Author: Scott McCarthy

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Case Study: Repair of a Leaking 200mm Fuel Oil Line Pressure Resistant to 44 bar in Libya

Sylmasta repair a 200mm underground oil fuel line in Brega, Libya suffering from a crack caused by heavy corrosion

Fuel for thought – a high pressure, high temperature pipe repair keeps an oil line in Libya operating

Heavy corrosion caused a small crack to appear in a 200mm fuel oil line buried underground in Libya, leaving the pipe requiring a repair that could withstand pressure up to 44 bar and temperatures up to 70°C

Case Study Data

Site
Underground fuel oil line
Location
Brega, Libya
Repair Type
Leak repair
Defect
Small crack in 200mm pipe

Products Used

Wrap & Seal Pipe Burst Tape
Multiple self-fusing silicone repair tapes used for creating a high pressure seal over the crack

SylWrap HD Pipe Repair Bandage
Provided an impact resistant protective shell over the initial repair, reinforcing the line

SylWrap Pipe Repair Contractor Case
Contains multiple Wrap & Seals and SylWrap HD Bandages to carry out up to six live leak repairs

Case Study PDF

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Case Study Details

The town of Brega serves as a major export hub for Libyan oil, being home to one of the five oil terminals operating in the eastern half of Libya. It is also the starting point of the 670 km Brega-Khoms Intisar gas pipeline.

A 200mm fuel oil line required repair after it was found to be leaking underground
Excavation revealed that the pipe was in poor condition

Heavy corrosion had caused a small crack to appear in a 200mm fuel oil line buried underground. Once the pipe had been excavated for inspection, it became clear that it was in terrible condition, badly pitted and covered in escaped oil.

To add to the complexity of the application, the line operated under 44 bar and at temperatures of up to 70°C. Any repair had to be able to withstand these pressure and heat extremes.

Oil leaking from a damaged 200mm fuel pipe line in Brega, Libya
The leak area was a small crack caused by corrosion

Prior to the application, the pipe was cleaned as best as it could be. Oil and dirt was removed and the surface smoothed off to enable a good connection between the line and Wrap & Seal Pipe Burst Tape, which made up the first stage of the repair.

Wrap & Seal is a self-amalgamating silicone repair tape which stretches by 300 percent and fuses to form a solid rubber band over holes and cracks. Multiple tapes can be applied over each other, where they will also fuse together, building repairs with high pressure resistance.

Multiple Wrap & Seal Tapes were used to seal the crack

Once several Wrap & Seals had been used and the team carrying out the repair was satisfied that the leak was suitably sealed, the repair was reinforced using SylWrap HD Pipe Repair Bandage.

SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes. It provides an impact resistant protective shell to pipes and structures, increasing life span and hoop strength.

200mm fuel oil line in Brega, Libya undergoes leak repair using a Sylmasta Pipe Repair Kit
The line was reinforced using SylWrap HD

Four SylWrap HD Bandages were used to cover the repair area, reinforcing the fuel oil line before it was reburied. Each Bandage cured within 2 to 5 minutes of application.

Both Wrap & Seal and SylWrap HD have a maximum service temperature of 250°C and using multiple products created a repair capable of withstanding the pressure that the line operated under.

Completed repair prior to the line being reburied

It took less than two hours to complete the application, notwithstanding the time to excavate and inspect the pipe. The repair was a cost-effective and less time-consuming alternative to replacing the damaged section, which could have left the line out of operation for a prolonged period.

The maintenance team who carried out the job in Brega have since gone onto use Sylmasta products to make numerous repairs to other oil lines in the region, taking advantage of the ease and convenience offer by the SylWrap range.

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 a Cracked Copper Pipe in a Camper Van Boiler System

A copper pipe in a camper van boiler system undergoes repair using Superfast Copper Epoxy Putty and a SylWrap HD Pipe Repair Bandage

Carry on camping – a difficult-to-access copper pipe in a camper van boiler system undergoes repair

A camper van owner manages to repair a crack in a copper pipe located within the van’s boiler system, despite the leak area being extremely difficult to access

Case Study Data

Site
Camper van boiler
Location
United Kingdom
Repair Type
Leak repair
Defect
Crack in a copper pipe

Products Used

Superfast Copper Epoxy Putty Stick
Fast-working epoxy putty pushed into the crack in the copper pipe to seal it

SylWrap HD Pipe Repair Bandage
Composite repair wrap applied over Superfast Copper to reinforce the initial repair

SylWrap Standard Pipe Repair Kit
Superfast Epoxy and SylWrap HD are supplied together in the Standard Pipe Repair Kit

Case Study PDF

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Case Study Details

The boiler system provided heat and hot water to the camper van. A deep crack appeared in a copper pipe located underneath the cover of the boiler, causing a pressurised jet of water to spray out whenever the boiler was turned on.

