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Case Study: Emergency Repair of Hospital 300mm Air Conditioning Pipe on Hottest Day of June

A water return pipe in a Lonndon hospital air conditioning unit undergoes a SylWrap repar to ensure that the system could remain in operation

Keep cool and carry on – a SylWrap repair gets a hospital air conditioning system back in operation on the hottest day of June

On a day when temperatures in London reached 27ºC, a burst 300mm water return pipe forced the shutdown of a hospital air conditioning system until a SylWrap emergency leak repair was made

Case Study Data


Site
Hospital
Location
London, United Kingdom
Repair Type
No pressure leak repair
Defect
Two deep cavities in a 300mm air conditioning water return pipe operating under 12 bar pressure

Products Used


Superfast Steel Epoxy Putty Stick
Fast setting epoxy putty used to fill in the deep cavities in the water return pipe

Wrap & Seal Pipe Burst Tape
Multiple self-fusing silicone repair tapes provided additional leak sealing security

SylWrap HD Pipe Repair Bandage
Two layer application completed the repair with an impact resistant protective sleeve

Case Study PDF


Case Study Details


The 300mm water return pipe was located in a cabinet alongside other service pipes. It burst through a previous repair attempt, requiring an immediate shutdown of the air conditioning system as water escaping the pipe at 12 bar pressure would have caused internal flooding.

This shutdown left the hospital building without any temperature control on the hottest day of the year. The burst was initially discovered in the middle of Sunday night, at which point the hospital immediately contacted their maintenance team.

The maintenance team arrived at Sylmasta HQ first thing on Monday morning to collect the products needed to carry out a repair. Sylmasta technicians were also able to offer technical assistance based on photos of the burst air conditioning pipe.

Coarse fibreglass strands remained on the pipe from the previous repair. It was decided to cut these away to enable the maintenance team to locate the actual leak site and have a better chance of sealing it.

Two distinct leak areas were stripped back, revealing two deep cavities in the pipe. These were filled with Superfast Steel Epoxy Putty, a fast curing putty supplied in stick format.

Superfast Steel is kneaded by hand and pushed into areas of damage whilst soft. Within 5 to 10 minutes, the putty had hardened to seal the cavities in the pipe.

Because of the inconsistent substrates in this case, it was decided to take a ‘belt and braces’ approach to the repair and use Wrap & Seal Pipe Burst Tape to provide additional leak sealing security.

The entire leak area was wrapped with multiple layers of Wrap & Seal, a self-amalgamating silicone repair tape which fuses to form a solid rubber band for high-pressure resistant repairs.

Combining Superfast Steel and multiple Wrap & Seals created a repair with resistance to the required 12 bar and ensured that there was no chance of seepage of water around the epoxy putty.

Once it had been established that the leak had been completely sealed, the application was finished with the wrapping of two SYL866HD SylWrap HD Pipe Repair Bandages over the repair.

SylWrap HD is a water activated composite wrap which sets rock hard in minutes. It provided a protective sleeve around the pipe, reinforcing the repair even further.

As the temperature began to heat up during Monday morning when the pipe remained out of operation, numerous alarms in the hospital building were triggered as equipment and machinery began to overheat without any air conditioning.

A 300mm water return pipe in a London hospital's air conditioning system is repaired using a SylWrap HD Pipe Repair Bandage
Repair completed with SylWrap HD

The ease and speed with which the products in the SylWrap Pipe Repair range can be applied meant that by Monday afternoon, the pipe was fixed and the air conditioning system back in operation.

Without the air con pipe repair method and the technical assistance provided by Sylmasta, the hospital could have gone days without any air conditioning – a clearly unsustainable situation when temperatures in London were peaking at 27ºC.

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: Buried 600mm Asbestos Cement Pipe Leaking Sleeve Repair in Mexico

A leaking asbestos cement pipe with water escaping from a sleeve undergoes repair in Mexico using a SylWrap Pipe Repair Kit

The 600mm asbestos cement pipe repair which showed Sylmasta have all kinds of tricks up their sleeve

When a water utility company in Mexico discovered that a 600mm asbestos cement pipe was leaking from both ends of a sleeve, they needed to access the buried line and seal the gaps with a repair method flexible enough to be effective when applied in a trench.

