Author: Scott McCarthy

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Case Study: Repair of a Cracked 90-year-old 70mm Malleable Iron Water Supply Pipe

A SylWrap Pipe Repair Kit is used to seal a crack on a 90-year-old malleable iron water supply pipe

Helping towards a century – the malleable iron pipe repair that kept a 90-year-old water supply line in operation

With replacement fittings of the required size and type no longer manufactured because of the age of a 90-year-old malleable iron water supply pipe, when the pipe became cracked a repair solution was needed to avoid digging out and replacing the entire line.

Case Study Data

Site
Domestic property
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Cracked 90-year-old malleable iron water supply pipe

Products Used

Superfast Steel Epoxy Putty Stick
Fast working epoxy putty used to seal all holes in the pipe

SylWrap HD Pipe Repair Bandage
Repair area was overwrapped with a SylWrap HD Bandage for reinforcement and protection

SylWrap Standard Pipe Repair Kit
Superfast Steel and SylWrap HD were provided together in the Standard Pipe Repair Kit

Case Study PDF

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Case Study Details

The 70mm malleable iron pipe connected a property with the public supply network. When the property owner was alerted to a potential leak, excavation revealed that an awkward-shaped large crack and several smaller holes had developed, through which water was now escaping.

Because the pipe was 90 years old, replacement fittings of the correct size and type were no longer manufactured. The crack and holes therefore had to either be repaired, or the entire section would need to be dug out and replaced with a new line at considerable expense.

Sylmasta recommended a SylWrap Standard Pipe Repair Kit for the application. All products in the Standard Kit have WRAS approval, meaning they are certified as safe to use for the repair and maintenance of pipes carrying drinking water.

Pressure was turned off and the malleable iron pipe cleaned and dried as best it could be prior to the two-stage repair.

A large crack and several holes in a 70mm malleable iron water supply pipe prior to being repaired with a SylWrap Pipe Repair Kit
Holes in the pipe included a large, awkward shaped crack

First, Superfast Steel Epoxy Putty Stick was used to seal the pipe. Superfast Steel is a fast working putty in an easy-to-use stick format which makes permanent repairs to steel, iron and other ferrous metals.

For the smaller holes, the required amount of epoxy was cut from the stick and kneaded by hand. It was pushed into all visible holes in the pipe, where it hardened within five minutes to plug all leaks.

To seal the large crack, Superfast Steel was formed into a disc bigger than the area of the pipe the crack covered. This guaranteed that no part would be missed when sealing.

This disc was then stretched over the entire crack area. Once in position, the edges of the disc were pushed tightly down onto the pipe, forming a good seal with the surface.

Repair of a 90-year-old cracked malleable iron water supply pipe made using a SylWrap Standard Pipe Repair Kit
The completed repair prior to the pipe being re-burried

Once the putty had become firmer but not completely cured, the entire repaired section was tightly wrapped with a SylWrap HD Pipe Repair Bandage to compress the putty into any remaining gaps.

SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes, providing an impact resistant protective layer around the pipe.

Once the application was completed, pressure was turned back on. The pipe had ceased leaking and could therefore be re-buried. The repair had cost less than £25 to complete, including delivery of the SylWrap Kit and the property owner described it as going “fantastically well.”

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: Corroded Tank Repair at a Puerto Rico Pharmaceutical Plant

A heavily corroded tank at a pharmaceutical plant in Puerto Rico undergoes repair using Ceramic Brushable Green Epoxy Coating

Putting a lid on corrosion – the roof of a heavily corroded tank undergoes repair using Ceramic Brushable Green

When rust finally breached the top of an industrial tank at a pharmaceutical plant in Puerto Rico, a repair method was needed to keep the corroded tank operational for several more years before a planned replacement.

Case Study Data

Site
Pharmaceutical plant
Location
Puerto Rico
Repair Type
Corrosion protection
Defect
Heavy corrosion to the top of an industrial sized tank

Products Used

E190 Brushable Epoxy
Brushable epoxy resin coated onto strips of Fibreglass Tape to make composite patch repairs to holes in the tank

Fibreglass Tape
Fibreglass Tape soaked with E190, after which it cured to form a rock hard material covering holes in the tank

Epoxy Composite Repair Kit
E190 Resin and Fibreglass Tape can be purchased in an Epoxy Composite Repair Kit for making complex patch repairs to pipes and tanks

Ceramic Brushable Green
Brushable epoxy coating repaired the top of the tank by creating a hard-wearing surface resistant to corrosion

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Case Study Details

The tank was suffering from heavy corrosion, especially at the top. The pharmaceutical company responsible for the plant had been determined to try and keep the system operational until the scheduled replacement of the tank.