Problematically, the crack was located at a point where the pipe angled towards the back casing of the boiler. It faced towards the side of the casing with access extremely limited.

  • A crack in a copper pipe which was part of a camper van boiler system before undergoing repair using a Sylmasta Pipe Repair Kit
A jet of water escaped the copper pipe whenever the boiler was put into operation

The confined space meant that there was no room to fit a pipe repair clamp, nor apply Wrap & Seal Pipe Burst Tape with enough stretch for it to self-amalgamate effectively.

Because the boiler could be turned off, Sylmasta recommended to the camper van owner that they use Superfast Copper Epoxy Putty Stick to plug the crack in the pipe.

Superfast Copper comes in a 114 gram stick format and has a work time of 5 to 10 minutes, enabling rapid repairs to be made to copper and other non-ferrous metals.

  • Superfast Copper Epoxy Putty being applied to repair a crack in a pipe which formed part of a camper van boiler system
Superfast Copper applied to the crack in the pipe

Before the application began, the pipe was cleaned and dried to aid the adhesion of the putty to the metalwork. The required amount of putty was cut from the stick and kneaded by hand.

Whilst soft, the putty was pushed into the crack in the copper pipe where it hardened, sealing the hole. Enough putty was used to cover the section of pipe both above and below the crack to improve the chances of success.

To reinforce the putty, the entire section of pipe was then covered with a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes to provide an impact resistant layer of protection.

  • Superfast Copper Epoxy Putty used to seal a hole on a copper pipe in a camper van boiler system
Superfast Copper and SylWrap HD successfully sealed the crack

Typically, SylWrap HD would be wrapped around the pipe. The space constraints meant that this could not be done effectively in this particular application, and so the bandage was cable tied to the pipe whilst it cured.

Once the copper pipe repair was completed, the boiler was turned back on. Water was no longer escaping from the crack, denoting a successful boiler pipe repair and saving a considerable amount of money for the camper van owner compared to the cost of fitting a replacement pipe.

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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What is epoxy coating, how does it work and what is it used for?

Liquid Metal epoxy coating applied to refurbish an old and worn red pipe at Sylmasta HQ

Brush up on your knowledge of brushable epoxy

Imagine if you could do something as a simple as paint a pipe, a part or a structure to provide it with a metal layer of armour capable of resisting corrosion, abrasion and chemical attack. Welcome to the world of the epoxy coating.

They say prevention is better than a cure and prevention of degrading surfaces does not come any better than epoxy coating. Within a couple of hours, a smooth, hard surface can be created that repairs existing wear and tear and prevents against future damage.

Here is the Sylmasta guide to epoxy coatings and how they can help you refurbish and extend the lifespan of systems, with potential savings of thousands and thousands of pounds.

What is an epoxy coating?

Epoxy coatings are made up of two separate liquid parts, one containing resin and the other containing hardener.

When these parts are mixed together, a chemical reaction takes place which results in the epoxy coating setting to form a hard wearing, ultra smooth coating.

What are epoxy coatings used for?

Epoxy coatings have two main uses. The first is for protecting and refurbishing structures, pipes, machinery and surfaces by providing them with an ultra-hard outer layer.

New parts which are coated with a brushable epoxy are protected against corrosion, abrasion, chemical attack, pitting, erosion and cavitation.

Old, worn or damaged parts are restored when an epoxy coating is applied via the creation of a new, hard layer which extends the lifespan of parts.

Take this repair made to aluminium extruder barrels in a pug mill putty machine for example. The rough initial finish of the barrels combined with the silica-filled putty causing damage as it was extruded had caused the aluminium to become worn.

This in turn was impacting on the efficiency of the machinery, as putty was being extruded at a reduced rate. Cleaning of the barrels also took longer because of the damage to the surface.

Applying an epoxy coating to the barrels repaired the worn surfaces, protected them from future abrasion caused by the putty and created an ultra-smooth layer for the putty to slide down, improving extrusion rate.

Epoxy coatings are also used for high-strength bonding of materials. Whilst still a liquid, they remain gel-like and sticky, during which components can be bonded to them.

When used in floor repair, ant-slip grit can be added to a floor painted with epoxy coating to create a non-slip surface. In pipe repair applications, an epoxy coating improves adhesion between the pipe and composite repair wrap.

How does an epoxy coating work?