Case Study Data


Site
Pipeline
Location
Mexico
Repair Type
No pressure leak repair
Defect
Leaking sleeve on a 600mm asbestos cement pipe

Products Used


Superfast Copper Epoxy Putty Stick
Fast-working epoxy putty pushed into gaps between the sleeve and the pipe to seal the leaks

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape used to force Superfast Copper further into the gaps, strengthening the repair

SylWrap HD Pipe Repair Bandage
Applied over the sleeve to provide an impact resistant layer of protection

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


Case Study Details


The water utility company had been carrying out maintenance work on a 500mm buried pipeline outside the city of Morelia, around a four hour drive from Mexico City.

Whilst undertaking this work, it was discovered that there was a failure in a 600mm asbestos cement parallel line. Water was escaping from both ends of a sleeve on the 600mm pipe.

To replace this damaged section would have been difficult; the pipeline passed under a building less than 10 metres away from the location of the leaking sleeve. Excavation of the pipe would also have been challenging.

A trench was dug to access the asbestos cement pipe, affording 500mm of space on one side, 1.7 metres on the other and minimal space between the line and the ground. Any repair method therefore needed to be effective in tight spaces.

Superfast Copper Epoxy Putty was used to plug the gaps between the sleeve and the surface of the pipe, through which water was escaping.

The Putty was kneaded by hand and pushed firmly into the gaps at both ends of the sleeve. Within 10 minutes, the Putty had begun to harden to seal the space.

To further reinforce the putty and add another leak sealing layer, each joint was wrapped with a Wrap & Seal Pipe Burst Tape. Despite the space constraints, the Tape was stretched by the maximum 300 percent to form a solid silicone band.

Completing the application, a SylWrap HD Pipe Repair Bandage was used to encompass the entire sleeve. SylWrap HD provided one final, impact resistant layer of protection to the pipe before it was re-buried.

All the products required for the repair were supplied as part of a SYL-PRO-50-150 SylWrap Pipe Repair Contractor Case, containing enough products to make up to six live leak repairs.

In this instance, the Case was the most suitable product as multiple Wrap & Seal and SylWrap HD were required due to the size of the asbestos cement pipe requiring repair.

The purpose of the Contractor Case normally though is to allow regular users to carry out several repairs. It is designed to be kept on-site or on the van, enabling rapid response to leaks when they are identified.

With the water utility company currently investing in leak detection technology, Sylmasta are providing assistance as to how the problems that the new technology identifies can be repaired as quickly as possible.

The Contractor Case works hand-in-hand with leak detection, equipping contractors with everything they need to fix leaks and burst as soon as they are discovered.

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: Industrial Metal Repairs a Large Gouge to Refurbish a Drill Base Stand

Industrial Metal used to repair a severely damaged drill base stand

Drill and fill – the repair and refurbishment of a badly damaged second-hand drill base stand

An engineer refurbished a second-hand drill base stand at a fraction of the cost of buying new, using Industrial Metal Epoxy Paste to repair a large gouge caused by the previous owner’s misuse.

Case Study Data


Repair Type
Metal repair and refurbishment
Defect
Large gouge in a drill base stand

Products Used


Industrial Metal Epoxy Paste
Epoxy paste used to fill the significant gouge suffered by the drill base

Case Study PDF



Case Study Review


The stand was suffering from a significant gouge where the drill had frequently been allowed to penetrate the base by the previous owner, who as a result had subsequently decided to sell the stand.

It was otherwise in good condition, meaning that if the engineer who bought the stand could refurbish it, then he would have a working second-hand drill base at a fraction of the cost of purchasing new stock.

After consulting Sylmasta, it was decided that Industrial Metal Epoxy Paste would be the most suitable material for filling in the gouge and returning the base to close to its original state.

A large crack in a drill base stand which required a repair to refurbish the stand to its original state
The large gouge in the drill base stand requiring repair

Industrial Metal is thixotropic, meaning it will not sag. It is virtually odourless, with no unpleasant smell compared to other epoxy pastes.

