Author: Scott McCarthy

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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

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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

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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

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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

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Video: How to repair a leaking step joint when pipe pressure cannot be turned off

Leaking step joint repair on a 100MM UPVC pipe using SylWrap repair products

This video was filmed at Bahrain International Airport, where the maintenance team made a live leak repair to seal a leaking step joint on a 100mm UPVC pipe in under 30 minutes after cement solvent bonds weakened and allowed water to seep out.

About this Pipe Repair Video

A leaking step joint where pressure cannot be turned off is difficult to repair. A pipe repair clamp is not effective because of the difference in height between the step and the line. Epoxy putty will not form an effective bond to repair a leak where water is seeping out.

The UPVC pipe played a vital role in a critical system at the airport and so could not be shut off for repair or replacement. The maintenance team therefore contacted Sylmasta for help with a live leak repair method.

Wrap & Seal Pipe Burst Tape was used to seal the leak. Wrap & Seal is a self-amalgamating tape which stretches by three times its length. When wrapped around a leaking pipe, it fuses to form a solid rubber band which contains content by creating a high-pressure repair.

Application began around 100mm away from the step. Wrap & Seal was wrapped towards the joint with a 50 percent overlay. Once the step was reached, the tape was wrapped directly on top of itself and a ridge built up to reach level height with the joint.

Wrap & Seal was then wrapped for a further 50mm along the step before application moved back to concentrate directly over the leak area.

Layers continued to be added until no more water was leaking from the pipe, indicating enough resistance had been created to seal the leak.

Two 50mm x 4m Wrap & Seal Tapes were used in the application. The repair was then reinforced with a SylWrap Pipe Repair Bandage. SylWrap is a composite fibreglass wrap with a water-activated resin.

It was wrapped and smoothed over the area covered by Wrap & Seal, setting rock hard in minutes to provide an impact resistant protective sleeve encompassing the step.

Completing the leaking step repair took less than 30 minutes whilst the pipe remained fully operational, meaning there was no impact to operations at the airport.

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

The products were supplied to the airport in a SYL-PRO-633 SylWrap Pipe Repair Contractor Case. A Contractor Case contains enough products to make up to six live leak repairs on pipes of all types and diameters.

It is easy-to-store on-site and transport via car or van, ensuring everything needed to fix a leaking pipe is close to hand for making repairs as soon as problems are identified.

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 Bandage 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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South East Export Business of the Year Award won by Sylmasta

Sylmasta was named South East Regional Chamber of Commerce Export Business of the Year

Sylmasta add South East Regional Chamber of Commerce Business of the Year Award to their Sussex title

Sylmasta have picked up their second Chamber of Commerce Business Award of 2023, being named South East Regional Global Player Export Business of the Year.

The Global Player Award goes to a company that has demonstrated significant and sustained growth internationally through harnessing the opportunity of overseas markets, proving that exporting can power business growth. 

Sylmasta were eligible for the accolade having won the Sussex Chamber of Commerce Export Business of the Year back in June. The South East Region covers Sussex, Kent, Hampshire, Isle of White, Surrey and Thames Valley.

Being named South East Regional Global Player sees Sylmasta progress to the national finals to take on other Export Business of the Year winners from around the United Kingdom.

2023 saw Sylmasta bring online new distribution in Malaysia, the Philippines and Indonesia. This built on partnerships confirmed with several Latin American countries in 2022, meaning exports account for 45 percent of sales.

Sylmasta now supply pipe repair, refurbishment and maintenance products to more than 20 countries worldwide, working with water companies, oil refineries, desalination plants, wastewater treatment works, nuclear power stations, pumping stations, quarry wash plants, shipping, agriculture and within the hospitality and leisure industries.

Managing director Simon Bedding said: “We were especially pleased to win this particular award because exporting is so close to our hearts here at Sylmasta.” 

“We consider it a win for everyone in our team, who continually work hard to ensure that we manufacture and deliver our SylWrap pipe repair solutions and Sylmasta epoxy repair compounds to customers around the globe.”

