Author: Scott McCarthy

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Case Study: Oil Refinery Repair Cooling Pipe System Attacked by Microbially Induced Corrosion

An oil refinery repair welded joints leaking due to microbially induced corrosion in the stainless steel water cooling pipe system

MIC at oil refinery – leaking joints in a water cooling system undergo repair to keep facility online despite microbially induced corrosion

A significant pipe repair programme at an oil refinery seals leaks in a stainless steel water cooling system after microbially induced corrosion caused the failure of welded joints across the site.

Case Study Data

Site
Oil refinery
Location
Middle East
Repair Type
Live leak pipe repair
Defect
Leaking welded joints in stainless steel water cooling system caused by microbially induced corrosion

Products Used

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

SylPad Pressure Resistance Multiplier
Increases the pressure resistance of Wrap & Seal by up to three times when making live leak repairs to pipes over 150mm diameter

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap sets rock hard, reinforcing and protecting the initial Wrap & Seal repair

SylWrap Pipe Repair Contractor Case
Easy-to-store Case containing enough Wrap & Seal and SylWrap to make multiple live leak repairs on pipes of various diameters

Case Study PDF

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Case Study Details

The stainless steel water cooling system at the oil refinery was meant to have a lifespan of up to 50 years, yet numerous welded joints across the site were already starting to fail after less than half that time.

Microbially induced corrosion was found to be the cause, a type of corrosion relatively little is known about compared to other forms. It occurs when microbes fix to a surface, producing a biofilm layer where multiple bacteria combine to accelerate the corrosive process.

This biofilm affects the electrochemical environment in multiple ways, including changing ion concentrations, pH values, oxidation levels and creating hydrogen sulphide.

As more biofilm layers form, the bacteria and microbes are given greater protection from treatment methods such as biocides, chemicals and temperature treatments. It becomes increasingly difficult to slow corrosion or eliminate microbes from the pipe system.

Stainless steel normally has enhanced protection against corrosion thanks to its passivation layer, which prohibits microbes attaching and makes a surface less prone to developing biofilms. But if the passivation layer is damaged, microbially induced corrosion will take place.

Installation of the water cooling system at the oil refinery included welding joints together. Unbeknown to the refinery, this had weakened the internal passivation layer of the stainless steel pipework.

When the water cooling system went live, microbes in the water were able to settle on the uneven surface at each welded joint. Bacteria collected and a corrosive action began between the metal and the microbes, attacking the stainless steel from the inside.

Eventually, a series of leaks appeared at welded joints throughout the water cooling system. This represented a major problem at a relatively new and expensively built facility. Replacing the stainless steel pipework was not an option due to the cost and disruption it would cause.

With every welded pipe joint now a potential point of failure, the oil refinery contacted Sylmasta to find a repair solution. Sylmasta recommended the refinery stock a range of different sized Wrap & Seal Pipe Burst Tape and SylWrap HD Pipe Repair Bandages, which permanently seal live leaks when used in conjunction.

Online pipe repair capability was essential to the oil refinery as draining the system would result in at least five days loss of production, along with vast costs for diversion of water.

Over 500 SylWrap HD Bandages and 1,700 Wrap & Seal Tapes were sent to the refinery. Sylmasta also flew to the Middle East and spent a week training, testing and certifying refinery installers and supervisors on using the products.

Workers were shown how to apply Wrap & Seal for high-pressure live leak repair. Wrap & Seal stretches by three times its length and amalgamates together, fusing to form a solid rubber band containing pipe content.

Wrap & Seal Pipe Burst Tape used to repair leaking welded joints in a water cooling pipe system
Multiple Wrap & Seal Tapes applied to leaking welded joints in the water cooling system built repairs with pressure resistance up to 10 bar

Multiple Wrap & Seal Tapes applied on top of each other amalgamate in the same way, building pressure resistance up to 30 bar. This was more than suitable for the cooling system, operating at a maximum 10 bar pressure.

For pipework 150mm diameter or above, workers were also trained in using SylPad Pressure Resistance Multiplier. SylPad is applied alongside Wrap & Seal when making live leak repairs to pipes 150mm diameter and above.

It better concentrates the pressure resistance of Wrap & Seal directly over the leak by directing more of the Tape’s elastic force downwards. Depending on pipe size, nature of the leak and repair quality, SylPad can increase the pressure resistance of Wrap & Seal by up to three times.