It is temperature resistant to 130°C and reinforced with corrosion-resistant metal platelets, giving it a smoother finish than regular epoxy repair pastes when machined.

The gouge in the stand requiring repair had penetrated right through the base. To prevent the Industrial Metal falling onto the floor as it was applied, a wooden plate was placed underneath the gouge.

Further wood was used to ensure that the necessary gaps included as part of the base’s design did not inadvertently become filled by the epoxy paste.

Before using Industrial Metal, the drill base had to undergo a degree of preparation. All traces of rust and grime were removed from the surface, which was then roughed up using abrasives.

Industrial Metal was applied as soon as the preparation stage was complete. The epoxy paste was pushed into the gouge using a hand tool, with the work time of 60 minutes allowing more of the paste to be mixed and applied without the threat of premature curing.

Industrial Metal Epoxy Paste applied to fill in a large crack in a drill base stand repair and refurbishment
Industrial Metal applied to fill the gouge
Completed repair of a drill base stand using Industrial Metal Epoxy Paste
The completed repair was sanded down to an ultra-smooth finish

A full cure was achieved in 24 hours, after which the surface of the drill stand was sanded down to provide an ultra-smooth finish which was seamless with the rest of the base. The rebuild using epoxy paste had been a complete success.

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 an 80mm Split to a Plastic Hose Supplying Water to a Pond

A longitudinal split in a plastic hose supplying water to a bond undergoes repair with a SylWrap Universal Pipe Repair Kit

Not sleeping with the fishes – a lengthy split in a plastic hose supplying water to a pond undergoes repair

During landscaping work, a pruning saw caused serious damage across a 300mm area of an unnoticed plastic hose supplying water to a pond, including a 80mm longitudinal split requiring repair.

Case Study Data


Site
Domestic Property
Location
United Kingdom
Repair Type
Leak repair
Defect
80mm longitudinal split and 300mm of damage to a plastic supply hose

Products Used


Wrap & Seal Pipe Burst Tape
Self-fusing silicone repair tape used to seal the split and other leaks

SylWrap HD Pipe Repair Bandage
Composite repair wrap provided an impact resistant layer to protect the repair and the hose

SylWrap Universal Pipe Repair Kit
The property owner was supplied with a Universal Pipe Repair Kit containing both products

Case Study PDF


Case Study Details


The pond was on a property cut into the side of a hill with a retaining wall behind it. The roots of shrubs, ivy, and other plants and weeds above the wall were beginning to cause damage to the structure and so the property owner decided to cut some of them away with a pruning saw.

Unfortunately, the owner did not realise that buried just beneath the soil was a hose made from industrial grade plastic supplying water to the pond. As they attempted to remove the shrubs using the saw, they inadvertently cut into the hose.

A plastic hose inadvertently cut into with a pruning saw prior to undergoing a SylWrap repair
Water spraying from the 80mm split in the plastic hose

The damage to the hose was severe with a 80mm longitudinal split from which pressurised water was spraying out. There were several smaller leaks either side of the main split, leaving a 300mm area of hose requiring repair.

Gaining access to make a hose repair was extremely difficult because of the roots, the shrubs and the proximity of the retaining wall. To repair the split in the plastic hose, a versatile solution was therefore needed.

The split in the hose once water pressure had been turned off

Sylmasta supplied the property owner with a SylWrap Universal Pipe Repair Kit for sealing live leaks, containing SylWrap HD Pipe Repair Bandage and Wrap & Seal Pipe Burst Tape. An additional roll of Wrap & Seal was included due to the 300mm coverage of the repair area.

Water supply was turned off and the hose was cleaned to remove all traces of soil. A plastic sheet was then placed underneath the hose to prevent any further soil or grit being picked up during the application of the Wrap & Seal, which was wrapped across the entire damaged section.

Despite the space constraints around the hose, the Wrap & Seal was successfully stretched by the maximum 300 percent. It fused to form a solid rubber band which sealed the 80mm split and the other smaller leaks present.