Unfortunately, the corrosion became so bad that a repair had to be made. The primary consideration was cost; the company did not want to spend thousands of dollars refurbishing a tank, only for it to be condemned within a few years.

A badly corroded tank top at a pharmaceutical plant in Puerto Rico prior to undergoing repair using a Sylmasta brushable epoxy
The top of the tank was suffering from heavy corrosion

It was decided to use Ceramic Brushable Green Epoxy Coating as a cost-effective and convenient means of both repairing the damaged tank roof and protecting it from further corrosion.

Ceramic Brushable Green is reinforced with silicone carbide and painted onto surfaces, structures and machinery to create an ultra-smooth, hard wearing protective layer.

It can be applied to old or new parts made from all metals and most plastics. It seals surfaces and protects against chemical attack, cavitation, erosion and pitting, as well as corrosion.

Large holes appeared in the tank during the surface preparation process

Before the application of Ceramic Brushable Green, the roof of the tank had to be cleaned to remove paint, rust and grime. During this process, several holes appeared in the tank owing to how brittle the metalwork had become.

The holes were bridged using Fibreglass Tape coated with Sylmasta E190 Brushable Epoxy Resin, available to purchase together as part of the Sylmasta Epoxy Composite Repair Kit.

Strips of Fibreglass Tape were cut off, soaked with E190 resin and then layered over each hole to build a composite patch repair. E190 has a work time of 30 minutes, after which the resin-soaked strips cured to form a rock-hard material sealing all holes.

  • A corroded tank top undergoing repair using a brushable epoxy
  • Ceramic Brushable Green used to repair a corroded tank top by creating a new hard wearing surface
E190 Epoxy Resin and Fibreglass Tape patch repaired holes. The tank was then coated with Ceramic Brushable Green Epoxy Coating

Once the holes had been path repaired, the entire tank was painted with Ceramic Brushable Green. The 90 minute gel time meant that large quantities of epoxy coating could be mixed without the threat of premature curing.

Three coatings of Ceramic Brushable Green were applied. The re-coat time between layers was around four hours. A full functional cure was achieved 24 hours after the last coating, with the entire application taking a little under two days to complete.

Although only set to be a temporary repair, complications down the line meant that the planned replacement of the tank had to be suspended. Five years later and the tank was still in service, fully functional thanks to Ceramic Brushable Green with no signs of further 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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Case Study: Liquid Metal Lays Anti Slip Flooring Surfaces at PepsiCo Plant in Chile

An anti slip flooring surface created using Liquid Metal Epoxy Coating and silicone carbide grit at an industrial plant in Chile

Getting a grip in Chile – Liquid Metal combined with silicon carbide grit lay new anti slip flooring at PepsiCo Plant

An industrial plant operated by PepsiCo in Chile required a cost effective method for laying new and replacement anti slip flooring across the site – a problem solved by combining Liquid Metal Epoxy Coating and silicon carbide grit.

Case Study Data

Site
PepsiCo industrial plant
Location
Chile
Repair Type
Creation of anti slip surfaces

Products Used

Liquid Metal Epoxy Coating
Brush applied to bond silicon carbide grit to floors, creating an anti slip surface

Case Study PDF

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Case Study Details

PepsiCo needed to lay anti slip flooring at various points in their industrial plant in Chile, both to replace existing surfaces which had lost their effectiveness and create new ones across the site.

12 different sections needed laying. These included the gritting of stainless steel ladders and staircases; the tiled floor of a warehouse; concrete corridors; a metal ramp; and the surface of an open lift used to transport goods between floors.

  • Exisiting anti slip flooring at the PepsiCo industrial plant had become worn and in effective prior to being repaired using Liquid Metal and silicone carbide grit
Existing anti slip surfaces had become worn and needed replacing

Because of the scale of the application, the maintenance team carrying out the job wanted to find as cost effective and convenient method for laying anti slip surfaces as possible.

