Author: Scott McCarthy

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Case Study: Extending the Life of 20m Pipe Bridges Through Leak Repair & Reinforcement

Pipe bridges leaking from rusting riveted joints undergo a leak repair and reinforcement using SylWrap HD Pipe Repair Bandage

Bridging the gap until replacement – the lifespan of two leaking pipe bridges is extended with a SylWrap leak and reinforcement repair

The complex repair of numerous corroded leaking joints on two 20m gravity-fed pipe bridges is followed by the entire reinforcement of both bridges to extend lifespan and offer maximum gain on investment.

Case Study Data

Site
Pipe Bridges
Location
Lancashire, United Kingdom
Repair Type
Leak repair & pipeline reinforcement
Defect
1.5m x 20m pipe bridge and 1.8m x 20m pipe bridge leaking from corroded riveted joints

Products Used

Wrap & Seal Pipe Burst Tape
Self-fusing silicone repair tape used to seal the numerous leaks on the two pipe bridges.

SylWrap HD Pipe Repair Bandage
Four-layer application over the entire length of the bridges for protection, strengthening and life-extension.

Case Study PDF

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Case Study Details

The two gravity-fed pipe bridges in Lancashire which were constructed of steel riveted plates had become corroded over time. They were now leaking in several places, allowing foul wastewater to fall into a stream below.

Although it was planned to replace these pipe bridges at some point in the future, an immediate solution was required to stop the leaks. At the same time, the lifespan of the bridges also needed extending so that maximum benefit could be gained from the investment required for such a complex repair.

Pipe Bridge in Lancashire, UK prior to undergoing a SylWrap repair and reinforcement application
One of the pipe bridges prior to undergoing repair

These complexities included building scaffolding on the riverbed and sourcing materials for the repair and reinforcement of such substantial pipe bridges: one being 1.5m x 20m and the other 1.8m x 20m.

A previous attempt had been made to seal some of the leaking joints using ratchet straps with a rubber pad. These however had proven unsuccessful and further leaks had appeared since.

A pipe bridge leaking from rusting joints before undergoing a SylWrap repair and and reinforcement
A previous repair attempt had been made the the leaking riveted joint

Sylmasta were consulted on the repair, and it was decided that Wrap & Seal Pipe Burst Tape would be used over the leak areas. Wrap & Seal is a heavy duty repair tape made from self-amalgamating silicone which, when stretched by 300 percent across a leak, forms a tight rubber seal. Multiple layers increase the pressure applied until the leak stops.

Once all leaks had been addressed, the entire structure was wrapped with SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite repair wrap with a water-activated resin which sets rock hard in minutes, providing protection and reinforcement to pipework.

Pipe bridge leak repair and reinforcement carried out using SylWrap HD Pipe Repair Bandage
Completed repair of the first pipe bridge
Repair of first pipe bridge as seen from underneath

Four layers of SYL1266HD (300mm x 20m) were applied to each of the pipe bridges along their 20m length, providing a substantial protective sleeve, completing the repair and guarding against future leakage and corrosion.

Although the utilities company responsible for the pipe bridges were only seeking a temporary solution, using SylWrap HD in the repair provided reinforcement and additional strength which will last for 20 years.

Repair of the second pipe bridge with scaffolding erected

Once the repair was completed, it was estimated that a saving of approximately £250,000 had been made compared to the cost of replacing both pipe bridges, so Sylmasta’s solution was very much welcomed by all involved.

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: Leak Repair & Encapsulation of a Steel & Iron Welded Pipe Joint

Pipe repair of a central heating system in a church which had begun to leak around a welded joint suffering from corrosion

Good deed done – Sylmasta answer a church’s prayers with a welded pipe leak repair and encapsulation

A church central heating system had suffered heavy damage caused by corrosion and begun leaking at the point where a 100mm cast iron pipe met a 50mm steel pipe via a welded steel plate, leading to a challenging leak repair and encapsulation application.