“From conversations with these customers, they see British-made goods as a badge of quality and our reputation remains for trust and fair dealing – something we in Britain don’t perhaps fully appreciate ourselves.” 

“In fact, many have demanded that we put ‘Made in UK’ on our packaging, and we have been happy to oblige. Being based in Sussex, we are fortunate to be in a great location for exporting goods as we are near to major ports and international airports. This enables us to respond to urgent orders quickly and meet the demands of our customers, no matter where in the world they are.”

Building on their success in 2023, Sylmasta are putting a renewed focus on product innovation looking ahead to 2024. New lines in pipe repair bandages and epoxy repair putty are set to be offered to the global distribution network.

These products will improve and increase the Sylmasta product range, allowing contractors worldwide to repair and maintain ageing pipework more quickly and easily than ever before. In doing so, Sylmasta are helping to reduce water loss at a time when climate change makes conserving every drop more critical than ever.

Worldwide repair and maintenance solutions

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Case Study: Alcohol Line Live Leak Pipe Repair at Sugar Mill in Costa Rica

Live leak pipe repair made to an alcohol line at a sugar mill in Costa Rica

The alcohol line repair which had a sugar mill in Costa Rica raising a glass of guaro to the SylWrap Pipe Repair Contractor Case

Having a SylWrap Pipe Repair Contractor Case on site enabled a sugar mill in Costa Rica to make an instant live leak pipe repair when a pinhole was discovered in an alcohol line running vertically up a tower.

Case Study Data

Site
Sugar mill
Location
Costa Rica
Repair Type
Live leak pipe repair
Defect
Pinhole leak in 70mm alcohol line

Products Used

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

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap which sets rock hard to reinforce and protect repairs

SylWrap Pipe Repair Contractor Case
Products were part of a Contractor Case kept on-site, capable of making up to six live leak repairs

Case Study PDF

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Case Study Details

A SylWrap Pipe Repair Contractor Case contains enough products to seal up to six live leaks, making it the ideal kit to keep on-site for rapid response to emergences.

The sugar mill had approved its use several years earlier. Because the milling season in Costa Rica lasts only around four months, efficiency is paramount. Any downtime, disruption or delays to production are costly.

Numerous repairs had since been made by the sugar mill using their stock of Contractor Cases. These included 90 degree elbow bends in elevated pipelines and a particularly challenging Y-joint leaking from the exact point where three separate pipes connected. Most of these pipes carried hot water.

Previous repairs made by the mill using Contractor Cases

The leaking alcohol line was 70mm in diameter and transported alcohol juice extracted from sugar cane during fermentation, which would eventually be used in the production of spirits including rum and guaro, the official liquor of Costa Rica.

It ran vertically up the tower, with the leak developing in a weakened section as the line passed through a circular hole in one of the upper floors. Alcohol juice was left spraying through the pinhole at around two bar pressure.

Alcohol juice extracted from sugar cane escaping through a pinhole leak in a 70mm steel pipe before repair
Alcohol juice spraying out of the pinhole leak in the pipe

As the pipe could not be isolated, Wrap & Seal Pipe Burst Tape was used as the leak sealant. Wrap & Seal is made from self-amalgamating silicone. When stretched by up to three times its length as it is wrapped around a pipe, the Tape fuses to form a solid rubber band capable of sealing live leaks .

Despite the space constraints around the pipe where it passed through the hole in the floor, the engineer making the repair managed to stretch the Tape to a suitable length so that it amalgamated successfully.

Wrap & Seal Pipe Burst Tape seals a live leak in an alcohol line at a sugar mill in Costa Rica
Wrap & Seal Pipe Burst Tape sealed the live leak

Once the engineer was satisfied the leak had been fully arrested and alcohol was no longer escaping, a SylWrap HD Pipe Repair Bandage was applied over the top to reinforce the Wrap & Seal.

