A burst underground carbon steel water main which had been leaking for 15 years
The burst carbon steel water main was buried underground with restricted accessibility

Because of the complexity of the repair and the lack of space in which the contractor attempting to fix the burst water main had to work, Sylmasta recommended the use of multiple Wrap & Seal Pipe Burst Tape and SylWrap HD Pipe Repair Bandage.

It was decided to double wrap 400mm from the flange up the tapered pipe. Double wrapping compensated for the fact that the waterproof repair tape could not be stretched by its full 300%, which could have resulted in less effective fusion.

Applying more than the required number of tapes increased the pressure resistance of the repair. These additional rolls of Wrap & Seal bond to each other in the same way that a single tape fuses to form a solid rubber band. This repair method sealed the leak on the water main.

The Wrap & Seal was then overwrapped using several SylWrap HD 416 Pipe Repair Bandages. On a pipe 400mm in diameter, Sylmasta would normally have advised the use of an 866 Bandage but at 200mm wide by 20m long, there would have been no room to apply such a large wrap to the pipe.

Multiple 416 Bandages were used to cover the same repair area as an 866 Bandage, providing an impact resistant, protective layer to the Wrap & Seal, turning the repair permanent. Once cured, it was evident that the job had worked. Sylmasta had done in an hour what nobody else had managed in a decade-and-a-half by finding a method to repair the burst water main.

SylWrap Universal Pipe Repair Kit successfully repairs a burst carbon steel underground water main which had been left to leak for 15 years
The repair of the carbon steel water main was a complete success

Wrap & Seal and SylWrap HD both have WRAS approval, meaning that they are safe to use on drinking water. With the water main in question connected to the public supply network, any repair materials had to meet the stringent criteria set out by WRAS so as not to pose a threat by contaminating water which could be consumed by humans.

The contractor carrying out the repair was delighted that after such a long period of time, they had finally been able to offer a solution. They said afterwards: “The repair was a complete success, as we knew it would be. The information that Sylmasta provided greatly supported the project and more importantly, future projects.”

Sylmasta have since recommended that the contractor take stock of the SylWrap Pipe Repair Contractor Case. The Case contains enough products to enable a user to carry out up to six live leak pipe repairs, allowing the contractor to fix burst and leaking pipes in under 30 minutes as soon as problems are reported.

They will never have to wait 15 years to repair a leak again.

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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3 quick and easy ways to fix a leaking PVC Pipe

A domestic bathroom that may require a PVC Pipe repair

At some point, most homeowners will need to find an answer to the question of how to fix a leaking PVC pipe. After all, plastic piping runs water in and out of bathrooms, kitchens and drainage systems in domestic properties all over the county.

Thankfully, you don’t have to be a fully trained plumber to fix a leaking plastic pipe. There are several products available which allow repairs to be carried out quickly and with no formal training needed – even when water flow cannot be turned off.

Here are some of the ways in which you can fix a leaking PVC pipe – without having to call out a plumber.

Pipe Burst Tape

The most common method of repairing leaking PVC pipes is with pipe burst tape. This specialist repair tape is made from silicone and is self-fusing, meaning that it bonds to itself when wrapped around a damaged pipe to form a permanent bond over the leak area.

The extra stretch which pipe burst tape provides – Wrap & Seal stretches to 300% – even allows it to seal live leaks where water flow cannot be turned off. This can be particularly useful if you cannot locate your home’s stopcock or the water valve happens to be too old, damaged or tight to use.

To apply pipe burst tape, you simply stretch and wrap it around the damaged area of the pipe enough times to permanently seal the leak. Repairs can be carried out in under 30 minutes, making this a quick and easy way to return leaking PVC pipes to full working order.

Epoxy Repair Putty

If you are trying to repair a pipe in a tight space, then you might not have enough room in which to apply Pipe Burst Tape. When this is the case, you should instead use an epoxy repair putty to seal the leak.

Epoxy putties are designed to bond different materials together and they can be used to plug holes with a working time of anywhere between 10 minutes and an hour depending on the product being used.

Superfast Copper Stick for example bonds to pipes of all types and sets in 5-10 minutes with a full cure in one hour; Superfast Plastic Stick – which has been used in countless PVC pipe repairs – takes a little longer at 35-40 minutes to harden and form a cohesive bond and 2-3 hours for the system to be put back into service.