Case Study Data

Site
Church
Location
United Kingdom
Repair Type
Leak Repair
Defect
Leaking welded joint between a 100mm cast iron pipe, a 50mm steel pipe, and a 6mm steel plate

Products Used

Sylmasta AB Original Epoxy Putty
Epoxy putty with two-hour work time allowing for careful application and watertight encapsulation of the leaking joint

Wrap & Seal Pipe Burst Tape
Self-fusing silicone repair tape used initially to seal leaks on the 100mm cast iron pipe

SylWrap HD Pipe Repair Bandage
Applied over Wrap & Seal to provide a rock hard, impact-resistant layer to the initial repair.

Case Study PDF

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Case Study Details

Several years previously, the central heating system in the church had undergone renovations when a 100mm cast iron pipe had been stepped down to a 50mm steel pipe.

To facilitate this, a 6mm thick steel plate had been attached to the end of the larger cast iron pipe with a hole cut into the middle, through which the smaller steel pipe was attached and welded.

Since the work had been carried out, the system had become badly corroded and was now leaking from numerous areas around the welded joint.

When a similar problem had developed on another heating pipe, the church had fitted a pipe repair clamp at considerable expense. Such a repair method was not possible on this occasion as the new leak was in a restricted space with no room for a clamp to be applied.

Initially, the church called in welders to try and fix the problem, but this just caused further leakage and left an even more uneven pipe surface needing to be sealed.

Diagram showing the repair in question

The main leak was between the steel plate and the 100mm cast iron pipe with particularly heavy corrosion at the point where they met. Once the corrosion was filed back, this was relatively straightforward to repair using a SylWrap Universal Pipe Repair Kit.

Wrap & Seal Pipe Burst Tape was applied around the pipe, fusing to form a solid rubber band over the problem area to seal the leak. This was then overwrapped with a SylWrap HD Pipe Repair Bandage, providing a rock hard, impact resistant shell to reinforce the initial repair.

More challenging was the repair of the joint between the smaller 50mm steel pipe and the steel plate. Here, leaking was caused by uneven welding, whilst a threaded section of pipe close by was also suffering from a leak.

It became clear that a softer repair material was needed to smear into the threaded section and to penetrate into the weld. Because of the complexity of the repair, Sylmasta recommended Sylmasta AB Original Epoxy Putty.

  • Leaking 100mm cast iron pipe prior to repair
  • Sylmasta AB Original Epoxy Putty used to encasuplate a leaking welded joint as part of a pipe repair application
    Completed repair with AB Original encapsulating the welded joint

AB Original is a smooth-setting epoxy with a two hour cure time. This longer working time allowed for the putty to be more carefully applied, encapsulating the whole section where the 100mm pipe, the 50mm pipe, and the steel plate all met.

The church were supplied with 1kg of Sylmasta AB, more than enough for their application. Unused AB Original stays fresh when left in its original packaging, ensuring the church has a supply of epoxy putty for any future applications.

Sylmasta AB Original putty was smoothed over the welded joint, filling in all imperfections and sealing all leak areas. It has excellent corrosion resistance, further protecting the pipe from future attack, and provided a smooth, ceramic-like finish to the application.

When the church first contacted Sylmasta, they had been looking for a repair method that would temporarily fix the leaking central heating system until funds allowed for either a longer lasting solution or for a new pipe to be installed.

Instead, the repair provided by Sylmasta will be permanent and was made at a fraction of the cost of other options, saving the church a considerable amount of money.

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: Badly Soldered Domestic Copper Pipe Leaking Joint Repair

Wrap & Seal Pipe Burst Tape used to repair a domestic copper pipe leaking from badly soldered joints

Soldering saviour – A Wrap & Seal repair to a long-term leaking copper pipe joint caused by shoddy soldering

After ignoring a leaking joint on a badly soldered copper pipe for a prolonged period of time, a property owner was spurred into carrying out a repair once it became known that escaping water had begun rotting wooden floorboards and a joist underneath the leak area.

Case Study Data

Site
Domestic property
Location
United Kingdom
Repair Type
Leak Repair
Defect
Leaking joint on a 22mm copper pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-fusing silicone repair tape which formed a solid, watertight seal around the joint

Case Study PDF

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Case Study Details

The problem pipe was a 22mm copper perimeter heating pipe which had been boxed in behind a grill. Poor soldering had caused it to leak, but the property owner deemed the water escaping to be so minimal that they did not feel it worth either attempting a repair themselves or going to the trouble and expense of hiring a plumber.