The final stage of repair involves overwrapping with SylWrap Bandage. SylWrap is a composite repair wrap with a water-activated resin which sets rock hard in minutes. It provides an impact resistant protective sleeve, reinforcing the repair.

SylWrap Pipe Repair Bandage applied to leaking welded joints on a stainless steel water cooling system at an oil refinery
SylWrap HD provided a rock hard, impact resistant protective sleeve around repairs – which could be made to difficult sections of pipes, including where the water cooling system ran overhead

Since Sylmasta visited, the refinery have used their extensive supply of SylWrap products to repair numerous leaks in the water cooling system – including to sections of overhead and difficult-to-access pipework where the system passes through constrained spaces.

With eliminating microbially induced corrosion from the system impossible, instant live leak repair has proven the best solution for the refinery.

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 repair a leaking flange when pipe pressure cannot be turned off

A leaking flange on a 150mm steel pipe undergoes repair by bonding a valve using underwater epoxy putty

This video was filmed at Sylmasta HQ to demonstrate how the wet surface adhesion properties of Superfast Aqua PW Epoxy Putty can be used in conjunction with a valve fitting to repair a leaking flange when pipe pressure remains on.

About this Pipe Repair Video

The 150mm steel pipe was leaking through a flange. Sylmasta sealed the leak whilst the pipe remained live and operating pressure was set via the test rig at 2 bar, meaning a stream of water was escaping the flange throughout.

Superfast Aqua PW Epoxy Putty was used to permanently bond a valve fitting over the leak area. This fitting channelled the leak path directly through the valve, which was then tapped off to contain pipe content.

The specialist formulation of Superfast Aqua PW offers very high wet surface and underwater adhesion. It bonds to metal, most plastics, ceramic, GRP and fibreglass in damp, wet, saltwater and freshwater conditions.

Superfast Aqua PW was kneaded by hand for three minutes until it turned a uniform white colour, indicating successful mixing. It was then attached to the bottom of the valve, before being fitted to the leak area.

The epoxy putty was pushed firmly against the pipe and flange before it hardened. Despite water continuing to saturate the pipe, Superfast Aqua PW formed a permanent bond and a watertight seal once it cured around 10 minutes after mixing began.

Once the valve had been fitted, all water leaving the pipe was directed through it. Tapping the valve ensured no more water could escape the pipe through the flange, completing the repair.

To showcase the effectiveness of a leaking pipe flange repair made with Superfast Aqua PW, Sylmasta increased pressure through the test rig from 2 bar up to 18 bar. The repair continued to hold.

The fast five minute work time of Superfast Aqua PW makes this a quick and easy repair method to seal a leaking flange when water pressure cannot be turned off.

Superfast Aqua PW has WRAS approval, meaning it is certified to British standards as safe to use on pipes and fittings carrying drinking water.

A similar repair could be made using Sylmasta AB Original Epoxy Putty. AB Original comes with a two-hour work time, making it more suitable for larger, complex repairs where longer is needed to apply the putty before curing begins.

Whilst AB Original offers the same excellent wet surface and underwater adhesion as Superfast Aqua PW, it does not have WRAS approval and so should not be used on pipes or fittings carrying drinking water.

Wet Surface Epoxy Putty

Superfast Aqua Potable Water Epoxy Putty Stick makes wet surface repairs which are safe to use on pipe and fittings carrying drinking water

Superfast Aqua PW Epoxy Putty Stick
WRAS approved epoxy putty in a 114g stick with a fast five minute work time for making quick wet surface and underwater repairs.

Sylmasta AB Original Stick supplies super strength epoxy putty with a two-hour work time in an easy-to-use pre-measured stick format

Sylmasta AB Original Epoxy Putty Stick
Super-strength epoxy putty in a 200g stick with a longer two-hour work time for use in complex wet surface and underwater 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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The comprehensive range of Sylmasta Epoxy Putty Sticks

Superfast Steel Epoxy Putty Stick used to repair deep cracks in a steel pipe

Industry leading epoxy putty sticks manufactured in the UK

Epoxy putty sticks have been used throughout industry for decades, particularly in repair and maintenance. Their popularity stems from being easy-to-use and capable of making fast, permanent repairs to many different materials.

Most epoxy putty sticks focus on a particular substrate. These include steel, copper, and wet surfaces. Some epoxy putties are formulated for high temperature repairs and others will bond underwater. An epoxy putty stick exists for most applications.