The repair was finished by wrapping SylWrap HD over the Tape. The water-activated composite repair wrap provided a rock hard, impact resistant layer in minutes to protect the hose prior to it being reburied in the ground.

Completed repair of a leaking plastic hose suffering from a 30mm longitudinal split
Completed repair of the split plastic hose

Completing the repair took less than 30 minutes and cost under £40. Afterwards, the property owner contacted Sylmasta to say: “There are no longer any leaks in the hose, so I am very happy with the repair.”

“SylWrap is an excellent piece of kit which I wish I had come across years ago and the technical assistance I received from Sylmasta was very much appreciated.”

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 22 Degree Cast Iron Pipe Elbows

Reinforcement of 22 degree elbows on cast iron water mains carried out by Sylmasta

Ending a potentially explosive situation – Sylmasta provide reinforcement for pipe elbows following a blowout in a valve chamber

A blowout in a valve chamber in Grimsby, United Kingdom, alerted a water company to the fact that numerous 22 degree 450mm cast iron pipe elbows were below specification and required urgent reinforcement to prevent further incidents occurring.

Case Study Data


Site
Valve Chamber
Location
Grimsby, United Kingdom
Repair Type
Elbow joint reinforcement
Defect
Below specification 22 degree elbow joints on 450mm cast iron water mains

Products Used


Liquid Metal Epoxy Coating
Offered protection to the pipework from factors such as corrosion and created a PCC-2 compliant load transfer layer with SylWrap HD.

SylWrap HD Pipe Repair Bandage
10 layer application reinforced each elbow joint by providing an impact-resistant protective sleeve.

Case Study PDF


Case Study Details


Numerous large diameter water mains made from cast iron were operated by the water company with most of these approximately 50 years old.

After an incident in a valve chamber in Grimsby where a 22 degree bend on a 450mm main blew apart, analysis of the cast iron showed that the original castings were below specification.

The incident was believed to have occurred when the water main pump from the reservoir to the treatment works stopped and the non-return valve closed, causing a pressure surge which peaked at 10 bar from zero.

Analysis of the cast iron pieces showed no corrosion along the crack lines. The blowout was therefore most likely caused by the low strength of the original casting which had a hardness of only 107.

To prevent similar incidents occurring again, the water company needed to carry out reinforcement of all remaining pipe elbows of the same specification.

The length of the repair area was 350mm between flanges and the application needed to withstand 8 bar operating pressure with fluctuations up to the 10 bar which had caused the original blowout.

Sylmasta advised using Liquid Metal Epoxy Coating and SylWrap HD Pipe Repair Bandage to strengthen the elbow joints against future pressure surges and other factors including corrosion.

Each pipe was cleaned prior to being coated with Liquid Metal, a metal-filled brushable epoxy which sets to a smooth, metallic, hard-wearing surface over pipework.

Coating the elbow joints with Liquid Metal provided corrosion protection and improved adhesion between the pipework and the SylWrap HD Bandage, creating a PCC-2 compliant load-transfer layer.

10 layers of SylWrap HD were then applied over the Liquid Metal. SylWrap HD is a composite repair wrap with a water-activated resin which sets rock hard in minutes, providing reinforcement to pipework pressure resistant to 30bar.

Each elbow joint could be reinforced in two to three hours and there was no need to turn off the water supply to complete an application. Sylmasta’s repair saved the water company considerable money compared to replacing the below specification pipework and the necessary shutdown of equipment.

After the repair, the strategic water operations manager told Sylmasta: “The wrapping materials have proved central to our project in securing the structural condition of some 22 degree bends found to be in weak condition.”

“The early success of the project in Grimsby has seen it already adopted by other sites in our network, with Hartlepool also happy with it as a preventative measure and more to follow.”

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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Earth Day: How pipe repair can help save the environment and the planet

Pipe repair can help protect the environment by producing the levels of water lost to leaks on public supply networks, helping to protect supplies

Water is precious – the more we can save, the better for our planet


Every year on April 22nd, the world marks Earth Day to demonstrate support for environmental protection. When we talk about pipe repair, it is mostly in the context of saving money or protecting homes and properties from water damage, but fixing a leaking pipe quickly and easily can also help save the environment.