After a significant period of time, the joint in question had leaked enough to rot away woodwork both underneath and around the pipe. Wooden flooring below had been badly impacted with the leak starting to cause damage to the joists further down.

To prevent the leak causing further deterioration to nearby wood, the property owner now needed to carry out a leak repair to the pipe. They were still keen to minimise cost and so came to Sylmasta, who recommended Wrap & Seal Pipe Burst Tape for the application.

  • A badly soldered copper pipe was leaking from a joint before Wrap & Seal Pipe Burst Tape was used to seal the problem area

Wrap & Seal is made from self-fusing silicone and stretches by 300 percent. When wrapped around a pipe, it forms a solid rubber band over holes, cracks, and leaking joints.

Having cleaned the pipe completely, the property owner applied Wrap & Seal around the badly soldered joint, ensuring a tight seal to permanently repair the leak.

The repair was completed in under 30 minutes. The property owner said afterwards had they known that fixing a leaking joint could be so straightforward, they would never have ignored the leak or left the problem unrepaired for so long.

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 fix a leaking pipe with a SylWrap Repair Kit

Sylmasta filmed a live leak pipe repair demonstration video showing how a SylWrap Pipe Repair Kit can permanently fix a leaking pipe in under 30 minutes

This video was filmed during an on-site demonstration as part of the Sylmasta Roadshow, showcasing to a water supply company in the United Kingdom how a SylWrap Pipe Repair Kit can permanently fix a live leak in under 30 minutes.

About this Pipe Repair Video

The pipe being repaired was made from steel and had a large split cut into it. To showcase the pressure resistance of a SylWrap Pipe Repair Kit to the water company, the pipe was put under 6bar for the demonstration.

Wrap & Seal Pipe Burst Tape was used to seal the initial leak. Wrap & Seal is made from self-fusing silicone and stretches by three times its length. When wrapped around a leaking pipe, it forms a solid rubber band over the leak area, creating a high-pressure repair.

The initial repair was then overwrapped with a SylWrap HD Pipe Repair Bandage. SylWrap is a composite fibreglass repair wrap with a water-activated resin. It is applied to the pipe to provide a rock-hard, impact resistant layer, reinforcing the repair through a protective shell.

Only one Wrap & Seal was used for this repair, but additional tapes could have increased the pressure resistance up to 30bar. To determine how many tapes are needed for a specific application, please input your data to the Wrap & Seal Repair Calculator to formulate the optimum repair.

This type of live leak repair using Wrap & Seal and SylWrap HD Pipe is also effective on pipes made of copper, PVC plastics, stainless steel, malleable iron, GRP, ceramic, clay, concrete, lead, and rubber.

Repairs can be made to leaking pipes in domestic settings, such as kitchen and bathroom pipes, as well as major pipelines involved in infrastructure and industry.

Both Wrap & Seal and SylWrap HD have WRAS approval, meaning that they can be used safely on pipes carrying drinking water. Repairs are temperature resistant to 200ºC and effective on pipes carrying hot and cold water and chemicals.

No training is required to make a SylWrap live leak repair; simply follow the instructions provided with the product.

Kits to Make This Repair

The SylWrap Universal Pipe Repair Kit enables anyone to fix a leaking pipe inside of 30 minutes

SylWrap Universal Pipe Repair Kit
Contains Superfast Epoxy Putty, Wrap & Seal and SylWrap HD for making a permanent live leak repair

SylWrap Pipe Repair Contractor Case
Easy-to-store, robust red case with enough SylWrap Pipe Repair products to make up to six permanent live leak repairs

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 resin cast using a two-part silicone mould

Sylmasta instructional video showing how to resin cast a highly detailed copy of a machine gear using polyurethane casting resin and a mould made from silicone moulding rubber

This instructional video shows how Sylmasta casting resins and silicone moulding rubber are used when creating a two-part mould to resin cast accurate copies of masters, in this case a gear.