The history of epoxy putty sticks

Epoxy putty stick technology and manufacturing originated in the United States. It has migrated to other sources in recent years, including Asia.

Whilst this has extended the supply chain, in some cases it has generated quality issues. The Covid-19 pandemic and its aftermath also highlighted the problems of an overreliance on importation, when there was an epoxy stick shortage across Europe.

Epoxy stick manufacturing in Europe

Sylmasta have invested in the latest manufacturing machinery and technology at their site in the United Kingdom. We are arguably the only manufacturer currently making our own epoxy putty sticks in Europe.

For customers, this means a reliable supply chain, reduced lead times, fresh product with guaranteed shelf life and almost zero minimum order quantities compared with importing from outside Europe.

In addition to manufacturing standard epoxy putty sticks like steel and damp surfaces, it also enables us to produce special formulations and unique products, such as Sylmasta AB Original.

Fast curing epoxy putty sticks

The main focus for epoxy putty sticks has tended to be on cure time, with an addiction to speed. The Sylmasta range of Superfast Epoxy Sticks includes Superfast Steel, Superfast Copper and Superfast Aqua PW, all of which have a fast work time of between five and 10 minutes.

This offers many advantages for small repairs, such as reduced downtime and minimal man-hours. For example, Superfast Epoxy Putt Sticks can be used in pipe repair applications to seal leaks quickly and easily.

They fill holes and cracks in pipework where pressure can be turned off, allowing systems to be put back into operation in one hour. Superfast Steel, Superfast Copper and Superfast Aqua PW all have WRAS approval for use with potable water.

When it comes to larger applications requiring greater quantities of putty to be mixed and applied, faster setting putties cure off too quickly. Such repairs normally require complicated, two-part epoxy pastes which can be carefully applied via a hand tool over the course of an hour.

Despite the desire for epoxy putty sticks to be fast working, it is clear that a slower curing epoxy stick can offer several benefits. Which is why Sylmasta have formulated AB Original.

Slower curing epoxy putty sticks

AB Original Epoxy Putty Stick offers an extended two-hour work time. It combines the easy application of an epoxy putty stick with the longer cure of a repair paste, enabling its use in larger and more complex applications.

Greater quantities of AB Original can be mixed and applied over hours rather than minutes without worry about premature curing. The stick format involves no mixing ratios or measuring out separate parts of resin and hardener.

AB Original is easily shaped, profiled and pushed into cracks and crevices. Its hand-led application means the user needs to mix only the quantity of putty needed for the repair, which can be applied without the use of any tools.

Being ceramic-filled, AB Original does not focus on one particular substrate. It bonds to most materials and offers excellent adhesion to wet, damp and underwater surfaces.

AB Original bridges the gap between an epoxy putty stick and two-part repair pastes. For complex and challenging repairs over larger areas where speed is not required, it is fast becoming the go-to product for industry.

To discover more about the Sylmasta range of epoxy putty sticks, please contact Sylmasta via email or on +44 (0)1444 831459

Epoxy putty repairs

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Case Study: 6 Bar Live Leak Repair to 300mm Steel Pipe at Malaysia Water Treatment Plant

A live leak in a 300mm steel pipe at a wastewater treatment plant in Malaysia live leak repair

6 bar sealed – water company in Malaysia seal online leak on 300mm pipe after two weeks of leaking

Just one week after Sylmasta carried out a series of demonstrations and site visits in Malaysia, a water company make their first repair using a SylWrap Contractor Case to seal a 6 bar live leak on a 300mm steel pipe at a water treatment plant.

Case Study Data

Site
Water treatment plant
Location
Malaysia
Repair Type
Live leak pipe repair
Defect
4mm hole in 300mm steel pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating repair tape which seals high pressure live leaks by fusing together to form a solid rubber band

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap which sets rock hard, reinforcing and protecting the initial repair

SylWrap Pipe Repair Contractor Case
Easy-to-store Case containing enough products to make multiple live leak repairs on pipes of various diameters

Case Study PDF

Download

Case Study Details

The pipe had been leaking for around two weeks through a 4mm hole. It could not be shutdown because of its importance to operations at the treatment plant, leaving a steady 6 bar jet of water escaping and saturating the floor.

Such a leak would normally be sealed by the water company using a pipe repair clamp. The hole though was located on a section of pipe with a saddle joint welded on, sitting approximately 15mm above the original line. A clamp would therefore be ineffective.