A leaking PVC pipe fixed using Superfast Plastic Epoxy Putty Stick
Pipe Repair Bandages

If you want to carry out a longer lasting repair to leaking PVC pipes, then you should combine either pipe burst tape or epoxy repair putty with a repair bandage.

Pipe Repair Bandages are fibreglass wraps coated with a water-activated resin which set rock hard in minutes. They are dipped in water and then wrapped over the top of the pipe burst tape or epoxy putty for a permanent repair.

Pipe Repair Bandages can be smoothed down as water is applied and are coloured white, meaning that they will blend in with PVC pipework which is also white in colour.

Wrap & Seal Pipe Burst Tape, Superfast Epoxy Putty and SylWrap Bandages can now all be purchased in one SylWrap Universal Pipe Repair Kit, providing all the equipment needed to fix leaking bathroom pipes.

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What is corrosion – and how can you stop it?

Corrosion costs the global economy over $2.5 trillion every year

Corrosion is one of the most damaging and costly naturally occurring events seen today. At its simplest level, it can cause a water tank in a back garden to rust or a domestic pipe to start leaking.

At its most damaging, it can weaken structures to the point that buildings and bridges collapse. Oil pipelines can break, containers that store radioactive waste can leak and beautiful monuments around the world can become damaged. Only emergency repair works saved the Statue of Liberty from the jaws of corrosion in the 1980s.

In 2016, a study carried out by NACE International put the annual global cost of the problem at around $2.5 trillion, or 3.4 percent of global GDP. It’s as dangerous as it is costly, and that’s why many individuals and businesses view corrosion protection as a worthwhile investment.

How does corrosion occur?

Corrosion happens as a result of chemical reactions between a metal and its environment. In most cases, the three components that cause the problem are the metal itself, oxygen and water.

Most metals found in manmade structures occur naturally in ore. In order for these metals to be turned into pipes, piles and beams, the metal must be separated out from the ore, a process which leads to reduced stability.

It is when these extracted metals react with their environment and begin to return to their natural states that corrosion occurs. Iron for example comes from iron ore and as a result, it will corrode quickly. In contrast, metals such as gold, silver and platinum – which are found in nature in their pure form rather than as an ore – corrode very rarely.

That’s what makes them so valuable and is why, unless you happen to be very, very rich, you don’t have water running through gold pipes in your home.

Types of corrosion

There are four common types of corrosion, all of which can have a devastating effect on metalwork if left untreated.

General corrosion is caused by chemical or electrochemical reactions and will attack the entire surface of a metal structure. It leads to an overall thinning of the metal but because it is a predictable issue that attacks whole structures, it is possible to plan for and manage which can help limit the damage.

Localised corrosion attacks smaller areas of metalwork. The most common form of this is pitting, which creates small holes, pits or cavities on metalwork. Because it targets single locations, it is harder to detect and therefore harder to prevent. Pitting often leads to pipework bursting or leaking and it can cause structural failure through cracking.

Other forms of localised corrosion include crevice corrosion and filiform corrosion. Crevice corrosion is found where there are gaps between two joining surfaces, such as where a screw or bolt has been drilled into metalwork. Filiform corrosion occurs when water is trapped against a metal surface by another layer, such as under a coating of paint.

Galvanic corrosion takes place when two different metals are located alongside an electrolyte which can carry an electrical current between the metals. One metal’s molecules are drawn towards the other, leading to a weakening in one of the metals.

It was galvanic which had such a devastating effect on the Statue of Liberty. The outside of the Statue is made from copper, the inner frame iron. With layers of paint and varnish holding water molecules applied between the two metals, conditions were ripe for iron molecules to travel over to the copper.

As a result, a survey in the 80s revealed that the iron frame was in some places half as thick as it had been when it was shipped over from France to Liberty Island 100 years previously.

Finally, there is environmental corrosion. This is where structures which are found in harsh environmental conditions such as in saltwater are gradually worn down over time. It can lead metalwork to become brittle, weakened, fatigued and ultimately, to crack.

How to protect against corrosion

There are numerous ways in which corrosion can be prevented. At a scientific level, resistant manmade alloys such as stainless steel have been invented. These alloys consist of two or more metals, making them stronger and giving them a greater resistance to corrosion.