Planet Earth has a water problem which is mainly attributed to climate change. Hotter, dryer summers have brought on widespread, record-breaking droughts to put extreme stress on supplies.

Eastern Australia experienced its worst ever drought in 2019. Water shortages became so bad in São Paulo in 2015 that it caused rioting and looting. An official state of calamity had to be declared and the army was on standby to restore order.

California meanwhile was in a constant state of drought between 2011 and 2017, the most extreme known in 1200 years. 95 percent of the state’s winter salmon were killed in 2013, 62 million trees were lost in 2016 and residents were frequently placed under mandatory water restrictions of 25 percent.

In the United Kingdom, the House of Commons Public Accounts Committee warned in a September 2020 report that taps could run dry by 2040 unless more was done to protect supplies in the face of not only climate change, but population growth. More people on Earth results in more water being drawn from nature.

To help the environment, the world cannot afford to waste water. Every drop is precious. One of the biggest contributors to water waste – arguably the biggest – is leakage on public supply networks. In 2019-20, 2.95 billion litres of water were lost every day to leaks on the UK water network.

That might seem like an eye-watering amount, but it is actually the lowest ever leakage figure since records began in the mid-1990s, when 4.5 billion litres of water was lost. A combination of new leak detection technology, innovative pipe repair methods and a firm focus on saving water from government and stakeholders has been responsible for the drop.

Still, there is clearly much to do if the UK is to avoid running out of supplies by 2040, as forecast by the Public Accounts Committee. Ofwat used its PR19 five-yearly review into the water industry to demand water companies in England and Wales reduce leaks by 16% by 2025, saving enough water to supply every person in the cities of Birmingham, Bristol, Cardiff, Leeds, Liverpool and Sheffield.

The Department for Environment, Food and Rural Affairs have gone further, saying that leakage must be cut by half its 2020 levels by 2050. That would mean nearly 1.5 billion litres of water being saved via pipe repair, a huge boost to supplies in the UK, the environment and the planet.

Detecting and fixing leaking pipes is not always easy. Bursts and leaks often occur deep underground and can go unnoticed for months. Even when they are discovered, many are not straightforward to repair. Access may be difficult, the problem could be on a challenging joint, or the only solution considered might be replacement.

For particularly challenging leaks and bursts, water companies may consider it too costly and disruptive to carry out a repair or replacement. Instead, they will simply leave pipes to leak water for many years. One example of this comes from a burst water main which had been leaking for 15 years.

The traditional means of repair used by water companies is a pipe repair clamp. Whilst extremely effective in the right situations, clamps are hefty and bulky. They cannot be applied around elbows or tees, and are not always flexible enough to be fitted in confined spaces.

This was the problem faced by the company responsible for the burst water main. Only one worker could access the hole at a time, there was no room for a clamp, and to replace the main would have meant severe disruption caused by shutting off supplies and digging up the surrounding area. As a result, it was considered unrepairable.

That was until a Sylmasta Live Leak Pipe Repair came along. Using a SylWrap Universal Pipe Repair Kit, the latest contractors hired by the water company to find a solution were able to carry out a permanent live leak repair in under an hour.

A SylWrap repair consists of a simple two-stage process. The leak is first sealed using either Wrap & Seal Pipe Burst Tape (if pressure cannot be isolated) or Superfast Epoxy Putty (if water can be turned off). A SylWrap HD Pipe Repair Bandage is then applied over the initial leak sealant to complete the repair. 

SylWrap HD is a water-activated, resin impregnated fibreglass tape which sets rock hard to provide an impact-resistant, protective shell around damaged pipework, strengthening it and extending its lifespan. Repairs can be made to pipes of any diameter or type, to leaking elbows, tees, rivet joints and other challenging sections of pipework, all without the need for any formal training.

Pipe repair becomes a task any person can carry out using a SylWrap Kit – including in domestic settings. A SylWrap Pipe Repair Kit means that a small leak on a bathroom or kitchen pipe not worth paying a plumber to look at can now be fixed by the property owner in less than 30 minutes for under £20.