6 bar live leak at a wastewater treatment plant in Malaysia before repair using a SylWrap Pipe Repair Contractor Case
Water was escaping the pipe through a 4mm hole at 6 bar pressure, saturating the surrounding floor

After a visit and presentation from Sylmasta a week earlier, the water company operating the treatment plant had taken a supply of SYL-PRO-866 SylWrap Pipe Repair Contractor Cases for sealing multiple leaks on pipework between 300mm and 600mm diameter.

One of the water company’s maintenance teams who Sylmasta had worked with whilst in Malaysia were tasked with using a Contractor Case to make a live leak repair to the pipe at the water treatment plant.

The leak was sealed with Wrap & Seal Pipe Burst Tape. Wrap & Seal stretches by three times its length and fuses together as it is wrapped around a pipe, forming a solid rubber band which seals the leak.

Applying multiple Wrap & Seals on top of each other builds pressure resistance. In high pressure repairs, tapes continue to be added until no water is seeping through and the user is satisfied the leak has been fully arrested.

Three 50mm x 11m Wrap & Seals were used by the maintenance team until the repair could withstand the 6 bar pressure. A SYL866HD SylWrap HD Pipe Repair Bandage was then applied to reinforce and protect the Wrap & Seal.

SylWrap Pipe Repair Bandage applied to a live leak in 300mm steel pipe at a wastewater treatment plant in Malaysia
Wrap & Seal was used to build a repair pressure resistant to 6 bar before overwrapping with a SYL866HD SylWrap HD Bandage

SylWrap HD has a fast-working, water activated resin. It was wrapped directly over the repair area, where it set rock hard within minutes to form an impact resistant outer shell.

Completing the repair took one hour. Having seen how quickly and easily it is to make a live leak repair when maintenance teams are equipped with a Contractor Case, the water company is already planning to expand their use – including onto the public supply network.

All the products in the Case have WRAS approval, meaning they are certified to British standards as safe to use with drinking water.

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: Underground 600mm Concrete Water Pipe Break Repair in Canada

A break in a 60mm underground concrete water pipe in Canda is repaired using Sylmasta products

BC pipe break repair – reducing water loss from an indefinable leak for a city in western Canada

A city authority in Canada repair an underground 600mm diameter concrete pipe with a difficult break at the point it passed through a wall, reducing a 2 bar leak losing significant amounts of water down to a slow and steady drip.

Case Study Data

Site
Public Water Network
Location
British Columbia, Canada
Repair Type
Leak Repair
Defect
Crack in a 600mm diameter concrete water supply pipe

Products Used

Sylmasta AB Original Epoxy Putty Stick
Epoxy putty offering excellent wet surface adhesion for sealing pipework which cannot be made dry before repair

SylWrap HD Pipe Repair Bandage
Composite wrap with water activated resin which sets rock hard to reinforce repairs by forming an impact resistant outer sleeve

Case Study PDF

Download

Case Study Details

The 600mm diameter pipe ran beneath a road in a city in British Columbia. A break was detected and with other concrete pipe bursts making headline news across Canada, the city authority carried out an immediate excavation to assess the problem and repair the leak.

A steady, hard spray of water was discovered jetting out of the pipe through a joint at the exact point the line passed into a solid concrete wall. This made identifying the exact source of the leak impossible.

The city authority contacted Sylmasta for help with what was a very challenging application. Not only was the precise leak point unknown, but the pipe was unable to be fully shutdown.

An underground water pipe in Canada with a break through which water was leaking at 2 bar pressure
The pipe was leaking from a break somewhere beneath a joint at the point it passed into a solid concrete wall

A further complication came with the break being so close to the wall, meaning the normal live leak repair method of applying Wrap & Seal Pipe Burst Tape would be ineffective.

There was insufficient space to stretch the tape by the required 300 percent to ensure it successfully amalgamated to form a solid rubber band.

Sylmasta suggested reducing the pressure as much as possible from the 2 bar the pipe operated at, followed by using AB Original Epoxy Putty to seal around the entire joint.

AB Original was recommended because it has excellent underwater adhesion, meaning it could bond to the pipe even if wet from the ongoing leak. Its two-hour work time also offers longer to work the putty without worrying about premature curing during application.

The importance of the pipe to the city network meant pressure could only be reduced between midnight and 5am, giving the two maintenance workers making the repair a five-hour window in which to work.