One of the ways they intended on doing this was by finding an epoxy coating capable of bonding to the variety of surfaces upon which the anti slip flooring was required.

  • A stainless steel floor prior to having a new anti slip flooring surface applied using an epoxy coating
Stainless steel floor with worn anti slip surface

Sylmasta therefore recommended the use of Liquid Metal Epoxy Coating combined with silicon carbide grit. Liquid Metal is a metal-filled, brushable epoxy which is painted onto surfaces.

Whilst sticky, it offers high strength adhesion. It cures on all materials, forming an ultra-smooth metallic layer. A gel time of 90 minutes allows for the coating to be mixed and carefully applied without the threat of premature curing, an important consideration for larger, more complex tasks.

Masking tape was used to mark out where the anti slip strips were required. The surface was then painted with Liquid Metal, silicon carbide was sprinkled over the epoxy coating, and the masking tape removed.

Liquid Metal and silicone carbide grit are used to create anti slip flooring at the PepsiCo industrial plant in Chile
Completed refurbishment of the anti slip surface on the stainless steel floor using Liquid Metal and silicone carbide grit

Once the Liquid Metal had cured, the grit was permanently bonded to the floor, creating a new anti slip surface. This method was used successfully across all 12 areas requiring attention on the site, no matter whether the surfaces were metal, concrete or tile.

The entire application was completed in 24 hours from when the final area was coated with Liquid Metal. The ease and speed of the installation has since led the maintenance company to use Liquid Metal for surface gritting at other plants, as well as for creating anti slip surfaces for delivery vans.

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: Domestic Malleable Iron Water Pipe Repair in a Restricted Space

Wrap & Seal Pipe Burst Tape used to repair a 20mm domestic malleable iron water pipe in a restricted space

No space, no problem – Wrap & Seal makes a repair to a malleable iron water pipe with severely restricted access

A 20mm domestic malleable iron water pipe undergoes a live leak repair using Wrap & Seal Pipe Burst Tape despite space being severely restricted by the leaking section’s position in close proximity to a wall.

Case Study Data

Site
Domestic property
Location
United Kingdom
Repair Type
Live leak pipe repair
Defect
Small hole in 20mm malleable iron water pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone tape which fuses to form a solid rubber band for high-pressure, live leak repairs

Case Study PDF

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Case Study Details

The malleable iron pipe had developed a small hole facing towards a brick wall in an outside area of a domestic property in the UK. Water was escaping at around 3 bar pressure and flow through the leaking section of pipe could not be isolated.

Because this was a live leak repair, epoxy putty was ruled out as a sealing material. Wrap & Seal Pipe Burst Tape would therefore have to be used, making the repair particularly challenging due to the restricted space on two sides of the pipe.

Between the pipe and the back wall behind, there was around only 30mm clearance. Approximately 150mm of space existed between the pipe and the ground. Clearly, there was not going to be enough room for the user making the repair to stretch the Wrap & Seal by three times its length whilst it was wrapped, as would have normally been the case.

Repair of a 20mm domestic malleable iron water pipe in a restricted space at a domestic property
To apply the tape, it was stretched towards the user where there was most space

The tape was anchored 50mm to the right of the leak and held tightly against the pipe by property owner carrying out the repair, using their thumb. They then stretched the tape as far towards them as space would allow with their other hand, before pulling it under the pipe and up through the restricted space between the pipe and the back wall.

As the first wrap around was completed, the tape was stretched half the width across the Wrap & Seal still being held down to the pipe with the thumb. This anchored the tape firmly to the pipe.

The wrapping process continued in this manner, with the tape being stretched as much as possible into the space away from the wall before the user looped it under the pipe and up through the gap at the back.

The tape was then wrapped under the pipe and up through the restricted space between the pipe and back wall

Despite the fact that it was not possible to stretch the tape by its maximum 300 percent, the self-amalgamating silicone still fused effectively to form a solid rubber band over the leak. The 3 bar pressure was easily held by the repair.

Once the end of the tape was reached, the pipe was dried off. No more water could be felt escaping, indicating that the repair had been a success.

The property owner was delighted to have been able to carry out a safe DIY pipe repair in spite of the initial challenges that seemed to come with the application, and at a fraction of the cost of hiring a plumber.