Galvanic corrosion can be prevented by coating iron or steel with a more active metal, such as zinc. Rather than the iron or steel corroding, it is instead the zinc that gives up its molecules.

Another method for protecting and strengthening structures is by using protection wraps. SylWrap CR is a resin-impregnated fibreglass bandage incorporated with corrosion inhibitors. When wrapped around pipework, pillars or structures, it sets rock hard to provide an impact resistant-protective layer, extending the lifespan of metalwork which could otherwise by ravaged by corrosion.

Brushable epoxies can also be applied to structures which are already being afflicted by the problem. Standard Epoxy 19000 can be brushed onto damaged areas, offering excellent protection and helping to repair existing problems. When used alongside Fibreglass Tape or as part of a Fibreglass Repair Kit, damaged tanks and vessels can have their lifespan extended.

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Case Study: Creating a Flexible Expansion Joint Filler for a Residential Property in the UK

Liquid Rubber used as an expansion joint filler to fill 25mm gaps between glass panels on a roof terrace at a residential property in Essex

Sealing the Dream – Sylmasta Liquid Rubber used as a flexible expansion joint filler eliminates problematic balcony drips at a dream home

An unexpected issue hit a dream home being built in Essex when water began to drip through glass panel expansion joint gaps in a roof terrace onto a balcony below – leading the homeowner to come up with a creative flexible filler solution to seal the joints

Case Study Data


Site
Residential Property
Location
Essex, United Kingdom
Repair Type
Expansion Joint Filler
Defect
Water dripping through expansion gaps in a roof terrace onto a balcony below

Products Used


Liquid Rubber 80
Rubber elastomer compound which was poured into the expansion joints to offer a water resistant and flexible filler

Case Study PDF


Case Study Review


The striking property overlooking the Thames Estuary featured a roof terrace with panoramic views. Surrounding the terrace were 26 glass panels with 25mm expansion gaps either side. Below the roof terrace was another balcony where electrical installations such as LED lights and speakers had been added.

Whenever it rained or spray blew in off the Thames, water would drip through the expansion gaps and onto the balcony below, causing issues with the electric equipment.

A residential property in Essex required a flexible expansion joint filler to eliminate drips from a roof terrace onto a balcony below
The residential property. The troublesome expansion gaps were allowing water to pass from the roof terrace onto the balcony below

To prevent this happening, the homeowner needed to find an expansion joint filler material which was both waterproof to eliminate the drips and flexible enough to allow the glass panels to expand.

After speaking with Sylmasta, the homeowner decided to fill the expansion gaps with a packing material which was then encapsulated with Sylmasta Liquid Rubber 80.

A 25mm expansion joint between panes of glass on a roof terrace
25mm expansion joints between the glass panels

Liquid Rubber is a tough but flexible repair compound which can also be used to refurbish conveyor belts, make moulds, and add noise-reducing and abrasion-resistant linings to equipment.

The packing material was first pushed into the expansion gaps. Once the material was in place, the homeowner mixed the two parts of Liquid Rubber together, pouring it into the joints to seal everything.

Liquid Rubber used as a filler for a 25mm expansion joint between glass panels on a roof terrace at a residential property in Essex
Each expansion gap was filled with a packing material which was then encapsulated with Liquid Rubber

Within 16 hours, the Liquid Rubber cured to provide a water resistant filler which could also cater for glass expansion.

Liquid Rubber sets to black, which meant that it blended in seamlessly with the resin which had been used on the rest of the roof terrace’s balustrade. Even on close inspection, you could not tell that two different materials had been used.

The Liquid Rubber blended in seamlessly with the existing resin used on the roof terrace
Sylmasta Liquid Rubber used as an expansion gap filler between glass panels on a roof terrace in Essex
The completed repair of the expansion joint gaps

The use of Liquid Rubber as an expansion joint filler was a complete success and eliminated all drips from the roof terrace to the balcony below.

The homeowner contacted Sylmasta after the repair had been completed, saying he was delighted that a solution had been found to complete the building work on his dream home.

