Author: Scott McCarthy

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

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

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

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

Case Study Data

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

Products Used

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

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Case Study Data

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

Products Used

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

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

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Case Study: Aluminium Conduit Pipe Carrying Cables Underneath Train Repair

All aboard for the SylWrap HD conduit pipe repair which helped keep a train on the tracks

Aluminium conduit pipe carrying cables underneath a train undergoes repair and reinforcement using SylWrap HD Pipe Repair Bandage after stones, ballast and other debris flying up from the railway track bed caused impact damage.

Case Study Data

Site
Railway network
Location
United Kingdom
Repair Type
Conduit pipe repair
Defect
Damaged aluminium conduit pipe carrying electrical cables underneath train

Products Used

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin encompasses pipes with a rock-hard, impact resistant outer sleeve

Case Study PDF

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Case Study Details

The railway network in some areas of the United Kingdom operates a third rail system. Rather than electricity coming from overhead cables, it is supplied to the train from a powered conductor rail on the track bed.

Metal blocks – known as shoegears – underneath the train make contact with the third rail. They take electricity from it, which then flows into the power system of the train through a series of cables also attached underneath.

Sylmasta were approached by a rail operator whose under-train cables were housed in aluminium conduit pipe. When the train hit high speeds on sections of the railway where the ballast track bed was loose, stones were becoming airborne and damaging the pipe.

Over time, this repeated impact caused tears to appear in the aluminium conduit. The cables inside were subsequently left dangerously exposed and at risk of being damaged themselves.

Impact caused by stones becoming airborne from the track bed had left the aluminium conduit pipe underneath the train damaged

The rail operator was looking to repair the holes in the aluminium and provide better protection from future damage, without having to take the train out of service for a long period of time to replace the entire conduit pipe.

Sylmasta recommended wrapping SylWrap HD Pipe Repair Bandage along the conduit pipe to seal the tears and provide the aluminium with a robust outer casing.

Unlike other suppliers of moisture cured composite wraps who import from Asia or North America, Sylmasta manufacture the SylWrap range of pipe repair bandages at their site in the UK.

It was therefore possible to produce a customised SylWrap HD based on the rail operator’s requirements. Black dye was used, colouring the bandages black instead of the standard white to better disguise the repair.

SylWrap HD Pipe Repair Bandage used to reinforce and protect aluminium conduit pipe attached underneath a train
SylWrap HD Pipe Repair Bandage was wrapped along the pipe, providing the aluminium with an impact-resistant outer protective shell

Additional inhibitors were also added to make the bandages more fire retardant, enabling them to comply with stringent regulations governing materials used on the railway.

Rail workers accessed the bottom of the train and applied eight layers of SylWrap HD to all areas of the conduit pipe requiring repair and protection. The fast-working resin set within minutes, curing to form a rock-hard shell offering total resistance to impact damage.

When stones, ballast and other materials now flew up from the track bed, they would be repelled by SylWrap HD rather than coming into contact with the aluminium conduit pipe.

The repair was completed inside a day and with a huge cost saving compared to replacing the conduit pipe. The train returned to service with the rail operator confident there would be no further damage.

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: Restoration of Clan MacGregor Dalmally Burial Stones Dated 1390-1528

Clan MacGregor Dalmally Burial Stones Restoration featuring a custom coloured Sylmasta AB Original Epoxy Putty

Customised coloured putty restoration puts Clan MacGregor Dalmally Burial Stones back on display for first time in 400 years

Sylmasta manufacture a specialist version of AB Original Epoxy Putty colour-matched to RAL 7037, helping the Clan MacGregor Dalmally Burial Stones go on display inside Glenorchy Parish Church following restoration for the first time in 400 years.

Case Study Data

Site
Church
Location
Scotland
Repair Type
Burial stones restoration
Defect
Pieces missing from base of burial stones

Products Used

Sylmasta AB Original Epoxy Putty
Super-strength epoxy putty which bonds to all materials, filling in and rebuilding large areas of damage

Case Study PDF

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Case Study Details

In 1996, the Clan Gregor Society discovered that seven burial stones sunk into the ground in the churchyard of the Glenorchy Parish Church at Dalmally, near Loch Awe, Scotland, belonged to the ancient chiefs of Clan MacGregor.