Sylmasta AB Original Epoxy Putty Stick used in the repair of a concrete water main pipe break in Canada
Two maintenance workers mixed AB Original Epoxy Putty by hand inside the hole dug to access the pipe before applying it to the leak area

Just under 8kg of AB Original was used in the repair, supplied in 200g sticks. Each stick was mixed by hand until it turned a uniform colour. It was then packed around the leaking joint, building a repair which encompassed the entire break area.

Despite water pouring out the top of the pipe during the repair, AB Original bonded successfully. After two hours, the putty had set to form a watertight material which reduced the amount of water being lost down to a slow drip.

The pipe was then wrapped with SylWrap HD Pipe Repair Bandage for added reinforcement. Two SYL866HD were used, creating a rock-hard outer shell to further protect the pipe and help increase the effectiveness of the repair.

SylWrap Pipe Repair Bandage used to reinforce a break in a concrete water main pipe in Canada
AB Original was packed around the break in the pipe, encompassing the leak area. The repair was then overwrapped with SylWrap HD Bandage.

Completing the application took around three hours. The city authority were particularly impressed with Symasta’s efficiency. It took under five days from initial contact for a repair method to be devised, the goods shipped from the UK to British Columbia and the leak reduced to an acceptable level until the section of pipe can be replaced.

The need for speed in addressing the leak before it could escalate into a major problem was particularly important at a time when Canada’s pipe network is under scrutiny following high-profile bursts in Calgary and Montreal which led to flooding and the rationing of public water supplies.

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 1.05-Metre Long Crack in Cast Iron Downpipe at UK Hospital

Repair of a crack in a cast iron downpipe at a UK hospital through which rainwater had previously been leaking

Emergency operation at UK Hospital… to repair a crack in a cast iron downpipe

A 1.05-metre long crack through which rainwater leaked from a cast iron downpipe located in a constrained wall cavity is sealed in under 30 minutes, with the ease and speed of repair limiting disruption to patients and staff at a busy UK hospital.

Case Study Data

Site
Hospital
Location
United Kingdom
Repair Type
Leak Repair
Defect
1.05-metre longitudinal crack in cast iron downpipe

Products Used

CrackSeal Pipe Sealant
Sealant extruded directly into cracks in cast iron pipework, setting almost instantly for rapid sealing and repairs

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin which sets rock hard to encompass pipes with an impact resistant outer 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

Download

Case Study Details

The hospital contained an internal 150mm diameter cast iron pipe system for taking away rainwater. The system was reaching the end of its lifespan, but budget restraints and the possibility of new facilities being built in the future meant replacing the ageing pipework was not considered viable.

Instead, the hospital was told to find cost-effective repair methods in the event of the system failing. Which is what happened when a 1.05-metre longitudinal crack developed in one section of pipework.

The leak was located in a constrained wall cavity where the pipe passed downwards through plasterboard on its way to the ground floor. The length of the crack meant it extended far enough on the pipe to also pass through the plasterboard.

Longitudinal crack in a cast iron downpipe before undergoing repair using a SylWrap Cracked Pipe Repair Kit
A 1.05-metre longitudinal crack had developed in the cast iron downpipe

When it rained, water escaped the pipe and saturated the plasterboard. This eventually led to rainwater dripping into a ward full of patients, at which point the hospital became aware of the problem. To ignore it would risk a significant leak developing into the ward, and damaging consequences for the ceiling and wall structure.

A specialist drainage engineer was called in. After accessing the wall cavity, removing some of the plasterboard and inspecting the crack, they decided to use the products in the SylWrap Drain & Waste Pipe Repair Kit to permanently seal the leak.

The Drain & Waste Pipe Repair Kit has been designed for repairing cracks and splits in low-pressure cast iron and plastic waste, soil and drain pipes. It comes in a robust red case which is easily kept on-site or on the van by facilities management teams, drain companies and others regularly required to repair such pipework.

Whenever a problem is identified, the user simply retrieves their Kit where everything needed to make multiple repairs quickly and easily is stored.

For this application, CrackSeal Pipe Sealant was used to fill the crack in the pipe. CrackSeal is a high-performance moisture curing sealant specially formulated to fill longitudinal cracks and splits in cast iron pipework.