About this Resin Casting & Mould Making Video

The video takes you through the entire process of casting and moulding a copy of a gear, using Sylmasta 380 Silicone Moulding Rubber and Polycast G26 Polyurethane Casting Resin.

A two-part mould was used and the same process can be followed using any of the various grades of Sylmasta rubbers and different viscosity casting resins, all of which are detailed at the bottom of the page.

The application began with the creation of a mould box, made using plasticard, Sylmasta CAE1500 High Viscosity Superglue and plasticine. The Moulding Rubber was then mixed with catalyst added to the rubber and stirred until streak free.

Once mixing had been completed, the Moulding Rubber was poured into the box to create the first component of the two-part mould. After the specified de-moulding had passed, the plasticine and the original gear were removed and mould release agent applied to prevent the two parts sticking.

More Moulding Rubber was then poured into the box to create the second component of the two-part mould. Once this had set, the mould was completed and removed from the box.

Next, the Casting Resin was mixed to the prescribed ratios and a monoject syringe used to inject the resin into the mould. After the recommended curing time had passed, the mould was opened up with a highly-detailed resin copy of the original gear left inside.

As the video shows, resin cast machine parts enable a user to make multiple copies of masters, offering a cheaper and faster alternative to fabricating new versions of parts. Moulds made from Sylmasta Silicone Moulding Rubbers are reusable, allowing up to 20 copies to be made from one mould.

The various accessories used throughout the process can be purchased alongside resins and rubbers as part of the Sylmasta Casting Kit. They are also available to purchase separately through SylCreate, Sylmasta’s specialist website dedicated to model making, craft, and restoration customers.

Casting & Moulding Kits

Sylmasta Casting Kit
Contains all the products and equipment needed to start resin casting and producing high-quality moulds

Sylmasta Casting Kit XL
Five times as much Resin and twice as much Moulding Rubber as the standard Kit

Casting Resins

Silicone Moulding Rubbers

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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Emergency pipe repair: A lesson from Hampshire in why you should always be prepared to fix a leak

A carpenter accidentally cut through a water pipe at a home in Essex but with no emergency pipe repair solution available, significant damage was caused

Why flooring and carpeting companies should always be prepared for pipework disasters

Emergency pipe repair is not just for plumbers. Pipes are everywhere and many trades encounter them on a daily basis. Electricians, builders, decorators, gardeners, carpenters, carpet fitters… the list goes on.

Having contact with pipes means that there is always a danger of accidentally cutting into one. When this happens, the damage can be severe, as a family in Hampshire discovered to their cost.

The Newton family were settling into their new home with their 12-month-old baby. Their kitchen had been refurbished and extended, the property newly decorated and new carpets fitted. Only one thing was bothering them – a loud, creaking nose from the floorboards in the bedroom.

They thought it may have been caused by all the construction work below. To get to the bottom of the problem, they called in a trained carpenter to investigate.

The upstairs flooring was chipboard rather than floorboards, so a section had to be cut away to gain access to the RSJ below. It was then decided that additional screws in the joists might reduce the creaking.

Unfortunately, the carpenter had not fully investigated what was lurking underneath the chipboard, resulting in the screws being placed in a perfect line down the centre of the mains water pipe supplying the tank in the loft.

Initially at least, the screws were not a major problem. Worse was to come however when the carpenter went to remove another section of chipboard, only to end up cutting through the pipe with a circular saw.

  • Damaged caused by a carpenter who accidentally drilled through a pipe with no emergency pipe repair kit available
  • Damage caused to a water pipe by a carpenter when no SylWrap Emergency Pipe Repair Kit was available
The carpenter drilled screws into the pipe located underneath floorboards in the bedroom before cutting through it with a circular saw

Catastrophic damage had now been caused to the already perforated pipe. With mains water gushing into the floor space, the family rushed to turn off the supply, only to find that the stopcock was seized up and could not be operated manually.

After some time, a wrench was found and the water turned off. The family then called a plumber to shut off the damaged section of pipe so that the home could still run other water services.

The plumber cut the pipe, plugged what he thought was the end leading to the mains, and turned the water back on. Alas, he had plugged the wrong end and so once more mains water was pumping into the floor space from an open-ended pipe.