Applying an epoxy coating is as simple as painting a wall. Once the two parts have been mixed to the prescribed ratio, a traditional paintbrush is used to coat the surface requiring protection.

The formulation of the epoxy coating will determine the cure time. Sylmasta epoxy coatings come with a 90 minute gel time, enabling more of the epoxy to be mixed without the threat of premature curing.

This is particularly useful in warmer climates, where heat accelerates the work time, reducing how long is available to carry out an application.

To create a pinhole free coating, it is recommended that two coats are used. The re-coating time is 5-8 hours after applying and a full cure is achieved in 24 hours.

Types of epoxy coating

Epoxy coatings can be filled with different materials to improve their effectiveness for use in specific applications, such as corrosion protection or prevention of abrasive wear.

Liquid Metal Epoxy Coating is metal-filled, setting to provide a layer of metallic armour to pipes, structures, machine parts and surfaces. It is formulated to offer excellent protection against corrosion and chemical attack.

Painting worn and damaged parts with Liquid Metal refurbishes them, extending the lifespan of systems. As well as metalwork, Liquid Metal can be used to give most plastics a metal coating.

For protection against surface wear, it is desirable to have an even harder epoxy coating. Ceramic Brushable Blue is ceramic-filled and reinforced with silicone carbide, enabling it to resist and repair damage caused by abrasion.

Sylmasta Epoxy Coatings

If you have any question about which product is most suitable for your repair or require technical assistance, then please contact Sylmasta via email or on +44 (0)1444 831459 and a technician will be happy to advise you.

Epoxy coating applications

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Case Study: Bahrain International Airport Repair of Leaking Step Joint on 100mm UPVC Pipe

A leaking 100mm UPVC pipe at Bahrain International Airport undergoes a live leak repair using a SylWrap Pipe Repair Contractor Case

Flying high – the live leak repair of a 100mm UPVC pipe step joint which kept a system operational at Bahrain International Airport

When a 100mm UPVC pipe which was part of an important system at Bahrain International Airport began leaking from a step joint, a quick-and-easy live leak repair method was required as shutting down the line was not an option.

Case Study Data

Site
Airport
Location
Bahrain
Repair Type
Live leak repair
Defect
Leaking step joint on a 100mm UPVC plastic pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape which sealed up and over the leaking step joint

SylWrap HD Pipe Repair Bandage
Applied over the sealed step joint to reinforce the repair by providing a rock hard, impact resistant layer

SylWrap Pipe Repair Contractor Case
Products were supplied as part of a Contractor Case, capable of making up to six live leak repairs

Case Study PDF

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Case Study Details

UPVC is a strong and versatile pipe material which is assembled using a solvent cement to bond pieces together. Sometimes, these bonds can loosen and begin leaking, which is what happened to the 100mm pipe at Bahrain Airport.

The leak in question was through a step joint connecting two sections of pipe together. The pipe could not be shut off for a repair because of the importance of the airport system it supported.

This meant that the normal method Sylmasta recommend to clients for sealing a leaking step – by using a Superfast Epoxy Putty Stick to plug the gaps between the joint and the pipe – would not be effective because the pipe was wet.

  • Wrap & Seal Pipe Burst Tape being used to repair a step joint on a UPVC Pipe at Bahrain International Airport
The pipe was leaking from behind the left hand side of the joint

The airport therefore had to use Wrap & Seal Pipe Burst Tape as their sealing material. Wrap & Seal is a self-amalgamating silicone repair tape which stretches by 300 percent, fusing to form a solid rubber band over leak areas.

Using Wrap & Seal on a step is not as straightforward as wrapping a straight section of pipe. To create a repair capable of sealing the step between the 100mm UPVC pipe and the sleeve, the maintenance team carrying out the application began wrapping approximately 100mm away from the joint.

  • Wrap & Seal Pipe Burst Tape applied to a step joint on a 100mm UPVC pipe as part of a live leak repair
A ridge was created using Wrap & Seal to seal up and over the step

After approaching the sleeve by overlapping the Tape by 50 percent, they then built up layers of Wrap & Seal immediately next to the joint. This created a ridge. When this ridge reached near-level height with the step, the application of the Tape continued for a further 50mm across the step joint to fully encompass it.

Two 50mm x 4m Wrap & Seals were required before it was established that water had stopped escaping the joint and the leak was fully sealed. The repair was then completed by applying a SylWrap HD Pipe Repair Bandage over the Tape.

SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes. The Bandage was wrapped around the pipe and smoothed down using water poured onto the pipe from a bottle. It cured to provide an impact resistant, protective shell.