Wrap & Seal has WRAS approval, meaning it is certified as safe to British standards to use on pipes which carry drinking water.

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: ‘Impossible’ Repair of a 900mm Water Main Flange Leak in an Underground Chamber

A 900mm steel water main leaking in an undeground chamber undergoes repair using Superfast Steel Epoxy Putty

Mission impossible – the repair of a leaking 900mm steel water main flooding an underground chamber in Malaysia

Water escaping from cracks caused by corrosion around a flange on a 900mm steel water main had flooded an underground chamber, leaving a pipe repair to be considered impossible until a determined Malaysia engineering team spent two days on the scene

Case Study Data

Site
Underground water main
Location
Malaysia
Repair Type
Leak repair
Defect
Cracks caused by corrosion on a 900mm steel pipe flange

Products Used

Superfast Steel Epoxy Putty Stick
Fast working epoxy putty for sealing holes and cracks in pipework, filling gaps between joints and high-strength adhesion

Case Study PDF

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Case Study Details

Heavy corrosion had caused numerous cracks to appear on the 900mm steel pipe around a stub flange. The leak point was located in an underground chamber, which had subsequently filled with water escaping the pipe at high pressure.

Accessing the pipe was difficult even before the flooding of the chamber. A repair clamp could not be fitted because of the flange, and the main was so close to the ground that there was insufficient room for pipe repair tapes or bandages to be wrapped around the pipe.

There was no visible means of isolating the main either, meaning that pressure could not be turned off or reduced. Replacing the damaged section would have involved excavating the chamber and shutting down the main for a prolonged period, something not considered an option by the water company operating the system.

The flooded chamber prior to water being pumped out
As water was removed from the chamber, the scale of the leaks on the main became evident

As a result, repairing the main had been considered impossible. It had been allowed to leak unabated since the problem was discovered, save for a few cursory checks and the pumping out of water when flood levels became dangerously high.

That was until an engineering team arrived on site, accompanied by a technician from Sylmasta, who were determined to formulate either a method for repairing the main or a means of substantially reducing the amount of water being lost.

Before any repair could be attempted, water had to be pumped out of the chamber. Once this had been done, an engineer accessed the pipe and hammered a series of plastic plugs into the larger cracks along the flange.

Water escaping a 900mm underground water main in Malaysia prior to undergoing a Sylmasta repair
An engineer hammered plastic plugs into the significant cracks, reducing the amount of water being lost so that an inspection could take place

The plugs reduced the amount of water escaping from the pipe enough for a proper inspection to take place. The engineer in the chamber then spotted a stopcock a little further along the pipe.

They were able to reach the stopcock, preventing flow into the leak area. With pressure now turned off, it meant that Superfast Steel Epoxy Putty could be used to attempt to permanently seal the cracks in the main.

Numerous Superfast Steel Epoxy Sticks were used for the repair

Superfast Steel has a fast, 10 minute work time and comes in an easy-to-use 114g stick format. A large number of sticks had to be used in the application because of the size of the repair.

Each stick was kneaded by hand. Whilst soft, the putty was pushed into visible holes in the pipe where it hardened, filling the crack. Superfast Steel was also used to seal the flange and as a means of permanently fixing the rubber plugs in place.

An engineer applies Superfast Steel Epoxy Putty Stick to a cracked 900mm steel water main during a repair in Malaysia
Superfast Steel plugged the visible cracks in the pipe and permanently fixed the rubber plugs in place

Because of the diameter of the pipe and the size of the damage area, it took over an hour to apply the necessary Superfast Steel. With flow isolated, it was difficult to tell whether all the leaks in the pipe had been found and sealed.

Even after pressure was restored, it was still hard to identify remaining problem areas. As a result, the maintenance team decided to return 24 hours later to check the effectiveness of the repair.

With the main continuing to leak the following day, further Superfast Steel was used to plug remaining cracks and a valve fitted

Unfortunately, this inspection revealed that the main was again leaking, although nowhere near as seriously as before. There were several small leak areas which had not been suitably arrested the previous day, alongside a larger jet of water escaping from a gap between the flange and the pipe.

Further Superfast Steel was used to seal the smaller leak areas. The epoxy putty was worked into a sausage shape and pushed into the remaining cracks in the pipe.