Crack in a cast iron downpipe filled as part of a repair involving CrackSeal Sealant
CrackSeal Sealant was extruded directly into the crack

Sufficient CrackSeal was extruded directly from its cartridge into the crack until it was totally filled. Although CrackSeal hardens almost instantly, it was left for 10 minutes to form a skin before the repair was reinforced with SylWrap HD Pipe Repair Bandage.

Two SYL616HD Bandages were wrapped along the entire length of the 1.05-metre crack, creating a two-layer repair. The water-activated resin set rock-hard in minutes, providing an impact resistant sleeve protecting both the CrackSeal and the rest of the downpipe.

SylWrap Pipe Repair Bandage applied during the repair of a crack in a cast iron downpipe
Two SYL616HD Bandages were applied around the pipe to create a two-layer repair, completing the application

Sylmasta normally recommend 10 layers of SylWrap HD Bandage be used for full reinforcement. Only two were needed for this application because the pipe took rainwater away at such low pressure.

The cast iron crack repair was completed in under 30 minutes with no disruption to patients or staff in the ward impacted by the leak. Numerous other repairs have now been using the Drain & Waste Pipe Repair Kit made to pipework across the hospital which has since failed.

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

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

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Case Study: Rotted Wooden Beam Repair in Home Renovation Project

Rotten wooden beam repair made using Sylmasta AB Original Epoxy Putty during a home renovation in Wales

Home facade is made ready for rendering thanks to a rotten wooden beam repair made with Sylmasta AB Original Epoxy Putty

Sylmasta AB Original Epoxy Putty is used to repair a rotted wooden beam, filling in large voids to help create a flat surface which enabled the outside of a home to be rendered as part of a renovation project.

Case Study Data

Site
Residential home
Location
Wales
Repair Type
Wood repair
Defect
Oak beam heavily rotted

Products Used

Sylmasta AB Original Epoxy Putty Stick
Epoxy putty with a two-hour work time applied to wood for repairing damage and filling in voids caused by rotting

Case Study PDF

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Case Study Details

A property owner in Wales was renovating a house they had inherited, including improving its exterior appearance. The facade consisted of an untidy mix of concrete breeze blocks, painted brick and a large oak beam.

The intention was to render the entire wall with cement. Doing so required a flat, sound surface for the cement to be applied to. Unfortunately, the ancient oak was badly rotted in places with large voids which made it impossible to render successfully.

To overcome the problem, the property owner decided to repair the rotted wooden beam using Sylmasta AB Original Epoxy Putty. AB Original was chosen for its super strength, ease of application and two-hour work time, meaning more of the putty could be mixed in one go and carefully applied without needing to rush through fear of premature curing.

Sylmasta AB Original used as a filler repair material for a rotten oak wooden beam
AB Original was used to fill the damage left where the oak beam had rotted

30kg of AB Original were delivered to the site. The putty was supplied in 200g sticks, whereby the resin and hardener are pre-measured. This eliminated the need to measure out separate components of Part A and Part B, making application quicker and more straightforward.

Each stick was kneaded by hand until it turned a uniform white colour. Whilst soft, AB Original was pushed into the voids left where the oak had rotted away, easily bonding to the damaged wood. The homeowner was particularly attracted to AB Original because no tools or equipment were needed for the repair.

Sylmasta AB Original Epoxy Putty used to bond hardwood to a rotten wooden beam as part of a house renovation
Hardwood inserts were bonded to AB Original in areas of the beam with significant damage

Where the gaps left by rot were particularly big, the homeowner added hardwood inserts on top of the putty to reduce the amount of AB Original required.

These inserts were pressed directly into the putty whilst it remained soft. A permanent bond was created between the putty and the hardwood once AB Original had cured to its final rock-hard, watertight material.

Home successfully rendered after rotten wooden beam underwent repair with Sylmasta AB Original Epoxy Putty
The repair helped create a smooth exterior facade which was then rendered

For the AB Original which remained exposed, a little water was used to create an ultra-smooth finish as the putty set. The cured material itself could be rendered onto directly, helping to make adding the cement coating a straightforward task.

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

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

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Video: How to make an abrasion resistant repair using WearShield

WearShield Epoxy Paste being applied to a metal demo piece to show it is highly resistant to abrasion and wear

This repair demonstration video shows how WearShield Epoxy Paste forms a toughened protective layer reinforced with alumina beads over surfaces which is highly resistant to wear, impact and abrasion.