SylWrap HD is a composite repair wrap containing a water activated resin. As it was wrapped and smoothed around the Wrap & Seal, it cured to form a rock-hard protective sleeve over the pipe.

SylWrap HD Pipe Repair Bandage applied during the live leak repair of an alcohol line at a sugar mill
SylWrap HD reinforced the repair with an impact resistant layer of protection

Both Wrap & Seal and SylWrap HD have WRAS approval, meaning they are safe to use with drinking water. The sugar mill were therefore reassured that neither product would affect the alcohol juice inside the pipe.

Because the sugar mill already had all the products required to repair the pipe on-site in their Contractor Case, it took less than 20 minutes to seal the alcohol line from the moment the pinhole was discovered.

Only a minimal amount of alcohol juice escaped thanks to the speed and ease of the repair. All systems remained fully operational, meaning there was no disruption whilst the application took place.

Had a Contractor Case not been available, a much greater quantity of juice would have been lost. The mill may have even been forced to shut down the leaking section until such time as it could be repaired at significant cost both financially and to production.

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 & Corroded Shared Water Supplying Eight Cottages

Liquid Metal Epoxy Coating used in the repair of a corroded shared water supply pipe

Cottages counter corrosion – the Sylmasta Pipe Refurbishment System is used to repair and reinforce a water supply line shared by eight properties

Four cottages in a terrace of eight in London use the Sylmasta Pipe Refurbishment System to repair and reinforce their respective sections of a 48 metre long shared water supply pipe weakened and breached by corrosion.

Case Study Data

Site
Terraced cottages
Location
London, UK
Repair Type
Leak repair and pipe reinforcement
Defect
Heavily corroded 48 metre long steel shared water supply pipe breached in places

Products Used

Superfast Aqua PW Epoxy Putty Stick
Fast working, WRAS approved epoxy putty with excellent wet surface adhesion used to seal leaks in pipework

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

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Case Study Details

The row of eight terraced cottages were built in the middle of the 19th century. They were connected to the public water network at a later date, which led to a somewhat unusual setup involving an above-ground shared supply pipe.

This steel pipe connected with a water main underground at one end of the terrace. It rose up the side of the first cottage and was then fixed at a height of around three metres to the back wall of all eight properties, along which it ran for 48 metres.

The height of the line meant it was surrounded by extensions built onto the cottages, downpipes, guttering and other installations and improvements added to the buildings over time. Access to certain sections was therefore severely restricted.

Lagging being removed from the section of pipe climbing up the side wall. The line then ran for 48 metres along the back of the cottages.

Each cottage was responsible for the section of pipe outside their property, giving them around six metres to maintain and upkeep. Lagging had been added around all 48 metres of the line to protect it during winter.

Unfortunately, low-quality insulation material was used which soaked up moisture like a sponge, causing water and condensation to become trapped against the steel. Over time, this led to heavy corrosion and a weakening of the pipe.

When temperatures in London dropped as low as -8°C in an unusually cold spell and water inside the pipe froze, the brittle metalwork was unable to cope. Several cracks appeared outside one cottage, requiring repair.

The lagging was removed from the leaking section to access the pipe, at which point the extent of the corrosion problem became clear. The other seven cottages were inevitably going to suffer from bursts on their sections in future if something were not done.

Corrosion covered the pipe where it ran along the back wall of the cottages

Initially, the cottages contacted their water company for help. Because the pipe was a shared supply line and not part of the public network, the water company said they had no responsibility for it. It was therefore down to the eight property owners to find a solution themselves.

The cottages were quoted £22,000 to replace the entire line. Some of the property owners did not wish to contribute £2,750 towards the cost, preferring instead to take a chance their section would not burst.

It next became clear that replacing individual sections of pipe for those cottages wanting to avoid future leaks would not be practical either. New fittings would struggle to connect with old, brittle pipes not being replaced.

Installation would also be disruptive to those cottages not undertaking work, with shared electrical boxes and satellite dishes having to be taken out of service whilst new sections of pipe were fitted.