Supply was again shut off and the plumber rectified the error. Still, several more gallons of water had been released, adding to the destruction of the home.

The damage led to damp and water ingress in the new kitchen and dining room. Much of downstairs had to be replastered and redecorated, as did the master bedroom where the pipe breach had occurred.

New carpet and underlay had to be fitted and a new living room ceiling. The home was also without water, heating and electricity for four days – hardly a good situation at the best of times, but catastrophic with a 12-month-old baby.

The water damage caused by the leaking pipe was extensive

Had the carpenter kept a SylWrap Pipe Repair Kit on his van in case of emergency, then all of that could have been avoided. SylWrap enables any user to permanently repair a leaking pipe in less than 30 minutes even when water flow cannot be turned off.

A SylWrap Kit can make repairs pressure resistant to 30bar and temperature resistant to to 200ºC. They are WRAS approved so can be used safely on pipes carrying drinking water and are effective on pipes of any size made from copper, PVC plastics, steel, stainless steel, malleable iron, GRP, ceramic, clay, concrete, lead, and rubber.

With SylWrap, the leak could have been minimised within minutes, preventing it wreaking such destruction. A full, permanent repair would have made the pipe serviceable and mains water could have been reinstated.

Accidents happen, as the Newton family, the carpenter and the plumber involved found out to their cost. Being prepared for emergencies by carrying a SylWrap Kit can help prevent them turning into the sort of disaster seen in Hampshire.

To speak to a Sylmasta technician about how your company might benefit from stocking SylWrap Pipe Repair solutions in case of an emergency, then please contact Sylmasta via email or on +44 (0)1444 831459.

SylWrap Emergency Pipe Repair Kits

The SylWrap Universal Pipe Repair Kit enables anyone to fix a leaking pipe inside of 30 minutes

SylWrap Universal Pipe Repair Kit
Contains Superfast Epoxy Putty, Wrap & Seal Pipe Burst Tape and SylWrap HD Pipe Repair Bandage for permanent live leak repairs

SylWrap Pipe Repair Contractor Case
Easy-to-store, robust red case with enough SylWrap Pipe Repair products to make up to six permanent live leak repairs

Repairs Made With SylWrap

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Case Study: Chip Filler Repair to a Damaged £500 Designer Bar Stool Made of SMC

A homeowner uses Sylmasta AB Original Epoxy Putty as a filler to repair a chip in an SMC designer bar stool

Money for the bar – a Sylmasta AB Epoxy Putty filler repair to a chip in an SMC bar stool saves a homeowner £222

When a designer bar stool made of a difficult-to-repair compound called SMC suffered a chip after it was knocked over, the owner sought a cost-effective DIY filler repair method after being quoted £222 by a restoration company.

Case Study Data

Repair Type
SMC filler repair
Defect
Chip in designer bar stool

Products Used

Sylmasta AB Original Epoxy Putty
Epoxy putty which bonds to all materials and is easy to shape for use as a filler

Case Study PDF

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Case Study Details

The homeowner had a beloved set of white designer bar stools worth around £500 each. Their children unfortunately knocked one of the stools over whilst playing, causing a large chip to the edge of the seat made from a difficult-to-repair material called SMC.

SMC is a moulding compound with an inbuilt mould release agent which can be inconsistent, which also meant that reattaching broken fragments was unlikely to be successful.

Each bar stool cost £500. To restore the chip would have cost £220

A professional restoration company quoted £222 to make a repair. The owner therefore decided to try and find a means of making a more cost-effective DIY repair to their damaged stool.

They consulted Sylmasta, who were able to recommend the use of Sylmasta AB Original Epoxy Putty, as although there was little chance of glues or adhesives forming a suitable bond with the SMC, Sylmasta AB would be able to anchor itself into the cavity.

  • Chip in a designer bar stool made from SMC prior to undergoing a filler repair using Sylmasta AB Epoxy Putty
Chip caused to the stool when it was accidentally knocked over

Sylmasta AB Original has a two-hour work time, offering plenty of time for the epoxy putty to be moulded, shaped and applied without the threat of premature curing.