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: Live Leak Contaminated Water Pipe Repair at a Wastewater Treatment Works

A contaminated water pipe at a wastewater treatment works in the United Kingdom is repaired after being accidentally breached during construction work

Clearing up a mess – a SylWrap live leak repair saves a Wastewater Treatment Works from an environmental catastrophe

A Wastewater Treatment Works was undergoing a major infrastructure upgrade when contractors mistakenly cut through a 450mm steel contaminated water pipe which required a rapid live leak repair to prevent a serious environmental incident.

Case Study Data


Site
Wastewater Treatment Works
Location
Sussex, United Kingdom
Repair Type
Live leak pipe repair
Defect
Highly pressurised leak on a 450mm steel contaminated water pipe

Products Used


SylWrap Pipe Repair Contractor Case
The site was recommended a Contractor Case in the aftermath of the incident as it would enable them to carry out up to six emergency live leak repairs in the future

Wrap & Seal Pipe Burst Tape
Multiple Wrap & Seal Pipe Burst Tapes were used to increase the pressure resistance of the repair

SylWrap HD Pipe Repair Bandage
SylWrap HD provided a protective layer over the initial repair

SylWrap Universal Pipe Repair Kit
Both Wrap & Seal and SylWrap HD are available as part of the Universal Pipe Repair Kit

Case Study PDF


Case Study Review


The contractors working at the Wastewater Treatment Works in the United Kingdom mistakenly believed the pipe in question had been decommissioned and was due for removal. In actual fact, it was one of the most important live pipes on site as it was linked to all the waste treatment ponds. As a result, there was no feasible way to stop the flow once the pipe had been breached.

From the moment the pipe was damaged, the severity of the cuts inflicted to such a highly pressurised pipe resulted in a significant amount of contaminated water escaping. A rapid, live leak repair to the wastewater pipe was therefore required to prevent a catastrophic situation from occurring.

A high pressure leak in a contaminated water pipe at a wastewater plant in the UK
The break in the contaminated water pipe allowed large amounts of contaminated water to escape

The contractor contacted Sylmasta for urgent assistance. Luckily, the Wastewater Treatment Works was located less than one hour from Sylmasta HQ and so our technical team were able to rush all the SylWrap Pipe Repair products needed to the site and offer assistance throughout the repair.

Several Wrap & Seal Pipe Burst Tape were first applied to the pipe. Wrap & Seal is made from self-fusing silicone which fuses to form a solid rubber band over the hole or crack, sealing the leak. The 450mm diameter of the pipe combined with the high pressure meant that multiple tapes were needed to provide an effective seal.

This initial repair was then overwrapped using a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite repair wrap with a water-activated resin which sets rock hard in 30 minutes, providing an impact resistant layer over the Wrap & Seal to protect the repair from further damage.

Within an hour of Sylmasta being on site, the contaminated water pipe had been permanently repaired at a cost of less than £300 to the contractor. This included additional SylWrap HD should there be any further mishaps or any existing pipes require strengthening or reinforcing during the construction works.

A live leak repair made using a SylWrap Universal Pipe Repair Kit is made to a steel contaminated water pipe at a wastewater treatment works in the UK
The successful repair of the contaminated water pipe

Had a live leak repair not been possible, then the Wastewater Treatment Works would have had to shut down the entire site to isolate the damaged pipe whilst a replacement was sourced and fitted. The cost of such a procedure would have been astronomical.

The speed of the SylWrap repair also prevented a serious environmental incident from unfolding. This could have been damaging in monetary terms through the cost of a clean up operation and possible fines, and for the reputations of both the Wastewater Treatment Works and the contractor involved.

Understandably, the project manager was extremely happy with the speed and ease with which the contaminated water pipe had been repaired. He emailed Sylmasta a few days after the repair, saying: “Thank you so much, the pipe repair worked a treat.”

Sylmasta have since recommended that the Wastewater Treatment Works takes stock of a SylWrap Pipe Repair Contractor Case. The Case contains enough equipment to carry out up to six live leak pipe repairs. By keeping one on site, the Wastewater Treatment Works will have everything they need to fix any future leaks as soon as a problem arises.

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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Slow the Sands of Time – Prevent Corrosion With Sylwrap CR

SylWrap CR is a new product developed by Sylmasta which is designed to prevent corrosion

Corrosion costs money. In 2016, a study carried out by NACE International put the annual global cost of corrosion at around $2.5 trillion, which is about 3.4 percent of global GDP.