The speed and ease with which repairs can be made using SylWrap has seen several of the UK’s water companies approve the SylWrap Contractor Case for use on their networks. The national supplier in Malaysia is also using the Contractor Case to fix leaks on the vast pipe network of Kuala Lumpur. SylWrap is a global solution to a worldwide leak problem.

Each case contains enough products to make up to six repairs and can be easily stored on a van. Whenever a leak is detected, a contractor simply has to reach for their case, where everything they require to make a live leak repair can be found.

Pipe repair is not the only way to save water and protect the environment. We can all do more to reduce the amount of water we use through simple, everyday lifestyle changes such as spending less time in the shower and not leaving the tap running when brushing our teeth. Those savings may seem like a drop in the ocean compared to the near-3 billion litres lost to leaking pipes every year, but every little helps.

A concerted push from the whole world can help preserve water supplies and play a part in saving the environment, and pipe repair should be at the forefront of it.

To speak to a Sylmasta technician about how your company might benefit from using SylWrap Pipe Repair solutions for carrying out pipe repairs, then please contact Sylmasta via email or on +44 (0)1444 831459.

SylWrap Pipe Repairs


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Case Study: Extending the Life of 20m Pipe Bridges Through Leak Repair & Reinforcement

Pipe bridges leaking from rusting riveted joints undergo a leak repair and reinforcement using SylWrap HD Pipe Repair Bandage

Bridging the gap until replacement – the lifespan of two leaking pipe bridges is extended with a SylWrap leak and reinforcement repair

The complex repair of numerous corroded leaking joints on two 20m gravity-fed pipe bridges is followed by the entire reinforcement of both bridges to extend lifespan and offer maximum gain on investment.

Case Study Data


Site
Pipe Bridges
Location
Lancashire, United Kingdom
Repair Type
Leak repair & pipeline reinforcement
Defect
1.5m x 20m pipe bridge and 1.8m x 20m pipe bridge leaking from corroded riveted joints

Products Used


Wrap & Seal Pipe Burst Tape
Self-fusing silicone repair tape used to seal the numerous leaks on the two pipe bridges.

SylWrap HD Pipe Repair Bandage
Four-layer application over the entire length of the bridges for protection, strengthening and life-extension.

Case Study PDF


Case Study Details


The two gravity-fed pipe bridges in Lancashire which were constructed of steel riveted plates had become corroded over time. They were now leaking in several places, allowing foul wastewater to fall into a stream below.

Although it was planned to replace these pipe bridges at some point in the future, an immediate solution was required to stop the leaks. At the same time, the lifespan of the bridges also needed extending so that maximum benefit could be gained from the investment required for such a complex repair.

Pipe Bridge in Lancashire, UK prior to undergoing a SylWrap repair and reinforcement application
One of the pipe bridges prior to undergoing repair

These complexities included building scaffolding on the riverbed and sourcing materials for the repair and reinforcement of such substantial pipe bridges: one being 1.5m x 20m and the other 1.8m x 20m.

A previous attempt had been made to seal some of the leaking joints using ratchet straps with a rubber pad. These however had proven unsuccessful and further leaks had appeared since.

A pipe bridge leaking from rusting joints before undergoing a SylWrap repair and and reinforcement
A previous repair attempt had been made the the leaking riveted joint

Sylmasta were consulted on the repair, and it was decided that Wrap & Seal Pipe Burst Tape would be used over the leak areas. Wrap & Seal is a heavy duty repair tape made from self-amalgamating silicone which, when stretched by 300 percent across a leak, forms a tight rubber seal. Multiple layers increase the pressure applied until the leak stops.

Once all leaks had been addressed, the entire structure was wrapped with SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite repair wrap with a water-activated resin which sets rock hard in minutes, providing protection and reinforcement to pipework.