Careful application of Sylmasta AB filled the chip in the stool. The homeowner was even able to recreate the pattern of the seat, using a brush to slightly indent the putty before it set.

  • Sylmasta AB Original Epoxy Putty used to repair a chipped bar stool
  • Reapir of a chip in an SMC designer bar stool made using Sylmasta AB Epoxy Putty Filler
Sylmasta AB filled the chip and was then painted to seamlessly blend in with the seat

AB Original sets to off-white as standard, but it can be painted once cured. The owner managed to colour-match a paint to the exact colour of the bar stool, ensuring that the epoxy putty blended in seamlessly with the rest of the seat.

The repair required only one 250g kit of AB Original at a cost of just £12.60 plus carriage – a far cry from the original £222 quote provided by the restoration company.

Plenty of epoxy putty was left over, and it remains reusable when kept in its original packaging – good news in the event of any future accidents involving the £500 designer bar stools.

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: Stainless Steel Pipe Repair Inside a Biomass Plant Heating Tank

A stainless steel pipe in a biomass power plant at a UK farm required a different live leak repair using a SylWrap Universal Pipe Repair Kit

SylWrap and biomass – the repair of an inaccessible stainless steel pipe in a biomass plant heating tank

Small pieces of farmyard debris had inadvertently entered a Norfolk farm’s biomass plant as part of feedstock, breaching a stainless steel pipe at the top of a 20 feet tall heating tank which now required a flexible and lightweight repair carried out from a ladder.

Case Study Data

Site
Biomass plant on an agricultural site
Location
Norfolk, United Kingdom
Repair Type
Leak Repair
Defect
Damaged stainless steel pipe

Products Used

Wrap & Seal Pipe Burst Tape
Repair tape with high pressure and temperature resistance to seal the leak

SylWrap HD Pipe Repair Bandage
Provided an impact-resistant layer to protect the pipe from further damage

SylWrap Universal Pipe Repair Kit
The products were supplied to the farm in a Universal Pipe Repair Kit

Case Study PDF

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Case Study Details

Anaerobic digester biomass plants are becoming more common on farms in the United Kingdom. They turn waste organic material – known as feedstock – into gas used for fuel and nutrients for crops. Feedstock can include specially grown plant matter, other waste plant material and animal manure.

At the core of a biomass plant system is its digester. Here, the feedstock is fed into an airless container where it ferments. A gas called biogas is captured from the process and used for fuel. The farm uses this fuel to power itself and can even sell surplus energy to the national grid.

The remaining material is known as digestate and is separated into liquid and solid form. The liquid digestate is sprayed back onto the farm as fertiliser. The dried-out solids have multiple uses, including in animal bedding and creating fibre plant pots.

Before adding the initial feedstock to the digester, the biomass plant on the farm in Norfolk had a pre-heating tank. Here, the farm mixed feedstock with some liquid digestate and heated it to the same temperature as the main digester. This enabled them to avoid adding cold feedstock straight to the digester, which can impact on the fermentation process.

A leaking stainless steel pipe in a biomass power plant boiler is repaired with a SylWrap Universal Pipe Repair Kit
The damaged pipe was located high up the inside of the heating tank

Multiple stainless steel pipes were located around the inside of the heating tank. It was one of these towards the very top which had become damaged when small pieces of farmyard debris had inadvertently been mixed in with the feedstock and dropped into the tank from the inlet above.

The farm’s preferred method of dealing with pipe repair applications was to weld. This though was not feasible; the leaking stainless steel pipe was located in a confined space at a height of 20 feet with access only available via a ladder.

To repair the leaking pipe in the biomass boiler power plant, the farm therefore needed a flexible repair method involving lightweight materials which could be easily applied from the top of a ladder.

The damaged section of steel pipe was only accessible from the top of a ladder

Sylmasta recommended a SylWrap Universal Pipe Repair Kit for the application. Wrap & Seal Pipe Burst Tape was wrapped around the pipe, fusing into a solid rubber band over the leak area for a high-pressure repair.

A SylWrap HD Pipe Repair Bandage was then applied over the top of the Wrap & Seal. SylWrap HD features a water-activated resin. It cures within five minutes to provide a rock-hard, impact resistant layer to the pipe.