The stones were originally placed around the high altar of the church to mark the burial spots of clan chiefs. The oldest belonged to John Macgregor of Glenurquay, who was buried on the north side of the High Altar of the original church in 1390. The most modern came from 1528.

Clan MacGregor fell from favour in the early 1600s. The name was banned by King James VI of Scotland following a particularly bloody bout of violence. It was one of his last acts before travelling to London to take up the British crown following the death of Elizabeth I.

The attempted erasure of Clan MacGregor by King James left them with no castle to call their own and the destruction of almost all their historical objects. The Dalmally Stones are therefore one of the few surviving examples of medieval heritage relating to the ancient Clan, whose proscription lasted 170 years.

It is believed the burial stones were removed from the high altar in 1615 when the church was rebuilt as part of The Reformation. They were taken outside and used to cover other grave plots in the churchyard.

By the time the Clan Gregor Society realised their importance, the burial stones had been on the ground for more than 350 years. Erosion, dirt ingress and other forms of damage as the stones sunk over the course of three centuries had left them in desperate need of conservation.

And so the Clan Gregor Society put together an ambitions plan to raise, restore and then return the Dalmally Stones to display inside the church.

It would take another 26 years until 2022 for the society to secure permissions from religious bodies, heritage societies, local and national government, as well as raising enough funds to make the project a reality.

After that time-consuming process was completed, Graciella Ainsworth Sculpture Conservation were commissioned to restore the stones. One challenge came from huge chunks missing from the base of the stones, leaving them unable to stand on display.

Sylmasta formulated a specialist version of AB Original Epoxy Putty colour-matched to RAL 7307, which the team at Graciela Ainsworth believed to be the closest match to the stones after they underwent thorough cleaning during the restoration process.

Dalmally Burial Stones restoration featuring Sylmasta AB Original Epoxy Putty used to repair missing chunks from base of stone
AB Original rebuilt missing areas at the base of the Dalmally Stones, creating a flat bottom edge to help them be upstanding on display in the church

AB Original was then used to create a flat, bottom edge on each stone, so that they could be placed standing inside the church. 30kg of AB Original was sent to Scotland. The putty was kneaded by hand and then applied to rebuild the bottom of each stone.

The two-hour work time of AB Original allowed for careful, precise application without the threat of premature curing. Once set, AB Original formed a ceramic-like material similar to the original stonework in both texture and colour.

AB Original was colour-matched to RAL 7307 to make the putty unobtrusive against the rest of the stone

After Graciella Ainsworth had completed their restoration of the Dalmally Stones, they were fixed in place inside the church for the first time in 400 years. A dedication ceremony was held as part of a weeklong Clan Gregor celebration, attended by society members who travelled to Scotland from around the world.

The beautiful carvings of knights and delicate patterns decorating the stones – which are considered fine examples of the Loch Awe School – can now be fully appreciated and are preserved for future generations to admire.

Display item at the New Perth Museum similar to the Dalmally Stones which underwent restoration with Sylmasta AB Original Epoxy Putty
Graciella Ainsworth have since used AB Original to create supporting bases for other similar display pieces at the New Perth Museum

AB Original has since been used by Graciella Ainsworth in similar applications, including creating supporting shoes for a series of display pieces at the New Perth Museum.

Sylmasta’s investment in the latest epoxy putty stick manufacturing technology at their site in the United Kingdom means other colour-customised putties can be quickly and easily made for future conservation and restoration projects depending on client requirements.

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

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

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Case Study: Repair of Domestic Water Main Pipe Leaking Due to Stone Damage and Corrosion

A heavily corroded and leaking domestic water main supply pipe undergoes repair and refurbishment

Stone the crows – underground domestic water main pipe damaged by corrosion and imbedded stones kept in service thanks to a homeowner DIY repair

A homeowner undertakes a DIY repair and refurbishment of a 2-metre section of domestic water main supply pipe leaking underneath their driveway because of heavy corrosion and surface damage caused by stones.