Superfast Steel Epoxy Putty Stick used to plug holes in a cracked 900mm water main repair
With most of the leaks arrested, the valve funnelled any water still attempting to escape into one area

For the larger leak, the engineering team manager hit upon the idea of fixing a valve in place using more Superfast Steel. The water trying to escape the main would be channelled towards this valve. A tap would be fitted and closed, sealing the pipe shut.

A tap was then fitted, shutting off the valve
Successful repair of a leaking 900mm water main in an underground chamber carried out by Sylmasta
The successful repair

Tapping off the main ended up being a success, much to the delight of the water company and the engineering team. Normally, Sylmasta would recommended reinforcing the epoxy putty with SylWrap HD Pipe Repair Bandage, but that was just not possible in this application.

It may have taken two days, but the ‘impossible’ water main repair had been completed, reducing the levels of water being lost and preventing any further flooding of the chamber.

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: Magic Corner Kitchen Unit Repair Saves a Client Over £200 in Replacement Costs

A magic corner kitchen unit undergoes repair using Superfast Steel Epoxy Putty after a pin snapped off

Magic repair of a magic corner – Superfast Steel prevents a broken kitchen unit needing a £290 replacement

When a magic corner unit in a Sylmasta client’s kitchen collapsed, they were left facing the prospect of paying £290 for a replacement – until it was decided to attempt a repair using the high-strength bonding properties of Superfast Steel Epoxy Putty.

Case Study Data

Repair Type
High-strength bonding
Defect
Collapsed magic corner kitchen unit

Products Used

Superfast Steel Epoxy Putty Stick
Epoxy putty used for super-strength adhesion between broken pin and unit which had previously been welded in place

Case Study PDF

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Case Study Details

A magic corner kitchen unit makes use of dead space in corner cupboards which are otherwise hard to access. A slide out mechanism attached to a cabinet door allows items to be easily stored and retrieved from blind corners.

There are several reasons why magic corners can break. Wear and tear is one. Frequent opening and closing of the cupboard and stress on the sliding mechanism will take its toll after many years.

Magic corners will often be overloaded in excess of the weight that the manufacturer recommends they carry. Because they are attached to a cupboard door rather than being a part of the actual unit, overloading can lead to units collapsing and subsequent damage to the door itself.

In this case, the magic corner unit was very old. The client also admitted that they may have overloaded it. Eventually, this led to the magic corner collapsing, detaching it from the kitchen cupboard door.

Upon inspecting the broken corner, the problem was discovered to have been caused by a vital pin on which the mechanism pivoted, breaking away from the frame and causing the detachment.

  • A broken magic corner kitchen unit before undergoing repair using Superfast Steel Epoxy Putty Stick
Photo on the left shows another pin welded to the magic corner for an idea of how it was attached. On the right, the broken section of the unit after the damaged pin snapped off

A replacement magic corner would have cost £290 and required some advanced DIY skills to fit. After consulting Sylmasta to see if a repair was possible, it was decided to attempt to fix the magic corner kitchen unit using Superfast Steel Epoxy Putty.

Superfast Steel is used for filling holes and cracks, restoring surface profile, fabricating new parts and for high-strength bonding between materials. For this particular application, it was Superfast Steel’s adhesive properties that were required.

To use Superfast Steel, the required amount is cut from the 114g stick and kneaded by hand. This causes a chemical reaction to take place between the resin and hardener contained within the stick, and within 10 minute the soft material will have cured into one as hard as steel.

The damaged pin was around 100mm in length and had been welded to the magic corner prior to the collapse. The pin was to be reattached to the unit using Superfast Steel, which would provide a bond as strong as the previous welding.

  • A broken pin on a magic corner kitchen unit is repaired using Superfast Steel Epoxy Putty Stick
The pin prior to being reattached to the magic corner using Superfast Steel

Completing the reattachment took less than 30 minutes. Within an hour, the putty had fully hardened. The magic corner could be filled with kitchen items again – although the client was careful not to overload it this time.

One Superfast Steel Stick was all that was required for the application . At an outlay of only £10.08 plus postage, the repair represented a huge saving compared to the cost of replacing the magic corner.