  • SylWrap HD Pipe Repair Bandage used to reinforce a 100mm UPVC pipe leaking from a step joint
The repair was completed with a SylWrap HD Bandage

The entire repair was carried out in less than 30 minutes whilst the pipe remained in operation. The two Wrap & Seal Tapes and SylWrap HD Bandage were supplied to the maintenance team as part of a SYL-PRO-633 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. The Case is easy-to-store on site and transport, ensuring that everything needed to fix a leaking pipe is close to hand and enabling repairs to be made as soon as problems are identified.

Following the success of the 100mm UPVC pipe repair, the maintenance team have since gone onto use Contractor Cases at the Airport to fix 150mm and 200mm pipes suffering from similar problems.

Case Study Video

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: Creating an Abrasion Resistant Surface for Pug Mill Extruder Barrels

Ceramic Brushabkle Blue Epoxy Paste created an abrasion resistant surface for worn aluminium barrels in a pug mill putty extruder

Putty in their hands – Ceramic Brushable provides an abrasion resistant surface coating to improve pug mill putty extruder efficiency

Aluminium barrels in several pug mill putty extruders suffering from both abrasive wear and a rough initial finish are given an ultra-smooth, abrasion resistant surface coating to improve their efficiency

Case Study Data

Repair Type
Abrasion Protection
Defect
Worn aluminium barrels in pug mill putty extruders

Products Used

Ceramic Brushable Blue Epoxy Coating
Ceramic-filled epoxy coating painted onto surfaces and parts to create a smooth, abrasion resistant layer

Case Study PDF

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Case Study Details

Silica-filled putty was extruded from the pug mills via aluminium barrels. Over time, the silica in the putty had caused abrasive wear to the surface of the barrels as it passed through.

This wear combined with the initial rough cast finish of the aluminium had caused the flow rate of putty from the pug mills to slow dramatically, impacting on efficiency.

  • A badly worn putty extruder had become inefficient because of abrasion
Barrels in the putty extruders were suffering from heavy wear

To help the extruders run more efficiently, a means of improving the flow rate through the barrels by filling in existing damage and creating an ultra-smooth finish was sought.

After researching cost and ease of repair, machining the barrels was ruled out as it would have been difficult, expensive and too time consuming.

Instead, it was decided to paint the aluminium barrels in every putty extruder with a low friction coating for increased extrusion rate. The coating used in the repair also needed to be abrasion resistant to protect the aluminium from further wear.

  • Ceramic Brushable Blue is an easy to use epoxy coating used to create abrasion resistant surface to machines, parts and surfaces of all materials
Ceramic Brushable Blue was easy to mix and apply to the extruder barrels

Ceramic Brushable Blue was the obvious solution. It is ceramic-filled and reinforced with silicone carbide for ultimate hardness. It is used on both new and old machines and parts in highly abrasive environments.

Coating new surfaces with Ceramic Brushable Blue provides a toughened, reinforced layer of protection from wear, extending the lifespan of parts.

When used on older machine parts and surfaces such as the putty extruder barrels, Ceramic Brushable Blue repairs damaged areas as well as offering protection against abrasion.

  • Ceramic Brushable Epoxy Coating applied to provide an abrasion resistant surface to a putty extruyder to improve efficiency
The epoxy coating gave a low friction surface to the barrels

Ceramic Brushable Blue was easy to apply. The parts were mixed and then the coating painted on using a conventional paintbrush. The 90 minute work time allowed larger quantities of epoxy to be mixed and applied in one go without the threat of premature curing.

It took one day to coat every pug mill putty extruder barrel with the required amount of Ceramic Brushable Blue. A full cure was achieved 24 hours after the final coat, meaning that there was minimal disruption to production.

  • Sylmasta Ceramic Brushable Epoxy Coating used to create an abrasion resistant surface for a pug mill putty extruder aluminium barrel
Ceramic Brushable Blue provided a low friction, ultra-smooth finish

The non-stick, smooth finish of Ceramic Brushable also enabled quicker and easy cleaning of the barrels. Less time needed for the maintenance of the extruders resulted in even greater efficiency for the pug mills.

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 & Refurbishment of a 19th Century Pit Wheel at Mordiford Mill

A 19th century cast iron pit wheel in Mordiford Mill, Herefordshire undergoes repair and refburbishment with Sylmasta AB Epoxy Putty

Big wheel keeps on turning – the repair and refurbishment of a 19th century pit wheel using Sylmasta AB Epoxy Putty

When the repair and refurbishment of a 19th century pit wheel required a waterproof, corrosion resistant material to protect the cast iron wheel from water and help bond two protective steel hoops for reinforcement, Sylmasta had the ideal solution.