Case Study Data

Site
Domestic property
Location
Devon, UK
Repair Type
Leak repair and pipe reinforcement
Defect
Water main supply pipe damaged by heavy corrosion and imbedded stones

Products Used

Superfast Aqua PW Epoxy Putty Stick
WRAS approved epoxy putty with excellent wet surface adhesion, used to seal leaks and fill other imperfections in pipework

Liquid Metal Epoxy Coating
Brush applied coating painted onto pipework to form a new, hard wearing, metallic outer surface with high corrosion resistance

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin encompasses pipes with a rock-hard, impact resistant outer sleeve

Case Study PDF

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Case Study Details

Abnormal levels of water use alerted the homeowner to a potential leak somewhere in their supply system. The problem was soon identified to be underneath the front driveway.

Because the leak was in the pipe between the property and the external stop tap connected to the public supply, repair was the responsibility of the homeowner and not their water supplier.

The homeowner excavated the pipe and discovered it to be heavily corroded. Stones were imbedded deeply at various points across the entire 2-metre line, and the metal had been breached and was leaking in multiple places.

Heavily corroded domestic water main supply pipe also imbedded with stones before a Sylmasta repair sealed and refurbished the line
Excavation revealed the pipe to be heavily corroded with stones also deeply imbedded into the metal

Sealing the leaks would therefore not be enough; the homeowner needed to strengthen the pipe to prevent further damage in the future, before it was reburied under the drive.

Water supply was turned off at the external stop tap and the system drained before the domestic water main pipe repair began. The homeowner then set about thoroughly cleaning the pipe as much as possible.

Stones imbedded in a domestic water main pipe before the line underwent a Sylmasta repair and refurbishment
The pipe exterior was so damaged that simply sealing the leaks would not be enough

This involved removing dirt, followed by surface corrosion. Next came the challenge of the stones, some of which were imbedded so deep into the pipe as to effectively be welded to the metal.

Many of the stones therefore left craters and severe surface damage in the pipe following their removal. These and the other leak areas identified after excavation were repaired with Superfast Aqua PW Epoxy Putty.

Superfast Aqua PW was chosen for its excellent wet surface adhesion; compensating for the possibility some water may have been left behind when the pipe was drained and could seep from the pipe during repair.

It also has WRAS Approval, meaning it is safe to use on pipes and fittings carrying drinking water. This was an important consideration with the main bringing supplies from the public network into the property.

The putty was kneaded by hand until it turned a uniform white colour. Whilst still soft, it was pushed into all leak holes and craters in the pipe. Within 20 minutes, Superfast Aqua PW had cured to a solid material, filling all damage.

Liquid Metal Epoxy Coating was then used to reinforce and refurbish the brittle steel. The homeowner painted 1kg of Liquid Metal in two coatings over the entire pipe and all joints. It set to form a new smooth, metallic, hard-wearing outer surface as a shield against corrosion.

Liquid Metal Epoxy Coating painted onto a pipe to refurbish after heavy corrosion in a domestic water main pipe repair
After surface damage was repaired with Superfast Aqua PW, Liquid Metal was coated across the entire pipe and all joints

Further reinforcement was provided by SylWrap HD Pipe Repair Bandage. SylWrap is a composite wrap with a water-activated resin which sets rock-hard in minutes.

Three SYL309HD Bandages were wrapped across the entire 2-metre section, including around a 90-degree elbow and another difficult geometry where the pipe began to climb up a wall.

SylWrap HD Pipe Repair Bandage used as a final layer of rock hard protection in a domestic water main pipe repair damaged by corrosion and imbedded stones
SylWrap HD provided the pipe with a rock-hard, impact resistant final layer of protection before it was reburied

The application of SylWrap began whilst the final coating of Liquid Metal remained slightly tacky, improving adhesion between the bandage and the pipe surface.

Once cured, SylWrap provided an impact-resistant sleeve around the pipe – preventing any stones from imbedding themselves and penetrating the water main in future.

The homeowner completed the repair over a weekend; one day for cleaning the pipe, removing debris and sealing holes. The second day for the application of Liquid Metal and SylWrap HD Bandage.

Water supply was turned back on to test the main. The combination of Superfast Aqua PW, Liquid Metal and SylWrap HD easily contained pipe content, as well as offering robust protection and a fully refurbished line. The pipe was then reburied.