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: 19th Century Lantern Restoration Using Superfast Steel Epoxy Putty

A 19th century lantern restoration undertaken using Superfast Steel Epoxy Putty Stick

Relighting a 19th century lantern – the restoration of a Victorian lamp made possible by Superfast Steel Epoxy Putty

Superfast Steel Epoxy Putty is used in the restoration of a lantern made by famous Birmingham lamp maker Arthur J. Poole and dated to the 1870s or 1880s, returning it to working order so that it could light up spaces as it did in its Victorian heyday.

Case Study Data

Repair Type
Restoration of a 19th century lantern
Defect
Broken candleholder and snapped door latch

Products Used

Superfast Steel Epoxy Putty Stick
Epoxy putty used to formulate new parts and for high-strength adhesion of metal-to-metal and plastic-to-metal

Case Study PDF

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Case Study Details

Arthur J. Poole manufactured a huge range of candle-lit lanterns, lanterns for police offices, lamps for use on the railways, maritime signal lamps capable of transmitting Morse code, and copper coal buckets from his factory in the heart of Birmingham during the 19th century.

The lantern in question was candle powered, dating it to the 1870s or 1880s before paraffin became more widely used. For an item the best part of 120 years old and which had clearly spent most of its life as a working lantern, it was in remarkably good condition.

There were two areas which needed attention before it could be used once again. The lantern no longer had a latch to close the door in place. Whenever there was a breeze or the device was being transported by its handle, the door would therefore swing open and the candle inside would be extinguished.

Original fitting for holding a candle in place. A new part needed to be made to hold larger, modern day candles

The other problem was that the original candleholder was very small, and not suited to most modern day candles. To overcome this, it was decided to make a round platform that could take tea lights or other larger candles and fix a spike on the bottom that could slot into the existing candleholder.

This was done using Superfast Steel Epoxy Putty. Superfast Steel comes in a pre-formatted 114g stick. The user cuts off the amount of putty required and then mixes it by hand, instigating a chemical reaction between the resin and hardener.

Superfast Steel has a work time of between 5-10 minutes. Whilst soft, it can be shaped and formed as desired. Once cured, it offers super-strength adhesion between different materials and forms a material as hard as steel.

Superfast Steel Epoxy Putty used to fabricate a new part in the restoration of a 19th century lantern
New candleholder fabricated from Superfast Steel. The platform has already been painted black

To create a new candleholder, Superfast Steel was moulded into the required shape to make the platform. Once the platform had cured, the spike was shaped and added. Whilst soft, the spike was pushed into the existing fitting to ensure it was a perfect fit.

The spike easily bonded to the platform, creating a new holder capable of supporting a modern candle inside the lantern and completing part one of the restoration.

The new candleholder enabled the lantern to hold a modern candle in place

To create a new handle for the door, a metal wire was bent into a T-shape by folding a strip in half, then bending the two ends at right angles. It was attached to the door via two plastic tubes which were bonded to the lantern using further Superfast Steel.

When the door was closed, this metal wire could now drop into an existing latch attached to the opposite side of the lantern, locking it in place and preventing the candle from blowing out.

Latch made from metal rod and plastic tube and attached to the lantern using Superfast Steel. All materials were then painted black to blend in seamlessly with the lantern
A 19th century lantern that underwent restoration using Superfast Steel Epoxy Putty Stick
The completed restoration

A coating of black paint was added to the wire, the plastic tubing and the Superfast Steel to complete the restoration at a cost of under £15.

The lantern is now lighting up a garden in East Sussex and ready for another 120 years of service. Arthur J. Poole himself would have been impressed.

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: Snapped Nozzle on a 1500mm Seawater Cooling Line Repair & Reinforcement

A 1500mm line in a seawater cooling system undergoes repair after it began leaking from a broken off nozzle

Keeping it cool – the repair and reinforcement of a leaking 1500mm seawater cooling system supply line

A petrochemical plant in Saudi Arabia needed an urgent repair to the 1500mm main supply line in their seawater cooling system after a nozzle snapped off, leaving a 50mm hole discharging water 5 metres vertically at a pressure of 3 bar.

Case Study Data

Site
Petrochemical plant
Location
Saudi Arabia
Repair Type
Leak repair and reinforcement
Defect
Snapped nozzle in a 1500mm seawater cooling pipe

Products Used

Sylmasta AB Original Epoxy Putty
Epoxy putty used alongside a PTFE plug to fill the 50mm hole left by the snapped nozzle

SylWrap HD Pipe Repair Bandage
Composite wrap reinforced the repair and was then applied around the diameter to strengthen the line

Case Study PDF

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Case Study Details

Seawater cooling systems allow water taken from the sea to be used for the cooling of machinery and other processes in industrial plants and factories.