Case Study Data

Site
Mordiford Mill
Location
Herefordshire, United Kingdom
Repair Type
Corrosion protection, water ingress prevention & high strength bonding
Defect
Cracked & weakened 19th century cast iron pit wheel

Products Used

Sylmasta AB Original Epoxy Putty
Water resistant epoxy putty with high strength adhesion and a long work time for complex and larger applications

Case Study PDF

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Case Study Details

Mordiford Mill is a 19th century tall stone corn mill in Herefordshire. A water wheel connects to a three metre diameter cast iron pit wheel which drives iron machinery and two pairs of stones.

The Mill ceased grinding flour in 1935. Over 80 years later and the Mill’s latest owner was undertaking a long-term refurbishment project to make it turnable again. One of the most challenging aspects of this was the repair of the pit wheel.

Pit Wheel at Mordiford Mill suffering from numerous cracks and breaks before refurbishment and repair with Sylmasta AB Epoxy Putty
The pit wheel was suffering from cracks and breaks in several places

Corrosion and the passage of time had weakened the castings of the wheel. Both the inner and outer castings had been unusually thin for a pit wheel when they were originally installed in the 1800s, and two generations of previous repair attempts had been unable to suitably reinforce them.

The wheel was cracked and broken in various places. Calculations indicated sudden impacts such as a cog breaking would cause the casting to break apart again – possibly irreparably.

Sylmasta AB Epoxy Putty applied to a 19th century cast iron pit wheel in Mordiford Mill, Herefordshire
Sylmasta AB being applied to the outer casting of the wheel

Replacement was not a viable option because the cost of doing so exceeded the budget of the project. The only way to get Mordiford Mill operating again was by finding a repair and refurbishment method for the pit wheel.

It was decided to strap both the inside and the outside of the wheel with steel hoops to encompass the 19th century ironwork. This would reinforce the pit wheel, ensuring it had adequate protection from future impacts.

Repair and refurbishment of a pit wheel at Mordiford Mill
Steel reinforcement hoop applied over Sylmasta AB and held in place with clamps

These steel hoops could not be welded to the pit wheel because of the dangers associated with welding old cast iron, which tends to explode due to air pockets within the iron. No welder would guarantee a result as success of such a process is less than 50 percent.

Welding would also have left gaps between the steel hoops and the uneven, damaged casting of the wheel. Water entering these gaps would potentially collect inside them, leading to further corrosion of the original cast iron.

Once the putty had cured, the steel hoop was screwed into place

As a water-resistant material capable of high-strength bonding, Sylmasta AB Original Epoxy Putty provided the ideal solution for encompassing the cast iron to prevent water ingress at the same time as aiding the adhesion of the steel hoops to the wheel.

Prior to the application of Sylmasta AB, the casting was cleaned with a needle gun and a wire brush on an angle grinder. This removed rust, grime and dirt from the surface.

The long work time of Sylmasta AB meant that large quantities could be mixed in one go without the worry of premature curing. The putty was applied to the outside casting of the wheel first, after which large sections of the steel hoop were fitted over the putty and held in place using clamps.

Steel hoop screwed into place on the outside casting

The steel hoop was then screwed in place and the clamps removed. The entire process was repeated to the inside casting, although this was slightly more challenge because of the spokes of the pit wheel connecting with the casting.

To overcome this, the application was broken down into smaller sections between each spoke. Sylmasta AB was applied and a small section of steel hoop added, clamped and screwed, before moving onto the next section on the inner wheel.

Clamps fitted to hold a smaller section of steel hoop to the inside of the pit wheel in-between spokes

Once completed, the original pit wheel was successfully reinforced with a steel casing that would last for many years and the presence of Sylmasta AB meant that no corrosion caused by trapped water could attack the ironwork.

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: Reinforcement of Weakened Pipe Elbow Joint on 100mm 22 bar Sulphuric Acid Line

A 100mm pipe elbow undergoes reinforcement after the sulphuric acid line it was part of was found to have degraded by 21mm thickness

Chemical romance – the repair and reinforcement of a sulphuric acid line pipe elbow found to have degraded in thickness by 21mm

A pipe elbow on a 100mm sulphuric acid line operating under 22 bar pressure which had degraded from 22mm thickness to just 1mm undergoes urgent repair and reinforcement in Saudi Arabia.