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: Leaking Dishwasher 50mm Plastic Pipe Repair in Golf Clubhouse Kitchen

A leaking 50mm plastic pipe connected to a dishwasher undergoes live leak repair at a golf club

SylWrap Universal Pipe Repair Kit seals hole in one with leaking dishwasher pipe repair at golf clubhouse

A dishwasher pipe discovered to be leaking at a golf clubhouse on Sunday morning undergoes repair in under 30 minutes using a SylWrap Universal Pipe Repair Kit, ensuring no disruption to the busy lunchtime service just a few hours away.

Case Study Data

Site
Golf club
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Split in 50mm plastic pipe connected to dishwasher

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating repair tape which fuses to form a solid rubber band, containing pipe content

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to reinforce and protect repairs

SylWrap Universal Pipe Repair Kit
Kit containing products needed to make a single permanent live leak repair in under 30 minutes

Case Study PDF

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Case Study Details

Staff arrived at the golf club on Sunday morning to discover a significant amount of water all over the kitchen floor, surrounding the dishwasher which was always left to run overnight.

After emptying the appliance and pulling it out from its position against the wall, they noticed a 50mm plastic drainpipe at the back of the dishwasher had a split around its diameter.

Staff arrived at the golf course on Sunday morning to discover a split in a 50mm plastic drainpipe connected to the dishwasher

Sunday is the busiest day of the week for the golf club; not just with members playing but also guests drinking in the bar and the restaurant serving brunch and Sunday lunch.

Washing everything by hand until the dishwasher pipe could be fixed by a plumber or replaced would therefore have been almost a full-time job for one member of staff.

The split went around the diameter of the plastic pipe

Worried about the disruption this would cause, the golf club initially considered calling someone in on their day off to try and help manage the load. But before doing that, they contacted the contractor who serviced their drains in the hope he might have a solution.

The contractor kept a stock of Sylmasta products on his van for fixing leaking pipes at hospitals and other facilities. After arriving at the clubhouse, the contractor opted to use a SylWrap Universal Pipe Repair Kit.

SylWrap Universal Pipe Repair Kit used to seal a leaking 50mm plastic pipe attached to a dishwasher at a golf club
A SylWrap Universal Pipe Repair Kit was used to seal the leak

Because the split covered the diameter of the pipe, the contractor applied Wrap & Seal Pipe Burst Tape for the first stage of repair. It was easier to wrap tape over the split than mixing and forming epoxy putty into a sausage before applying it all around the pipe.

Wrap & Seal was stretched by three times its length and as it was wrapped, fused together to form a solid rubber band exerting enough force over the leak to withstand 25 bar pressure.

This easily contained the leak in the dishwasher drain pipe, which operated at no more than 2 bar. The repair was then reinforced with SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water-activated resin.

SylWrap HD Pipe Repair Bandage applied around a leaking dishwasher pipe at a golf club
The repair was completed in under 30 minutes

It was wrapped and smoothed over the Wrap & Seal, where it cured within minutes to form a rock-hard, impact resistant layer of protection.

The contractor completed the repair in under 30 minutes before the lunchtime rush began. Thanks to the ease and speed with which the leak was sealed, the dishwasher was back in operation for staff to clear the minimal backlog of dirty dishes from breakfast without needing to clean any by hand.

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: Landscaping Materials Company Repair & Protect Warehouse Metal Pallets

Ceramic Brushable Blue Epoxy Coating is used to repair metal pallets damaged by impact, abrasion and wear

Ceramic Brushable Blue helps a landscaping materials supplier lay a path to metal pallets protection

A landscaping materials company use Ceramic Brushable Epoxy Coating to repair and protect metal pallets at their central warehouse left damaged by years of having heavy and abrasive items like driveway paving, garden slabs and natural stones stacked on them.

Case Study Data

Site
Landscaping materials supplier warehouse
Location
United Kingdom
Repair Type
Metal repair and protection
Defect
Metal pallets damaged and worn by storage of abrasive, heavy materials

Products Used

Ceramic Brushable Epoxy Coating
Epoxy coating reinforced with silicon-carbide which protects metal surfaces against wear, abrasion and impact

Case Study PDF

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Case Study Details

As one of the biggest suppliers of landscaping materials in the United Kingdom, the company had a vast central warehouse storing items which were then sent to distributors around the country.

These materials included driveway paving, garden slabs, kerbs, edges, porcelain, natural stone and bricks. All were stacked and stored on metal pallets.

The weight of these materials, their abrasive nature and the impact from moving them on and off the metal pallets meant that over time, the metalwork began to show visible signs of wear.