The petrochemical plant were extracting from the Red Sea. A nozzle on the 1500mm diameter main line supplying the cooling system had snapped off from the flange, causing a jet of pressurised water to shoot 5 metres into the air from a 50mm hole.

An engineer fits the PTFE plug to the leaking line

When this seawater returned to ground, it saturated the surface of the pipe, causing external damage, discolouration, mould to form and a suspected weakening of the line.

Losing so much water also had a serious impact on the efficiency of the system. The plant therefore decided to call in a maintenance team to attempt to fix the problem as a matter of urgency.

The supply line was shut off whilst the repair took place. The application began by securing the hole left in the pipe by the snapped nozzle with a plug made from PTFE.

Sylmasta AB Epoxy Putty used to repair a seawater supply line by fixing a PTFE plug in place
Sylmasta AB Original was used to fix the plug in place, creating a watertight seal

To create a watertight seal around the PTFE plug and fix it in place permanently, the nozzle was then encompassed using Sylmasta AB Original Epoxy Putty.

Sylmasta AB is a smooth-setting putty capable of bonding to all materials, including wet surfaces. It has a two hour work time, allowing more of the putty to be mixed, shaped and applied without premature curing that may have otherwise been caused by the hot Saudi climate.

SylWrap HD Pipe Repair Bandage applied to a snapped nozzle in a seawater supply line repair
The plug and AB Original were encompassed with SylWrap HD

Further reinforcement of the plug and the surrounding AB Original was provided by SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets rock in hard in minutes.

Seven layers of SYL412HD were wrapped and smoothed around the nozzle, creating an impact resistant layer of protection. This completely sealed the hole with a repair pressure resistant up to 30 bar.

SylWrap HD Pipe Repair Bandage being applied to a 1500mm seawater supply line
Further SylWrap reinforced the weakened section of pipe around the plug

When the line was put back into operation, the engineers who had carried out the repair noticed during their inspection that the pipe around the nozzle had indeed weakened as suspected.

Although no major leaks were present, the surface could be seen bubbling with air and water. They therefore decided to reinforce the entire area of pipe underneath the nozzle by wrapping the 1500mm diameter with four SYL616HD Pipe Repair Bandages.

Repair and reinforcement of a 1500mm seawater supply line after a nozzle snapped off
The repair was completed in two hours, leaving the line sealed and strengthened

This provided a protective sleeve around the weakened section of the line, strengthening it against potential future breaches and thus extending the lifespan of the pipe.

Completing the repair of the nozzle and the reinforcement of the line took less than two hours, after which the seawater cooling system was able to operate at full capacity once again.

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

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

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Fraser & Ellis become London stockists of SylWrap Pipe Repair Kits

Universal Pipe Repair Kits now available to buy in London

Sylmasta are pleased to announce that Battersea-based Fraser & Ellis have become London stockists of the SylWrap Universal Pipe Repair Kit range.

Established as one of the premier plumbing merchants in London for over 100 years, their dedicated and knowledgable staff will be a great addition to the SylWrap family in helping those in the capital with pipe repair applications.

The Universal Pipe Repair Kit enables any user to permanently repair a leaking pipe without the need for any formal training. Full instructions are provided with the Kit for carrying out the two-stage process which is effective on pipes made of copper, steel, iron, PVC plastic, lead and other materials.

A repair begins by using a sealing material to plug the hole in the pipework. When pressure can be turned off, this is done with Superfast Epoxy Putty, which is hand kneaded and applied to damage areas whilst soft. Within 5 to 10 minutes, it will harden to fill the crack.

When pressure cannot be turned off, Wrap & Seal Pipe Burst Tape is instead used. Made from self-amalgamating silicone, it stretches by 300 percent and fuses to form a solid rubber band over a leak area, creating a pressure-resistant repair.

The initial repair is then overwrapped with a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin. It sets rock hard in minutes, providing an impact resistant layer of protection which reinforces the repair.