About this Epoxy Paste Video

WearShield is applied to machinery and equipment subjected to intense processes in highly abrasive environments.

Its dense alumina bead structure and high resin content enable WearShield to offer ultimate resistance against impact, wear, corrosion and chemical attack by forming an alumina-reinforced outer shell up to 6mm thick over parts and surfaces.

Originally formulated for the tough requirements of the South American mining industry, WearShield is now used worldwide in power plants, quarries and mills.

It protects a wide range of processing and plant equipment including ash handling systems, scrubbers, silos, chutes, mineral nozzles, agglomerator drums, trunions and metal castings.

This video was filmed as part of a WearShield demonstration at Sylmasta HQ. A metal test piece underwent surface preparation, being roughened up to improve adhesion with WearShield and then cleaned.

WearShield was mixed and applied using a metal spatula. Solvent was sprayed onto the spatula to smooth off the epoxy paste after it had been coated onto the test piece. WearShield was left to cure.

Once a full cure had been achieved, the test piece was attacked with an angle grinder and hammer for abrasion and impact testing. There was no chipping or fracturing of the cured WearShield.

Lastly, the demonstration showed the benefits of top coating WearShield with Ceramic Brushable Blue Epoxy Coating to create a low-friction surface over the initial repair.

Ceramic Brushable is silicone-carbide filled, giving it an ultra-smooth finish. When used in conjunction with WearShield, it further reduces abrasion damage by limiting friction between parts. It also makes clean up more effective.

Two grades of WearShield are available. Standard comes with a work time of between 30 and 60 minutes, a functional cure of 8–12 hours. and a 24-hour full cure.

It is used at higher ambient temperatures or where large amounts of WearShield are being mixed at once, removing the threat of premature curing from the application process.

WearShield Rapid has a five-minute work time, a functional cure of 45 minutes and a full cure of three hours. It allows an abrasion resistant repair to be made quickly, minimising downtime and disruption.

WearShield Epoxy Paste

WearShield is an alumina filled epoxy paste used to protect parts and machinery against impact and wear

WearShield Impact Resistant Epoxy Paste
Alumina bead-filled epoxy paste which forms a toughened layer of protection against impact damage and wear

WearShield Rapid is a fast working alumina filled epoxy paste for making parts and machinery impact resistant

WearShield Rapid 5 Minute Epoxy Paste
Fast working version of WearShield with a three hour full cure, reducing equipment downtime

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

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

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Case Study: Pipe Joints Sealed in Cast Iron Rainwater Stack Repair at London Office Block

A 250-metre cast iron rainwater pipe undergoes repair after it was found to be leaking through corroded joints

Three hundred not out – 300 joints are sealed in a leaking rainwater stack which threatened to derail the timeframe of an office block refurbishment

The refurbishment of a five-floor office block in central London is kept on track thanks to Sylmasta AB Original Epoxy Putty sealing 300 pipe joints in the repair of a 250-metre long internal cast iron rainwater stack leaking due to corrosion.

Case Study Data

Site
Office block
Location
London, UK
Repair Type
Leak repair
Defect
Corroded joints in cast iron rainwater stack

Products Used

Sylmasta AB Original Epoxy Putty Stick
Waterproof epoxy putty with a two-hour work time for thorough leak sealing without the threat of curing before application is complete

Case Study PDF

Download

Case Study Details

With the entire office block stripped out as part of the refurbishment, the internal cast iron rainwater stack was accessed for the first time in many years. This revealed that 30-year-old rubber seals used to attach different sections of pipe together had begun to fail and would need replacing.

When these rubber seals were removed, the pipe ends underneath were discovered to be badly corroded where water had become trapped. Because of the uneven pipe surface, pitting and breaches caused by corrosion, it was now impossible to achieve a watertight seal.

Corrosion had left the pipe ends pitted, uneven and breached,, making it impossible to create a watertight joint using seals or clamps

The engineering company carrying out the office refurbishment tried new rubber seals, metal seals, pipe repair clamps and pipe repair clamps with teeth. When the joints continued to leak, it appeared the only option was to replace the entire 250 metres of pipework at considerable cost and with significant delay to the office refurbishment.

Sylmasta were called in to see if there was a better solution to repair the rainwater stack rather than total replacement. It was soon established the newly installed clamps could be removed and Wrap & Seal Pipe Burst Tape used to reconnect the pipe joints together, sealing them much more effectively.