There has often been this misconception that you cannot prevent corrosion, nor control it. Whilst it is true that corrosion cannot be eliminated, there are ways in which its impact to structures and industries across the world can be limited. You can slow the sands of time.

Which is why SylWrap CR Corrosion & Protection Wrap has been developed. The newest variation of SylWrap is a resin-impregnated fibreglass bandage infused with corrosion inhibitors, making it the only water-activated wrap to offer corrosion protection.

SylWrap CR strengthens and protects structures in harsh and aggressive environments. It is used to reinforce underwater piles and pier supports in saltwater environments. It strengthens steel and concrete against the effects of environmental corrosion. It helps extend the lifespan of metalwork and machinery, preventing the need for costly and time-consuming shutdowns. It protects pipes and metal parts against abrasive wear and it prevents substrate corrosion.

The Wrap is designed to be easy to use in the field and requires minimal training. To apply the bandage, you simply dip in water and wrap around the structure that requires protection or repair. Because it is water-activated, SylWrap CR is ready to use underwater without any prior preparation. The cured wrap sets hard in 30 minutes to provide a permanent, impact-resistant protective layer.

In testing, SylWrap CR has returned a wrapped metal structure in a corrosion-free state after 1,000 hours of saltwater exposure. It can also be used to repair cracked or leaking pipework in high-pressure and high-temperature situations.

SylWrap CR Corrosion Protection & Repair Wrap leaves a corrosion free structure when removed even in the most extreme of salt water conditions

When cured, SylWrap CR has a lifespan of 10-20 years depending on a variety of factors. It comes in different sizes depending on the diameter of the framework and it is coloured black for minimum visual impact.

To find out more about SylWrap CR and how it can help to prevent corrosion, then visit our SylWrap CR Product Page.

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How to prepare and protect pipes and tanks for winter

How to protect and repair broken pipes ahead of winter

With winter on its way, now is the time to start thinking about how you can prepare and protect pipes and tanks from the damage that can be caused by plummeting temperatures.

As water freezes, it expands. What this means for pipes or tanks is that as they are exposed to colder temperatures, the water inside begins to exert extra pressure on the structure in which it is being carried or stored. This in turn puts the whole system at risk of rupturing, increasing the likelihood of damage and breakdowns during the winter months.

Which is a problem. The last thing that anybody wants to be dealing with in the depths of winter is cracks, bursts or reduced flow rates – especially as water damage resulting from leaks can cause serious harm to property and belongings.

Thankfully, there are several measures you can take to prepare pipes for winter. Here are the steps that we recommend so that your property is ready for when freezing temperatures arrive.

Drain outdoor pipes ahead of winter

One of the easiest ways to prevent exterior pipes or tanks from breaking down is to drain those that will not be used during winter ahead of the freezing temperatures arriving. If appliances such as hose pipes can be moved indoors, then you should bring them in during the winter months.

If you have exterior taps, then close the indoor valves but leave the outdoor valves open. This allows the water to expand safely when it freezes due to the lack of pressurisation.

One step that you should not take is to pass antifreeze through these pipes. The chemical can damage the pipework as well as having a significant detrimental impact on the environment.

Insulate your pipes to prevent freezing

Insulation of exterior pipes is one of the most effective ways in which you can protect and prepare pipes for winter. On the face of it, this may seem like a costly and time-consuming exercise, but it can actually be relatively easy and cheap to carry out.

Most DIY stores will sell pipe lagging which can be used for insulation. The lagging is fitted around pipes to prevent them from becoming damaged or bursting. The lagging works by keeping heat inside the pipes. It can also help to reduce gas and electric bills by cutting the amount of energy needed to heat water throughout a property.

Leave the heating on

For interior pipes, one of the easiest ways to ensure that water temperature does not drop too low is by leaving the heating in your property on. Setting your thermostat to between 12-15C when you away from the property ensures that the air inside remains warm to prevent pipes from freezing.

Water cannot freeze when it is on the move, so turning your taps on regularly to flush the system can also prevent interior pipes from freezing. Those not on a water meter could even consider letting their taps trickle so there is a constant flow when temperatures really plummet.

Repair leaks to protect and prepare pipes for winter

If your property is already suffering from leaking pipes, then it is imperative that you repair them before winter in order to prevent the problem becoming worse. A tiny leak now can easily turn into a burst pipe in the depths of December or January thanks to the freezing temperatures.