Removing all existing pallets from the warehouse and installing replacements would have been a time-consuming and expensive task.

The landscaping company therefore contacted a mechanical engineering specialist who used and distributed Sylmasta products for advice. They suggested Ceramic Brushable Blue Epoxy Coating to repair the metal pallets in the warehouse.

Ceramic Brushable is reinforced with silicon-carbide for hardness and an ultra-smooth finish. It is painted onto parts and surfaces to create an outer layer with extreme resistance to abrasion, corrosion, chemical attack, cavitation, erosion and pitting.

Ceramic Brushable Blue was painted onto the top parts of the metal pallet which came into contact with landscaping materials

Two coatings of Ceramic Brushable were applied to the top part of the pallets which the landscaping materials sat on. It cured to form a hardened shell, protecting the original metalwork against abrasion and impact damage caused by the materials.

Initially, only a few pallets were treated as a trial run to test the performance of Ceramic Brushable. Six months later and there were no visible signs of damage to any of the coatings applied during the trial.

Metal pallets in a landscaping materials supplier warehouse are coated with Ceramic Brushable Epoxy to repair them after impact and abrasion damage
Once cured, Ceramic Brushable formed a silicon-carbide reinforced layer which was ultra-smooth and offered high resistance against impact and abrasion

Satisfied with the performance of Ceramic Brushable, the landscaping company purchased 10kg to repair and protect more metal pallets throughout the warehouse.

They are also now considering opting for a two-layer wear indicator coating, whereby a topcoat of Ceramic Brushable Green or Black is applied over the existing Blue.

When the Blue layer begins to show through, it will indicate a new topcoat of Green or Black is required to maintain suitable protection levels for the pallet.

Having a clear system showing when to reapply Ceramic Brushable will help the company continually extend the lifespan of its metal pallets for years to come.

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: Heat Exchanger Plenum Chamber Corrosion Protection at Power Plant

Corrosion protection given to the inside of a heat exchanger water box using Liquid Metal Epoxy Coating

Productivity improved at power plant as corrosion protection for heat exchanger removes annual repair requirement

Having spent many years annually reapplying a standard epoxy coating to the inside of a heat exchanger plenum chamber, a power plant in Thailand seek a more robust corrosion protection method to improve system efficiency and reduce downtime.

Case Study Data

Site
Power plant
Location
Thailand
Repair Type
Corrosion protection
Defect
Heavily corroded metalwork and parts inside heat exchanger plenum chamber

Products Used

Liquid Metal Epoxy Coating
Brush applied coating which cures to a hard wearing, metallic layer protecting surfaces and parts against corrosion

Case Study PDF

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Case Study Details

A plenum chamber – sometimes known as a water box – is found at the end of a heat exchanger. It supplies and directs the flow of water through the tubes of the heat exchanger.

Conditions inside a plenum chamber are perfect for galvanic corrosion and cavitation. Extreme temperatures, high pressure and unpurified water passing through the box leave the metalwork under constant attack and requiring frequent repair.

The power plant had spent many years using a standard epoxy coating to protect the plenum chamber. The rate of corrosion meant a new coating had to be applied annually.

Conditions inside the plenum chamber were perfect for galvanic corrosion and cavitation

This involved shutting down the system, disassembling the heat exchanger, applying the coating and then putting it all back together. It was a disruptive process which resulted in significant downtime for the plant.

It was therefore decided to find a more robust, effective coating to protect the plenum chamber which did not require yearly reapplication. The plant analysed conditions inside the water box and came up with a specification for their ideal epoxy coating.

Temperature resistance had to be as a high as 149°C with long-term performance at operational temperatures of 25–40°C. It needed to be resistant to pH 8-10 and pressure up to 3 bar. Most importantly, the plant wanted a coating strong enough to last several years at least.

Tubes within the water box and a condenser faceplate were also heavily corroded

Taking these requirements into consideration, Sylmasta recommended using Liquid Metal Epoxy Coating to protect the inside of the plenum chamber, the tubes within the water box and its condenser faceplate.

Liquid Metal is metal-filled, meaning it offers superior corrosion resistance and enhanced durability by creating a thicker, more resilient layer. The cured material has Shore D hardness in excess of 80 and a maximum service temperature of 150°C.