With no common route forward found, the cottage with the leaking section contacted Sylmasta for advice on sealing the holes on their part of the line. At this point, the owner also explained the complications caused by the shared water supply pipe and the concern about how it might deteriorate further.

Sylmasta suggested that in addition to sealing the cracked section of pipe outside one cottage, their Pipe Refurbishment System be used to reinforce individual sections along the line for those property owners wanting protection against future leaks.

Two cottages requested their sections be attended to, and so Sylmasta sent an approved contractor to London to carry out the repair and strengthening of the shared water supply pipe.

Superfast Aqua PW Epoxy Putty used to repair a crack in a heavily corroded shared water supply line
Superfast Aqua PW Epoxy Putty sealed the holes in the section of pipe which had burst

Once the lagging had been removed, the first stage of the Pipe Refurbishment System involved application of the leak sealant – in this case, Superfast Aqua PW Epoxy Putty.

Superfast Aqua PW was chosen for its excellent wet surface adhesion to alleviate concerns the pipe may have been weeping water. It has WRAS approval, meaning it is certified as safe to come into contact with potable water.

Aqua PW is supplied in a pre-measured 114g stick. The required amount of putty was cut from the stick, kneaded by hand and then pushed into the cracks and damage in the pipe whilst soft. Within 20 minutes, it cured to form a rock-hard sealing material.

Liquid Metal could be easily painted onto difficult-to-access areas of the pipe

The second stage of the Pipe Refurbishment System saw Liquid Metal Epoxy Coating applied to strengthen the line and protect it from corrosion. Liquid Metal was painted on by brush to sections of the pipe outside every cottage who wanted their part of the line reinforced.

Repair of a shared water supply pipe made using Liquid Metal Epoxy Coating
Liquid Metal coated around a bend in the repair of a shared water supply line
Liquid Metal applied during the repair of a section of shared water supply running awkwardly behind a gutter down section
Liquid Metal coated onto the pipe to form a new metallic outer surface

Once cured, Liquid Metal formed a smooth, metallic, hard-wearing outer surface around the pipe to act as a shield against external corrosion. Should the brittle steel be breached from the inside by freezing temperatures in future, the Liquid Metal shell will contain the contents of the pipe.

Liquid Metal Epoxy Coating brush applied during the repair of a corroded shard water supply line
The cottages who did not wish for their sections of pipe to be reinforced were left with the original lagging and corroded pipe, contrasting with the refurbishment provided by Liquid Metal

SylWrap HD Pipe Repair Bandage was added as the final stage of the Pipe Refurbishment System, to provide the shared water supply pipe with another layer of protection. SylWrap HD is a composite repair wrap with a water-activated resin which sets rock-hard in minutes when wrapped and smoothed around pipework.

SylWrap HD Pipe Repair Bandage reinforces a shared water supply pipe during a repair
The pipe was given further protection using SylWrap HD Pipe Repair Bandage

Nine SylWrap Bandages were applied per cottage to build up thickness to four layers, with the application taking place whilst the Liquid Metal remained tacky to improve adhesion to the pipe. Once cured, SylWrap HD formed an impact resistant shell encompassing the pipe.

In addition to the two planned repairs, a third cottage owner asked for their section to be reinforced, having seen how straightforward and cost-effective the process was. Their part of the shared water supply pipe had not been as badly weakened by corrosion and therefore required only Liquid Metal for suitable strengthening.

All three cottages were completed in a single day, with the approved contractor also installing new lagging to replace the original insulation which had to be removed. A fourth cottage then requested the approved contractor return and attend to their part of the pipe, meaning half the 48 metres had been reinforced.

Lagging installed for insulation during the repair of a shared water supply pipe
Lagging added to complete the repair

Around one year after the original repair and a fifth cottage contacted Sylmasta. 12 months of further corrosion had left their section of the pipe on the verge of collapse.

Refurbishment of this section was now far more challenging and costly than the repair the other four cottages had opted for – highlighting the benefits of strengthening and protecting systems before more serious problems develop.

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