Case Study Data

Site
Petrochemical Refinery
Location
Saudi Arabia
Repair Type
Pipeline reinforcement
Defect
Weakened elbow joint on a 100mm sulphuric acid line

Products Used

Industrial Metal Epoxy Paste
Applied to the elbow joint to strengthen it via the creation of a shell resistant to corrosion and chemical attack

SylWrap HD Pipe Repair Bandage
Applied over Industrial Metal for further reinforcement by encompassing the elbow with a rock hard protective sleeve and increased hoop strength

Case Study PDF

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Case Study Details

The petrochemical refinery produces over 140 million barrels of petroleum products and 5 million tons of petrochemical products every year, including naphtha, kerosene, gasoline, diesel and fuel oil.

During a routine inspection, a 100mm sulphuric acid line operating under 22 bar pressure was found to have degraded to only 1mm thickness from 22mm on an elbow joint. This required urgent attention before the line failed.

The scale of production at the site meant that the petrochemical company were keen not to have to shut down the line to replace the weakened section, as this would severely impacted on output.

They therefore needed a flexible method of reinforcement for making an effective repair to the elbow on the sulphuric acid line which, for example, a pipe repair clamp would not have been capable of.

A pipe elbow in a line carrying sulphuric acid undergoes repair using Sylmasta Industrial Metal Epoxy Paste
The elbow joint was reinforced using Industrial Metal Epoxy Paste

The petrochemical refinery consulted an engineering company with whom Sylmasta work with in the region, and they decided to apply Industrial Metal Epoxy Paste to the elbow to strengthen it.

Industrial Metal is reinforced with corrosion-resistant metal platelets which provide excellent protection against corrosion and chemical attack, creating a tough outer shell around pipes and structures.

Industrial Metal Epoxy Paste is applied to a pipe elbow joint in Saudi Arabia to reinforce a weakened 100mm sulphuric acid line
Industrial Metal applied to the elbow using a putty knife

The epoxy paste was spread over the area requiring reinforcement using a putty knife. The 60 minute work time allowed for a large quantity of paste to be mixed and applied without the threat of premature curing, an especially important consideration given the hot climate.

If the remaining 1mm degraded further and the original line was breached, its contents would now be contained by a casing with high chemical and corrosion resistance surrounding the elbow provided by the cured Industrial Metal.

To further reinforce the elbow, SylWrap HD Pipe Repair Bandage was applied over the Industrial Metal. SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in 30 minutes.

It provided an impact resistant layer of protection over the elbow, increasing the hoop strength of the line until such time as a replacement could be conveniently carried out.

Repair completed with SylWrap HD for increased hoop strength

Whilst the reinforcement took place, the pressure was reduced to 8 bar with only a minor amount of disruption to operations at the site. 24 hours after the repair had been completed, the line was restored to its normal 22 bar pressure..

The petrochemical refinery were delighted with the ease and speed of repair made possible by Sylmasta. Regular inspections of the line showed that there had been little to no decrease in the strength of the repair over two years later.

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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Sylmasta are Industrial Process Pipe Maintenance Company of the Month

A contaminated water pipe at a wastewater treatment works in the United Kingdom is repaired after being accidentally breached during construction work

Industrial Process News Magazine recognise Sylmasta’s contribution to leak reduction through composite pipe repairs

Sylmasta have been named as Pipe Maintenance Company of the Month in the July 2021 edition of Industrial Process News Magazine.

The editorial team were impressed with the work Sylmasta have carried out on reducing leakage on the United Kingdom’s water network and in other industries worldwide through their SylWrap range of pipe repair products.

Sylmasta have partnered with several of the UK’s water utilities company, supplying them with SylWrap Pipe Repair Contractor Kits. Each kit enables any contractor to make up to six WRAS approved live leak repairs to pipes of all types and diameters without the need for any formal training in under 30 minutes.

The Case is designed to be easily stored on a van. As soon as a burst is identified by a water company on their network, they can send a vehicle equipped with everything needed to fix the problem. This rapid response time reduces the amount of water lost.

A SylWrap repair is effective on complex sections of pipe such as tees and elbows where pipe repair clamps cannot be deployed. The materials involved are also more lightweight, making them easier to manoeuvre and transport than heavy, bulky clamps.

Carrying out a SylWrap repair is a simple two-stage process. The leak is sealed with Superfast Epoxy Putty if pressure can be turned off or Wrap & Seal Pipe Burst Tape if pressure cannot be turned off. The initial sealing material is then overwrapped with a SylWrap HD Pipe Repair Bandage.

SylWrap HD is a water-activated composite wrap which sets rock hard in minutes, reinforcing the repair and providing an impact resistant protective sleeve over pipework.