Repairing leaking pipes has never been easier. A SylWrap Pipe Repair Kit contains all the equipment needed to permanently seal leaking pipes.

The kits are extremely easy to use, offering a permanent repair inside 30 minutes with no formal training needed. You simply follow the instructions provided. SylWrap kits are WRAS approved, meaning they have been certified as safe to use with drinking water.

Take steps to prevent draughts and cold air flows

Interior pipes in locations such as garages and warehouses may freeze if those areas of a property are not draught-proofed or are subjected to cold air flows.

Small gaps between doors or in structures allows the cold to get in, which in turn will cool down and potentially freeze pipes. This is because the colder air speeds up the process of ice formation.

You can prevent this from happening by draught proofing areas which may have otherwise been neglected because they are not habitable or well-used. Plug up gaps using insulation, wood or plastic to try and keep the cold away from interior pipes or tanks.

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Case Study: Heavily Damaged Metal Machinery Repair Saves a Puerto Rico Ball Mill $60 million

A repair carried out to machinery in a Ball Mill which helped to save a company around $60 million

Having a Ball – The metal machinery repair which saved a Ball Mill in Puerto Rico $60 million in lost revenue

A three week lead time on replacing heavily damaged metal machinery at a Ball Mill in Puerto Rico looked set to cost a company $60 million in lost revenue – until Sylmasta Ceramic Supergrade carried out a repair in under 24 hours

Case Study Data


Site
Ball Mill
Location
Puerto Rico
Repair Type
Metal Repair
Defect
Heavily damaged metal machine part

Products Used


Ceramic Supergrade
Ceramic Supergrade epoxy paste filled in the significant crack in the metal machine for a hard wearing surface repair

Case Study PDF


Case Study Review


Ball Mills are used for mixing a wide variety of materials together by grinding particles down in size, often with the aim of turning them into powders.

A rotating shell is filled with balls or beads alongside the materials which are to be turned into powder. As the shell rotates, the balls and beads drop from near the top and impact on the materials towards the bottom, which grinds them down.

The process is hard wearing and the balls and beads have to be regularly replaced as a result. Whilst this maintenance work was being carried out, a part had been forced, causing significant damage to a metal part.

Metal machinery in a Ball Mill in Puerto Rico suffering from a heavy crack after being accidentally damaged during maintenance work
The cracked metal part in the machinery which required repair

It was not until a few days after the maintenance work had been completed that the Ball Mill noticed there was a problem. Water which ran between the liner and the outer wall of the machine was now leaking into the tank through a visible crack.

The cost of a replacement part was $200,000 with a three week delivery time from Germany. A specialist installer would also have to be flown over to Puerto Rico to fit the new part.

More pressing a concern for the Ball Mill was that daily production was worth $4 million. A three week wait would therefore have cost the Mill approaching $60 million in lost revenue.

Rather than replace the part, the Mill instead sought out a means to carry out a repair to the metal machinery. Sylmasta recommended the use of Ceramic Supergrade, a two-part epoxy paste designed to repair heavy damage to industrial machinery including silos, chutes, pumps, impeller blades, valves, fan blades, metals castings and tanks.

Sylmasta Ceramic Supergrade epoxy paste used to repair heavy damage to metal machinery at a Ball Mill
Ceramic Supergrade applied to the damaged machinery

The ease with which Ceramic Supergrade can be applied enabled the Ball Mill to carry out the repair themselves. Prior to application, the surface of the metal machinery undergoing repair was prepared by roughening it up. The epoxy paste was then spread over and pushed into the crack with a trowel, filling in the damage before it hardened.

Ceramic Supergrade is reinforced with silicon carbide for ultimate surface hardness, offers excellent protection against future wear and corrosion, and is moisture tolerant which would prevent any water leaking into the shell.

Repair to a metal machine part using Sylmasta Ceramic Supergrade epoxy paste saved a Ball Mill $60 million in lost production
The completed repair saved the Ball Mill $60 million in lost revenue

The repair was carried out whilst the Ball Mill was shut for business on a Sunday. Ceramic Supergrade has a full cure time of 24 hours. By the time the site reopened for business on Monday, the Ball Mill was able to operate at full capacity with tens of millions of dollars saved.

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