Pipe bridge leak repair and reinforcement carried out using SylWrap HD Pipe Repair Bandage
Completed repair of the first pipe bridge

Four layers of SYL1266HD (300mm x 20m) were applied to each of the pipe bridges along their 20m length, providing a substantial protective sleeve, completing the repair and guarding against future leakage and corrosion.

Although the utilities company responsible for the pipe bridges were only seeking a temporary solution, using SylWrap HD in the repair provided reinforcement and additional strength which will last for 20 years.

Once the repair was completed, it was estimated that a saving of approximately £250,000 had been made compared to the cost of replacing both pipe bridges, so Sylmasta’s solution was very much welcomed by all involved.

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: Leak Repair & Encapsulation of a Steel & Iron Welded Pipe Joint

Pipe repair of a central heating system in a church which had begun to leak around a welded joint suffering from corrosion

Good deed done – Sylmasta answer a church’s prayers with a welded pipe leak repair and encapsulation

A church central heating system had suffered heavy damage caused by corrosion and begun leaking at the point where a 100mm cast iron pipe met a 50mm steel pipe via a welded steel plate, leading to a challenging leak repair and encapsulation application.

Case Study Data


Site
Church
Location
United Kingdom
Repair Type
Leak Repair
Defect
Leaking welded joint between a 100mm cast iron pipe, a 50mm steel pipe, and a 6mm steel plate

Products Used


Sylmasta AB Original Epoxy Putty
Epoxy putty with two-hour work time allowing for careful application and watertight encapsulation of the leaking joint

Wrap & Seal Pipe Burst Tape
Self-fusing silicone repair tape used initially to seal leaks on the 100mm cast iron pipe

SylWrap HD Pipe Repair Bandage
Applied over Wrap & Seal to provide a rock hard, impact-resistant layer to the initial repair.

Case Study PDF


Case Study Details


Several years previously, the central heating system in the church had undergone renovations when a 100mm cast iron pipe had been stepped down to a 50mm steel pipe.

To facilitate this, a 6mm thick steel plate had been attached to the end of the larger cast iron pipe with a hole cut into the middle, through which the smaller steel pipe was attached and welded.

Since the work had been carried out, the system had become badly corroded and was now leaking from numerous areas around the welded joint.

When a similar problem had developed on another heating pipe, the church had fitted a pipe repair clamp at considerable expense. Such a repair method was not possible on this occasion as the new leak was in a restricted space with no room for a clamp to be applied.

Initially, the church called in welders to try and fix the problem, but this just caused further leakage and left an even more uneven pipe surface needing to be sealed.

Diagram showing the repair in question

The main leak was between the steel plate and the 100mm cast iron pipe with particularly heavy corrosion at the point where they met. Once the corrosion was filed back, this was relatively straightforward to repair using a SylWrap Universal Pipe Repair Kit.

Wrap & Seal Pipe Burst Tape was applied around the pipe, fusing to form a solid rubber band over the problem area to seal the leak. This was then overwrapped with a SylWrap HD Pipe Repair Bandage, providing a rock hard, impact resistant shell to reinforce the initial repair.

More challenging was the repair of the joint between the smaller 50mm steel pipe and the steel plate. Here, leaking was caused by uneven welding, whilst a threaded section of pipe close by was also suffering from a leak.

It became clear that a softer repair material was needed to smear into the threaded section and to penetrate into the weld. Because of the complexity of the repair, Sylmasta recommended Sylmasta AB Original Epoxy Putty.

AB Original is a smooth-setting epoxy with a two hour cure time. This longer working time allowed for the putty to be more carefully applied, encapsulating the whole section where the 100mm pipe, the 50mm pipe, and the steel plate all met.

The church were supplied with 1kg of Sylmasta AB, more than enough for their application. Unused AB Original stays fresh when left in its original packaging, ensuring the church has a supply of epoxy putty for any future applications.

Sylmasta AB Original putty was smoothed over the welded joint, filling in all imperfections and sealing all leak areas. It has excellent corrosion resistance, further protecting the pipe from future attack, and provided a smooth, ceramic-like finish to the application.

When the church first contacted Sylmasta, they had been looking for a repair method that would temporarily fix the leaking central heating system until funds allowed for either a longer lasting solution or for a new pipe to be installed.