Before application, the metal surface was thoroughly cleaned to remove rust, other contaminants and any traces of the previously applied standard epoxy coatings.

Liquid Metal Epoxy Coating applied to the internal metalwork of a heat exchanger plenum chamber for corrosion protection
Liquid Metal provided a robust protective layer to the internal metalwork of the plenum chamber

Liquid Metal was then painted onto the areas requiring protection using a brush. Three coatings 1mm thick were applied. Liquid Metal has a 90-minute gel and a four hour re-coat time. The entire repair was completed over two days.

Once the final coating had cured, the original metalwork inside the heat exchanger plenum chamber, tubes and the condenser faceplate were covered with a 3mm thick metallic layer, offering ultimate protection against corrosion and cavitation.

Liquid Metal Epoxy Coating used to give corrosion protection to tubes inside a power plant heat exchanger
Corrosion protection given to a condenser faceplate in a heat exchanger at a Thailand power station
Liquid Metal was also applied to the tubes inside the water box and the condenser faceplate

Six months after the repair, the manager of the engineering company responsible for maintenance at the plant contacted Sylmasta with an update.

“I had a good experience with Liquid Metal. We have looked at the heat exchanger and condenser again and the coating has fully performed and protected from corrosion very well.”

“We now want to use Liquid Metal on 22 blowdown tanks at this plant and more systems at other power plants in Thailand where we run maintenance.”

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

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

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Case Study: Repair of Leaking Expansion Joint Fitted to Water Main Pipe on UK Road Bridge

A leaking expansion joint on a 225mm steel water main pipe undergoes repair with Wrap & Seal Pipe Burst Tape

Contracting a leak from an expansion joint – Wrap & Seal repair keeps water supply strong between two counties

A water company in southwest England repair a leaking aluminium expansion joint fitted to a 225mm steel water main pipe, running the length of a suspension bridge carrying a major A road over a river.

Case Study Data

Site
Road suspension bridge
Location
United Kingdom
Repair Type
Expansion joint repair
Defect
Leaking expansion joint fitted to a 225mm steel water main pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating repair tape which fuses to form a solid rubber band, containing high pressure leaks

SylWrap Pipe Repair Contractor Case
Three PB-50x4m Wrap & Seal Tapes were used from a Contractor Case containing enough products to make up to six pipe repairs

Case Study PDF

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Case Study Details

The 335-metre-long suspension bridge linked Devon and Cornwall with the main helping transport water between the two counties. The aluminium expansion joint was fitted to reduce stress on the steel pipe caused by the movement of the bridge.

After it became known the pipe was leaking, a team of engineers accessed the pipe. It ran beneath the road deck of the bridge in a severely constrained space.

The steel water main ran beneath the bridge road deck in a severely constrained space

They discovered a split in the expansion joint between two bellows, through which water was now flowing out. Comparing the position of the fitting from its previous mandatory safety inspection revealed it had moved and contracted significantly.

For this reason, the water company needed a flexible live leak repair solution which could seal the leaking expansion joint but also allow for future movement of the fitting.

The expansion joint was leaking through a split between the final two bellows on the righthand side

They therefore decided to use Wrap & Seal Pipe Burst Tape for the application. Wrap & Seal self-amalgamates as it is wrapped around a pipe, forming a rubber band which exerts pressure over the leak to contain pipe content.

On the day of the repair, the expansion joint had contracted to the point of failure. Whilst this meant the engineers were not battling a stream of water, it reduced the available space between the bellows into which Wrap & Seal could be applied.

Engineers apply Wrap & Seal Pipe Burst Tape during the repair of a 225mm steel water pipe expansion joint
Wrap & Seal was wrapped between the bellows, over the split in the joint

The versatility of Wrap & Seal still made a repair possible. Despite the space constraints, the engineers were able to stretch the tape by its maximum 300 percent to achieve full amalgamation.

Multiple Wrap & Seals wrapped on top of each other fuse together in the same way, increasing pressure resistance. Three PB-50x4m Wrap & Seals were applied until no more water was seeping from the pipe, leaving the engineers satisfied the leak had been fully arrested.