All the products in the Universal Pipe Repair Kit have WRAS approval, meaning that they are certified for safe use with drinking water. The Kit makes pressure resistant repairs up to 30 bar, is temperature resistant to 200ºC, and is effective on pipes carrying hot and cold water and chemicals.

Ample parking is available at Fraser & Ellis’ convenient location near Chelsea Bridge, where they have been based since 2016. For emergency pipe repair enquiries in London, they can be contacted via phone on 020 7228 9999 or email at sales@fraserellis.co.uk. You can also view the Fraser & Ellis website by clicking here.

Universal Kit Case Studies

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Case Study: Live Leak Pinhole Repair on 150mm Elbow at Pumping House in Malaysia

A SylWrap Live Leak repair made to a pinhole leak on a 6 bar 150mm elbow joint with a pinhole leak

Fixing an elbow – a pumping house in Malaysia stays operational thanks to a SylWrap live leak repair

When a 150mm steel pipe elbow in a Malaysia pumping house developed a pinhole leak through which water was spraying out at 6 bar pressure, the company responsible for the facility turned to Sylmasta for a rapid live leak repair.

Case Study Data

Site
Pumping house
Location
Malaysia
Repair Type
Live leak repair
Defect
Pinhole leak in 150mm steel pipe elbow joint

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape used to seal the live leak on the elbow joint

SylWrap HD Pipe Repair Bandage
Composite repair wrap applied to reinforce the initial repair via an impact resistant protective layer

SylWrap Pipe Repair Contractor Case
Contains enough products to make up to six live leak repairs, now approved for use on Kuala Lumpur’s vast network

Case Study PDF

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Case Study Details

The steel pipe was an important part of the system at the pumping house, operated by a water company. A pinhole leak had appeared on an elbow joint weakened by corrosion where two sections of metalwork joined together.

Because the leak was on an elbow, a repair clamp could not be fitted. The pipe could not be taken out of operation for repair or replacement due to its importance to operations at the pumping house.

A pinhole leak on an elbow joint in a Malaysia pumping station prior to undergoing a live leak repair
The pinhole was located on an elbow
A pressurised jet of water escaping from a 150mm pipe elbow in a Malaysia pumping station
Pressurised jet of water spraying from the pinhole leak

The water company’s maintenance team therefore used a SylWrap Universal Pipe Repair Kit to carry out a live leak repair which would be effective on the 150mm elbow operating under 6 bar pressure.

Wrap & Seal Pipe Burst Tape was used to seal the pinhole leak in the pipe. Wrap & Seal is made from self-amalgamating silicone. It stretches by 300 percent and fuses to form a solid rubber band over holes and cracks in pipework.

Wrap & Seal Pioe Burst Tape used to repair a pinhole leak on a 150mm pipe elbow in Malaysia
Wrap & Seal Pipe Burst Tape was stretched by its maximum 300 percent
Wrap & Seal successfully sealed the pinhole leak

Once the Tape had successfully sealed the hole in the pipe, it was overwrapped with a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets rock hard in minutes.

The Bandage was wrapped around the elbow and smoothed down whilst water from a bucket was poured over it at sporadic intervals. Once cured, SylWrap HD provided an impact resistant shell around the elbow, preventing it from any future leaks or bursts.

Within 30 minutes of the start of the application, the maintenance team had successfully repaired the elbow with no interruption to operations at the pumping house.

SylWrap HD Pipe Repair Bandage used to reinforce a repair on a 150mm elbow joint in a Malaysia pumping station
SylWrap HD Bandage was used to reinforce the repair
The repair was completed in less than 30 minutes

Both Wrap & Seal and SylWrap HD are WRAS approved, meaning that they are certified as safe to use on pipes and fittings carrying drinking water according to British Standards.

Numerous other successful pipe repair applications have since been made in Malaysia using Wrap & Seal and SylWrap HD supplied in a SylWrap Pipe Repair Contractor Case.

This has led the Case to be approved by the national supplier in Malaysia for carrying out leak repairs across Kuala Lumpur’s vast pipe network.

Each Contractor Case contains enough products to make up to six live leak repairs on pipes of all diameters and types without the need for any training.

The Case can be easily stored on-the-van, providing a lightweight and more versatile alternative to carrying around heavy, bulky pipe repair clamps.

When leaks and bursts on the water network are identified, a contractor simply has to reach for the Case on their van to repair the problem in under 30 minutes.

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