The materials in the SylWrap Universal Pipe Repair Kit are temperature resistant to 200ºC, enabling the repair to withstand conditions within the heating tank. To further protect the pipe, a steel deflector plate was tied to the top of the SylWrap HD Bandage.

A steel deflector plate was tied to the top of the SylWrap HD Bandage after completion of the repair

Completing the repair took less than 30 minutes, cutting downtime of the biomass plant to a minimum. It was carried out by the farm’s own engineers, negating the need to hire contractors, and cost a fraction of fitting a replacement pipe.

The engineer in charge of the repair told Sylmasta afterwards he was pleased with how straightforward the application had been. With pipes a huge part of biomass systems and agriculture in general, Sylmasta are now advising on other ways in which their pipe repair solutions could benefit the sector.

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: Argentina Oil Well 900mm Steel Pipe Surface Restoration & Repair

A 900mm steel pipe in an oil well in Argentina was badly corroded and leaking before Sylmasta carried out a repair

Well, well, well – A SylWrap pipe repair keeps the oil pumping at a well in Argentina

An oil well in Argentina needed to repair a badly corroded, ruptured 900mm steel pipe if they were to keep the oil pumping. When a pipe repair clamp failed because of the leak being positioned on a tee, they turned to a more versatile Sylmasta repair

Case Study Data

Site
Oil well
Location
Argentina
Repair Type
Leak repair and corrosion protection
Defect
Pitting and cracking on a 900mm steel pipe

Products Used

Superfast Copper Epoxy Putty Stick
Fast-working epoxy putty sealed cracks in the pipe and smoothed off pitting caused by corrosion

Wrap & Seal Pipe Burst Tape
Repair tape with high chemical resistance used to reinforce the epoxy putty

SylWrap HD Pipe Repair Bandage
Applied over the repair to provide a layer of protection to a vast section of pipe

Case Study PDF

Download

Case Study Review

The 900mm steel pipe pumped water into the well, filling it and in turn pushing oil towards the top for extraction. If the pipe was unable to supply the well with sufficient levels of water, then removing oil became extremely difficult.

Corrosion to the pipe had caused heavy pitting and a number of ruptures to appear. The oil well initially attempted to seal the pipe using two repair clamps.

A 900mm steel pipe in an oil well at Argentina with a pipe repair clamp applied
The initial repair using a pipe repair clamp failed

Problematically, the leak area was located close to a tee and a welded joint, preventing the repair clamp from working effectively.

A more flexible repair method was required and so the oil well turned to Sylmasta for a solution. Superfast Copper Epoxy Putty was used to plug the holes in the pipe and to smooth off the damage caused by corrosion, restoring the surface profile of the pipe.

A 900mm steel pipe showing signs of serious surface damage caused by corrosion
Surface damage caused to the steel pipe through corrosion
Superfast Copper Epoxy Putty applied to a leaking steel pipe in an oil well
Superfast Copper Epoxy Putty applied to seal cracks and restore surface profile

Because the exterior of the steel pipe was extremely oily, the oil well decided to reinforce the Superfast Copper with Wrap & Seal Pipe Burst Tape.

Combining a self-fusing silicone repair tape like Wrap & Seal with Superfast Copper increased pressure resistance and chemical protection.

The entire repair was then overwrapped with SylWrap HD Pipe Bandage. The flexibility of SylWrap HD meant that it could be easily applied to the pipe around both the tee and the welded joint.

Wrap & Seal Pipe Burst Tape applied to a 900mm steel pipe
Wrap & Seal Pipe Burst Tape provided further pressure and chemical resistance
SylWrap HD Pipe Repair Bandage applied to a badly corroded, leaking 900mm steel pipe at an Argentinian oil well
The repair of the 900mm steel pipe was completed with SylWrap HD Pipe Repair Bandages

SylWrap HD provided an impact-resistant, rock-hard layer to the repaired damage area, protecting a vast section of pipe from future corrosion, breaches, and general wear and tear.

Despite the size of the pipe and the challenges posed by the tee and welded joint, the repair was a complete success.