Repairs made using SylWrap are permanent and they offer a cost-effective alternative to replacing damaged sections of pipeline.

Sylmasta’s recognition by Industrial Process News comes at a time when there is growing pressure to reduce leaks across all industries, with the water industry under particular scrutiny.

A report by the House of Commons Public Accounts Committee released in 2020 said that unless urgent action was taken to cut water wastage, Britain could experience water shortages by 2040.

The water industry have been set ambitious targets when it comes to leak reduction by the regulator Ofwat and the Department for Environment, Food and Rural Affairs (DEFRA).

In England and Wales, leaks must be reduced by 16 percent by 2025, a saving of 561 million. Longer-term targets are to cut water loss from 2020 levels by a third before 2030 and by half before 2050.

Whilst water companies are focused on identifying bursts which may otherwise leak for weeks, months or even years without ever been noticed, there is a growing realisation that this is only half the battle.

Companies also need to be able to repair these leaks quickly and efficiently to reduce leakage levels. The quick repair time of SylWrap can play an important role in doing so.

Away from water, Industrial Process News highlighted the work that Sylmasta do in helping other sectors repair and maintain their own systems, saving water and helping to reduce downtime.

SylWrap pipe repair solutions are used in wastewater treatment, nuclear power stations, petrochemical plants, quarries, agriculture, and by facilities management companies responsible for hotels, leisure facilities and hospitals to name but a few.

SylWrap pipe repair kits are already used on a worldwide scale with several countries in Africa, South America and Asia adopting composite repair.

They are approved by the national water supplier for use on Kuala Lumpur’s vast pipe network and have been used on the water network of Mexico.

With the importance of preserving water for the good of the planet likely to become a more pressing issue in the years to come, the reach of Sylmasta and the SylWrap range of pipe repair kits is only going to extend.

Click here to read issue 702 of Industrial Process News in which Sylmasta were named Pipe Maintenance Company of the Month

Sylmasta Leak Repair Case Studies

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Case Study: 650mm Ductile Iron Pipe Located in Pit Undergoes Live Leak Coupling Joint Repair

A 2 metre section of 650mm pipe buried in an inspection chamber was discovered to be leaking, excavated and then sealed using SylWrap pipe repair products

Coupling goals – the challenging repair of an iron water pipe discovered to be leaking from coupling joints in a disused pipe inspection chamber

A 2 metre section of 650mm ductile iron pipe buried in a former underground inspection pit is excavated by a UK water company to undergo repair after it was found to be leaking from two coupling joints.

Case Study Data

Site
Inspection Pit
Location
United Kingdom
Repair Type
Live leak repair
Defect
650mm ductile iron pipe leaking from coupling joints

Products Used

Wrap & Seal Pipe Burst Tape
Multiple self-fusing silicone repair tapes used for building up a repair to seal the coupling joints

SylWrap HD Pipe Repair Bandage
Reinforced the coupling repair and fortified the pipe from further deterioration before it was reburied

SylWrap Pipe Repair Contractor Case
Contains multiple Wrap & Seals and SylWrap HD to carry out up to six live leak repairs

Case Study PDF

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Case Study Details

The pit had originally been an inspection chamber housing a valve. Many years ago, the valve had been replaced with a two metre section of straight ductile iron pipe attached to the existing pipe carrying mains water via two coupling joints.

After the straight section was fitted, the whole chamber had been filled in with earth and covered over, where it remained forgotten. That was until the water company responsible for the pipe rediscovered it during maintenance work.

Contractors discovered a 2 metre long section of 650mm ductile iron pipe buried in what used to be a valve chamber was leaking
The 2 metre section of pipe with raised couplings at either end

Soil within the pit was found to be extremely muddy, suggesting that the pipe was leaking in the chamber. After excavating the entire pit to investigate further, the water company discovered that the pipe was in poor condition with slight seepage from both couplings.

The water company decided to seal the couplings to prevent further leakage. Each coupling was 80mm wide but 100mm higher than the 650mm pipe, presenting contractors with an awkward ridge that the repair needed to wrap over.

There were also challenges with the clearance in the pit. The two couplings gave only 35mm underneath in which to work. Conditions within the chamber meant that any repair material wrapped around the pipe would be in danger of picking up mud and dirt off the floor.

Coupling joints on a 650mm ductile iron pipe were leaking before undergoing a leak repair using SylWrap Pipe Repair products
Raised couplings were 100mm higher than the pipe

To overcome this, a polythene sheet was squeezed underneath the pipe. For sealing the couplings, multiple Wrap & Seal Pipe Burst Tape were used to build a repair over and around the couplings.