However, the rainwater stack system running close to walls, floors and ceilings made it awkward in some areas to apply Wrap & Seal with the required 300 percent stretch. Removing every clamp would also be a time-consuming task.

It was instead decided to seal each clamp with Sylmasta AB Original Epoxy Putty Stick. Enough putty was cut from the 200g stick and kneaded by hand. Whilst soft, AB Original was forced into both ends of the clamp, filling the gaps between it and the corroded pipe surface.

Pipe repair clamp holding together a corroded joint in a cast iron rainwater stack sealed with AB Original Epoxy Putty
AB Original Epoxy Putty was pushed between the newly installed clamps and the pipe surface, filling all gaps to seal the leaks

Once AB Original had hardened, it permanently sealed any leak paths. The repair was so effective that the engineering company decided to apply AB Original to all 300 joints on the rainwater stack, giving them full confidence the system would have no leaks once it was boxed back in and inaccessible.

The extended two-hour work time of AB Original allowed the engineers to thoroughly seal every joint at a reasonable pace without fear the putty would set before being properly applied.

120kg of AB Original was used for the repair. Supplying the epoxy putty in stick format eliminated the need to measure out separate components of Part A and Part B, making application quicker and more straightforward.

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: Corrosion Protection of 600mm Ductile Pipe & Outlets in Underground Pumping Station

A ductile pipe system in an underground pumping station undergoes corrosion protection measures

Protection at the pumping station – corrosion prevention measures for a complex ductile pipe system

A water company take corrosion protection measures to avoid the future weakening of a 600mm diameter ductile pipe system with three outlets to isolation valves in an underground pumping station.

Case Study Data

Site
Underground pumping station
Location
United Kingdom
Repair Type
Corrosion protection
Defect
600mm ductile pipe showing early signs of surface damage

Products Used

Liquid Metal Epoxy Coating
Brush applied coating which cures to a hard wearing, metallic surface for strengthening pipes and protecting against corrosion

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin which sets rock hard to encompass pipes with an impact resistant outer sleeve

Case Study PDF

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Case Study Details

Conditions inside the underground pumping station housing the pipework were damp, grimy and ripe for corrosion. Rainwater, dirt, sand and other contaminates were able to enter the chamber and settle on the pipework.

As a result, the ductile pipe system was beginning to show very early signs of exterior surface damage. This was of particular concern to the water company operating the pumping house because of the complexity of the pipework and the issues that would come in the event of heavy corrosion developing.

Diagram of the pipe system layout inside the underground pumping station

The main section of pipe entered the chamber through a wall. It was five metres long with three flanges at equal intervals. The three outlets branching off were two metres in length, had one flange each and a reducing spool to 200mm diameter at the isolation valves.

Carrying out any sort of leak repair or replacing sections of the system would present a serious challenge. Instead, the water company sought enhanced corrosion protection measures for the ductile pipe to lessen the chances of the line becoming breached.

Ductile pipe in an underground pumping station before undergoing corrosion protection measures
Pipework in the chamber was showing early signs of surface damage

Rust and dirt were cleaned from the pipe before it was coated with Liquid Metal Epoxy Coating. Liquid Metal is brush applied and cures to form a smooth, metallic, hard-wearing outer surface which acts as a shield against external corrosion.

The entire main section of pipe, the three outlets, reducing spools and all six flanges were painted in Liquid Metal. The protective layer provided by the epoxy coating was then further reinforced using SylWrap HD Pipe Repair Bandage.

SylWrap HD is a composite wrap with a water-activated resin. It is wrapped and smoothed around pipework, curing in minutes to provide a rock-hard, impact resistant layer of protection.

The engineers carrying out the repair wrapped all sections of the pipe system in four layers of SylWrap HD, running the Bandage as close to the flange plates as possible to ensure maximum coverage.

Liquid Metal coated onto a ductile pipe as corrosion protection in an underground pumping station
The completed repair with final coating of Liquid Metal painted onto SylWrap HD Bandage

Despite the space constraints where the pipe ran close to the floor, the engineers were still able to successfully apply SylWrap HD around the bottom of the line. Once SylWrap HD had been applied, another coating of Liquid Metal was added over the top as an additional corrosion prevention measure.

With the repair completed, the water company could now be satisfied that the two coatings of Liquid Metal and several layers of SylWrap HD would offer robust protection for the ductile pipe system inside the underground pumping station against corrosion.

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