Instead, the repair provided by Sylmasta will be permanent and was made at a fraction of the cost of other options, saving the church a considerable amount of money.

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: Badly Soldered Domestic Copper Pipe Leaking Joint Repair

Wrap & Seal Pipe Burst Tape used to repair a domestic copper pipe leaking from badly soldered joints

Soldering saviour – A Wrap & Seal repair to a long-term leaking copper pipe joint caused by shoddy soldering

After ignoring a leaking joint on a badly soldered copper pipe for a prolonged period of time, a property owner was spurred into carrying out a repair once it became known that escaping water had begun rotting wooden floorboards and a joist underneath the leak area.

Case Study Data


Site
Domestic property
Location
United Kingdom
Repair Type
Leak Repair
Defect
Leaking joint on a 22mm copper pipe

Products Used


Wrap & Seal Pipe Burst Tape
Self-fusing silicone repair tape which formed a solid, watertight seal around the joint

Case Study PDF


Case Study Details


The problem pipe was a 22mm copper perimeter heating pipe which had been boxed in behind a grill. Poor soldering had caused it to leak, but the property owner deemed the water escaping to be so minimal that they did not feel it worth either attempting a repair themselves or going to the trouble and expense of hiring a plumber.

After a significant period of time, the joint in question had leaked enough to rot away woodwork both underneath and around the pipe. Wooden flooring below had been badly impacted with the leak starting to cause damage to the joists further down.

To prevent the leak causing further deterioration to nearby wood, the property owner now needed to carry out a leak repair to the pipe. They were still keen to minimise cost and so came to Sylmasta, who recommended Wrap & Seal Pipe Burst Tape for the application.

Wrap & Seal is made from self-fusing silicone and stretches by 300 percent. When wrapped around a pipe, it forms a solid rubber band over holes, cracks, and leaking joints.

Having cleaned the pipe completely, the property owner applied Wrap & Seal around the badly soldered joint, ensuring a tight seal to permanently repair the leak.

The repair was completed in under 30 minutes. The property owner said afterwards had they known that fixing a leaking joint could be so straightforward, they would never have ignored the leak or left the problem unrepaired for so long.

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 fix a leaking pipe with a SylWrap Repair Kit

Sylmasta filmed a live leak pipe repair demonstration video showing how a SylWrap Pipe Repair Kit can permanently fix a leaking pipe in under 30 minutes

This video was filmed during an on-site demonstration as part of the Sylmasta Roadshow, showcasing to a water supply company in the United Kingdom how a SylWrap Pipe Repair Kit can permanently fix a live leak in under 30 minutes.


About this Pipe Repair Video


The pipe being repaired was made from steel and had a large split cut into it. To showcase the pressure resistance of a SylWrap Pipe Repair Kit to the water company, the pipe was put under 6bar for the demonstration.

Wrap & Seal Pipe Burst Tape was used to seal the initial leak. Wrap & Seal is made from self-fusing silicone and stretches by three times its length. When wrapped around a leaking pipe, it forms a solid rubber band over the leak area, creating a high-pressure repair.

The initial repair was then overwrapped with a SylWrap HD Pipe Repair Bandage. SylWrap is a composite fibreglass repair wrap with a water-activated resin. It is applied to the pipe to provide a rock-hard, impact resistant layer, reinforcing the repair through a protective shell.

Only one Wrap & Seal was used for this repair, but additional tapes could have increased the pressure resistance up to 30bar. To determine how many tapes are needed for a specific application, please input your data to the Wrap & Seal Repair Calculator to formulate the optimum repair.

This type of live leak repair using Wrap & Seal and SylWrap HD Pipe is also effective on pipes made of copper, PVC plastics, stainless steel, malleable iron, GRP, ceramic, clay, concrete, lead, and rubber.

Repairs can be made to leaking pipes in domestic settings, such as kitchen and bathroom pipes, as well as major pipelines involved in infrastructure and industry.

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

No training is required to make a SylWrap live leak repair; simply follow the instructions provided with the product.

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 HD 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