Wrap & Seal is made from self-amalgamating silicone which fuses to form a solid rubber band for live leak repairs. Separate Tapes will also fuse to each other, this being how the repair was built up and the difficult ridge shape of the coupling sealed.

Each coupling and the surrounding area was then encompassed with a SYL1266HD SylWrap Pipe Repair Bandage. SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes to provide an impact resistant layer of protection.

  • A 2 metre section of pipe in a valve chamber leaking from coupling connections undergoes repair
The completed repair with both couplings encapsulated with SylWrap HD

SYL1266HD Bandages are 300mm wide, giving them more than enough coverage to be moulded around the raised coupling. With the reinforcement provided by SylWrap, the water company could rebury the pipe safe in the knowledge that the leaks were sealed and the pipe had been suitably fortified to prevent further deterioration.

Both Wrap & Seal and SylWrap HD have WRAS approval, meaning that they are certified to British standards as safe to use on pipes carrying drinking water. Because the pipe carried mains water, it was a legal requirement that any repair materials used had to be WRAS approved.

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: Live Leak Repair of a Cracked 4 bar 250mm PCCP Pipe Stub in Saudi Arabia

A PCCP pipe stub leaking through several cracks undergoes a live leak repair in Saudi Arabia

No more stress over a cracked prestressed concrete cylinder pipe – the SylWrap live leak repair which sealed a PCCP stub

After several failed attempts to repair a badly cracked 250mm PCCP pipe stub with no isolation valve, an engineering company in Saudi Arabia turned to Sylmasta for a live leak repair method

Case Study Data

Site
Industrial Site
Location
Saudi Arabia
Repair Type
Live leak repair
Defect
Cracked 250mm PCCP stub with no isolation valve operating under 4 bar pressure

Products Used

Wrap & Seal Pipe Burst Tape
Multiple self-fusing silicone repair tapes combined to build a high pressure seal over the leak areas

SylWrap HD Pipe Repair Bandage
Reinforced the initial repair with wrapping extended to protect the entire stub

SylWrap Pipe Repair Contractor Case
Contains multiple Wrap & Seals and SylWrap HD to carry out up to six live leak repairs

Case Study PDF

Download

Case Study Details

The prestressed concrete cylinder pipe (PCCP) stub was connected to a main header operating under 4 bar pressure. Wear and tear had caused numerous cracks to appear in the stub, through which significant amounts of water was escaping and causing flooding.

Because there was no isolation valve, preventing flow to the stub from the main header was impossible. Shutting off the main pipe for carrying out either a repair or replacement was impractical and there was not enough room between the stub and the floor to fit a pipe repair clamp.

A 250mm prestressed concrete cylinder pipe leaking from several cracks
Water was gushing from several cracks on the PCCP stub

A live leak repair method was therefore needed. This proved extremely challenging and after several attempts which failed to make any reductions in the amount of water being lost, the engineers charged with fixing the stub turned to Sylmasta.

As this was a live leak, Wrap & Seal Pipe Burst Tape was used to seal the cracks on the stub. Wrap & Seal is made from self-amalgamating silicone and stretches by 300 percent to fuse into a solid rubber band around pipework.

SylWrap HD Pipe Repair Bandage being used to reinforce Wrap & Seal as part of a live leak repair on a 250mm leaking PCCP stub pipe
SylWrap HD was applied over the top of multiple Wrap & Seal Pipe Burst Tapes

Multiple Wrap & Seals were applied down a 200mm area of the stub. In the same way in which a single tape amalgamates to itself, these separate tapes fused together to create a repair with enough pressure resistance to seal the cracks.

Once the engineers were satisfied that the leaks had been suitably arrested, the stub was overwrapped with SylWrap HD Pipe Repair Bandages.

Repair reinforced with initial layer of SylWrap HD

SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes. It reinforced the repair by providing an impact resistant sleeve around the PCCP pipe stub

After this section of the stub had been sealed, it was decided to reinforce the underground section at the same time. Doing so would protect the remainder of the ageing pipe from future ruptures, which might prove difficult to identify if they were leaking below the floor.

Completed live leak repair of a 250mm PCCP pipe stub in Saudi Arabia
Entire pipe protected with SylWrap after the floor was removed to access the buried section

The floor was dug up around the stub to reach the pipe. Once accessed, a further 200mm section of previously underground pipe was wrapped with SylWrap HD.

One final covering of SylWrap HD was then applied over the bandages already covering the two phases of the repair, encompassing the entire stub and providing reinforcement before the floor was relaid.

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