Wrap & Seal Pipe Burst Tape used to repair a leaking expansion joint on a 225mm steel water main pipe
The completed repair left a solid rubber band compacted over the leak, containing pipe content

By the time the repair was complete, a solid rubber band had been compacted over the leak, filling the gap between the two bellows. Measurements were then taken of the expansion joint, so a replacement could be made and fitted at a later date.

The three PB-50x4m Wrap & Seal Tapes used in the repair came from a SYL-PRO-50-150 SylWrap Pipe Repair Contractor Case, a product the water company had recently approved to be carried by all engineers for use on their network.

A Contractor Case is easily stored on-site or on a van and contains enough Wrap & Seal, Superfast Steel Epoxy Putty and SylWrap HD Pipe Repair Bandages to make up to six WRAS approved live leak repairs.

Feeding back to Sylmasta after the expansion joint repair, the engineers said: “The SylWrap Contractor Case was extremely useful in the scenario. Having a variety of products within the repair pack provided plenty of options to us once the problem had been fully evaluated.”

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

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

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Case Study: Bilge Pipe Leaking Through Corroded Welded Joint Repair On Board Superyacht

SylWrap Pipe Repair Kit used to seal a pinhole leak in a steel bilge pipe onboard a superyacht

The seventy pound bilge pipe repair which kept a multimillion dollar superyacht sailing safely

A leaking bilge pipe on board a multimillion dollar superyacht undergoes repair after corrosion at a welded joint caused a hole to appear in an area of the steel line where it was impossible to fit a clamp.

Case Study Data

Site
Superyacht
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Hole in a steel bilge pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape fuses to form a solid rubber band, sealing high pressure leaks

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to reinforce and protect repairs

SylWrap Pipe Repair Contractor Case
Products supplied in a Contractor Case, enabling up to six live leak repairs to be made to pipes of different diameters

Case Study PDF

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Case Study Details

Bilge pumps are one of the most important systems on any boat for keeping the vessel dry and safe. Water naturally collects at the lowest point on board a boat from everyday sources like rainwater, waves when sailing rough seas and spray.

The bilge pump removes this excess water and other fluids which may have found their way to the bottom of the vessel – such as engine oil – by pumping it through a series of pipes and out via an exit hole in the hull.

This prevents flooding impacting the balance of the boat and causing overflow into other areas. Oily water coming into contact with machinery or electrics in the engine room for example can cause serious problems, potentially destroying a boat’s system.

In the event of a hull breach, a bilge pump removing water as it is being taken onboard buys time to slow or repair the leak. If major damage is obtained, the bilge pump allows for safe evacuation by helping keep the vessel afloat for longer than would otherwise be possible.

Corrosion had caused the leak in the superyacht bilge pipe by attacking the steel at a welded joint. The subsequent hole was close to a 90-degree elbow and the hull of the boat.

It was also surrounded by other pipes and equipment, making it impossible to repair with a clamp. With water jetting out the pipe whenever the bilge pump went into operation, the hole needed to be urgently sealed until a new pipe could be fabricated and installed.

Hole caused by corrosion in a bilge pipe onboard a superyacht leaking before a SylWrap repair
Corrosion attacking a welded joint had caused a hole to appear in the steel bilge pipe

The superyacht were sent a SylWrap Pipe Repair Contractor Case, from which Wrap & Seal Pipe Burst Tape was used to seal the leak. Wrap & Seal is a self-amalgamating repair tape with a unique tapered profile which stretches by three times its length.

As it was wrapped around the pipe, it fused to form a solid rubber band capable of containing the water sent through the line by the bilge pump at around 2 bar pressure.

The repair was then reinforced using a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin. It was wrapped and smoothed around the pipe, curing in minutes to form a rock hard, impact resistant sleeve.

SylWrap HD Pipe Repair Bandage used to seal a leaking bilge pipe onboard a superyacht
The pipe was repaired using Wrap & Seal Pipe Burst Tape before overwrapping with SylWrap HD Pipe Repair Bandage

Completing the bilge pipe repair took under 30 minutes at a material cost of a little less than £70. And having discovered how quick and easy a SylWrap repair is, the superyacht now permanently carries a Pipe Repair Contractor Case on board.

The Case contains enough products to make up to six live leak repairs to pipes of different diameters. It is easily stored onboard and means repairs can be made to any boat pipes on the superyacht as soon as leaks develop – even when sailing the high seas.

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

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