Within two hours, water was again filling the well. Oil extraction could resume at a fraction of what a replacement pipe would have cost in new fittings, installation and downtime whilst the oil well was out of operation.

Although this particular repair was made with Superfast Copper, Superfast Steel Epoxy Putty Stick would have been equally effective had it been available at the time.

Superfast Steel, Wrap & Seal Pipe and SylWrap HD can all be purchased as part of the SylWrap Universal Pipe Repair Kit for fixing live leaks.

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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How much waterproof pipe repair tape do I need to seal my leak?

Wrap & Seal waterproof pipe repair tape can make high-pressure live leak repairs to pipes capable of holding up to 30bar

Introducing the Wrap & Seal Pipe Burst Tape Repair Calculator

Using a waterproof pipe repair tape to fix a leaking pipe just became that little bit easier thanks to the introduction of the Sylmasta Wrap & Seal Pipe Burst Tape Repair Calculator.

Gone are the days of trying to manually work out how many tapes are needed to make a repair with high enough pressure resistance. Simply enter the data about your repair into the Sylmasta Wrap & Seal Calculator and it will do the rest for you.

For fixing pipes in domestic plumbing, using one 25mm x 2m Wrap & Seal has usually been suitable. This small version of Sylmasta’s waterproof pipe repair tape holds pressure up to 5bar and with most plumbing applications operating at between 1bar and 2bar, there has never been much confusion over the quantity of tape required.

When it comes to larger, industrial repairs however, clients have not always been sure of the number of Wrap & Seal required. Factors which influence the number of tapes include pipe pressure, pipe diameter, the dimensions of the crack, and the size of Wrap & Seal being purchased.

For complex applications, this would often lead to clients having to contact Sylmasta before procurement to ascertain the quantity of waterproof repair tape required.

A combination of extensive testing at Sylmasta HQ and the introduction of the Pipe Burst Tape Repair Calculator removes that additional layer from the buying process. Sylmasta’s clients can now simply enter their repair data on the relevant product page, discover the number of Wrap & Seals their repair requires and then order accordingly.

To use the Calculator, a customer enters the water pressure of the repair, the diameter of the pipe in millimetres, and the length of the crack. For pinhole leaks, the repair length field is left blank.

Once they have entered their data, selecting the size of a specific Wrap & Seal Tape will show the quantity of that specific tape recommended for completing the repair. You can try the Calculator for yourself:

Wrap & Seal is made from self-fusing silicone, is twice as thick as most other waterproof repair tapes and stretches by 300 percent. It features a unique tapered profile which prevents water tacking underneath.

As it is wrapped around a pipe, Wrap & Seal forms a solid rubber band over the leak area for a high-pressure repair. Additional tapes will bond to previously applied layers, enabling a repair to be built capable of holding up to 30bar.

The Repair Calculator has been added to the product pages of Wrap & Seal Pipe Burst Tape, the SylWrap Universal Pipe Repair Kit, and the SylWrap Pipe Contractor Case.

Wrap & Seal is available in three sizes when purchased as a standalone product; Small 25m x 2m, Large 50mm x 4m, X-Large 50mm x 11m.

The Universal Pipe Repair Kit contains one roll of Wrap & Seal alongside Superfast Steel Epoxy Putty and a SylWrap HD Pipe Repair Bandage. Additional Wrap & Seal can be purchased separately to increase the pressure resistance of repairs made with the Universal Kit. The Repair Calculator now formulates how many additional tapes are required prior to purchase.

A SylWrap Contractor Case features multiple Wrap & Seal and SylWrap HD along with Superfast Steel. It allows regular pipe repair users, including water companies and facilities management, to make up to six live leak repairs at a cheaper-cost-per repair than when using individual kits.

Contractor Case users can now determine the number of Wrap & Seal they require from their Case to carry out a high-pressure repair. They can also order any additional tapes as recommended.

(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. If you are unsure, then more than one Wrap & Seal can be used to stop the leak.)

If you have any question about making a repair using Wrap & Seal Pipe Burst Tape or require technical assistance, then please contact Sylmasta via email or on +44 (0)1444 831459 and a technician will be happy to advise you.

Wrap & Seal Pipe Repairs