Author: Scott McCarthy

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Case Study: Leak Repair of a Bathroom Sink PVC Plastic Drain Pipe

Superfast Plastic Epoxy Putty Stick used to repair a leak in a PVC plastic pipe connected to a bathroom sink

Stopping that sinking feeling – Superfast Plastic plugs a leak in a DIY bathroom plastic pipe repair

A homeowner used Superfast Plastic Epoxy Putty Stick to make a quick and easy DIY leak repair to cracks in a PVC plastic drain pipe located in a cupboard underneath their bathroom sink.

Case Study Data

Site
Domestic bathroom
Location
United Kingdom
Repair Type
Leak repair
Defect
Cracks in a PVC plastic sink drain pipe

Products Used

Superfast Plastic Epoxy Putty Stick
Specially formulated epoxy putty used to permanently seal holes and cracks in all types of plastic pipe

Case Study PDF

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Case Study Details

The homeowner was alerted to the problem when they noticed that the bathroom floor next to the cupboard below the sink was wet. After inspecting inside the cupboard, it was discovered that several small cracks had developed in the PVC plastic drain pipe at the point where it connected with the sink.

The homeowner did not want to go to the expense of hiring a plumber to fix what they considered a minor problem. They instead purchased a Superfast Plastic Epoxy Putty Stick from Sylmasta to carry out a DIY repair of their own.

Cracks in a PVC plastic bathroom sink pipe before undergoing repair with a Superfast Plastic Epoxy Putty Stick
Several cracks had appeared in the pipe where it met the sink fitting

Superfast Plastic is a semi-flexible epoxy repair putty in an easy-to-use 114g stick format. It sets white and has been specifically formulated for the repair and bonding of all major plastic types, including PVC.

Before the repair began, the pipe was dried and cleaned. The required amount of putty was cut from the stick and kneaded by hand. Superfast Plastic starts out blue before the dye within the putty turns white to indicate successful mixing, after which it can be applied.

Superfast Plastic formed into a sausage shape and pushed into the cracks

Once the putty had become white, it was formed into a sausage shape and pushed against the cracks in the PVC pipe. After 25 minutes, it began to harden. Within 45 minutes, the putty had cured to provide a watertight seal, filling all cracks in the pipe.

Superfast Plastic achieves full properties in two hours, at which point the homeowner ran the tap on their sink. With no water escaping from the pipe into the bathroom cupboard as the sink drained, the leak repair had been a success.

Completed leak repair of a plastic PVC pipe suffering from cracks where it connected to a bathroom sink
The completed repair with the pipe successfully sealed

Carrying out a DIY PVC pipe repair using Superfast Plastic cost less than £20, including shipping. The repair was permanent and the putty blended in unnoticed with the PVC plastic – just in case a future homeowner was a perfectionist and wanted a pipe in a darkened cupboard under the bathroom sink to look aesthetically pleasing.

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 6 Metres of Corroded Steel Pipe in a Fire Station Pumping House

A steel water pipe suffering from heavy corrosion undergoes repair and refubishment in a protection application carried out using SylWrap HD Pipe Repair Bandage

Pump it up – the SylWrap reinforcement of a corroded steel water pipe which kept a fire station pumping water

A six metre long section of steel pipe – which included two 90 degree elbow bends – operating in a water pumping house at a fire station in Saudi Arabia required urgent reinforcement before the heavy corrosion the pipe was suffering from breached the line.

Case Study Data

Site
Fire station pump house
Location
Saudi Arabia
Repair Type
Pipe reinforcement
Defect
Six metre long section of steel pipe suffering from heavy corrosion

Products Used

SylWrap HD Pipe Repair Bandage
Composite repair wrap which was wrapped and moulded around the pipe, forming an impact resistant protective sleeve

Case Study PDF

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Case Study Details

The 150mm steel pipe brought water from a reservoir on the lower levels of the pumping house up to the top levels, where it was required for different operations at the fire station.

After many years of service, the pipe was suffering from heavy corrosion. The damage was particularly bad on the section of pipe beneath the surface of the reservoir, where it was exposed to constant contact with water.

The pipe was suffering from heavy corrosion, particularly towards the bottom of the line

Although the pipe had not yet been breached, the metalwork had been weakened to the point where it was only a matter of time before corrosion caused cracks and holes to appear. Replacing the six metre section after this happened would have been difficult because of the shape of the pipe.

There were two 90 degree elbow bends in the pipe. The first changed the pipe direction from running vertically up and out of the reservoir to horizontally at the point where the line reached the upper levels of the building. The second was some 50cm further along, taking the pipe off to the right to connect with valves and equipment.

A steel pipe suffering from corrosion prior to undergoing reinforcement using SylWrap HD Pipe Repair Bandage
Two 90 degree bends in the pipe meant replacing the damaged section would be difficult

The complex shape meant that replacing the line would require specially fabricated parts at considerable expense. Not only was the cost prohibitive, but there was the possibility the station might be decomissioned in several years time.

With resources stretched, spending money on the expensive installation of a replacement pipe only for the pump house to be taken out of service within a decade would not have been a good use of funds.

The station therefore sought to carry out pipe reinforcement of the existing steel line instead, strengthening it and protecting it against further corrosion. This would extend the lifespan of the line until a decision was made about the future of the pump house and the station.

SylWrap HD is applied to a steel pipe at a fire station as part of a reinforcement application
SylWrap HD could be easily moulded around the complex shape of the pipe

It was decided to wrap the entire six metre section in SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets in minutes to provide an impact resistant protective sleeve around pipes and structures.

Starting from the upper level of the pump house, SylWrap HD was applied to the pipe with a 50 percent overlay. More water was used to smooth the bandage as it was wrapped, moulding it tightly to the line and around both of the bends.

The reinforcement of a steel pipe at a Saudi Arabia fire station made using SylWrap HD Repair Bandage
Completed reinforcement of the top level of the pipe
Completed reinforcement of the bottom level, including the underwater section

The repair continued in this manner as the line headed down to the lower levels of the pump house, including when the pipe went beneath the surface of the reservoir.

SylWrap can be applied and sets underwater, enabling every part of the pipe to be refurbished. Once fully cured, the bandage formed a rock hard shell encompassing the entire line and offering new strength to the pipe.

Within two hours, the repair had been completed and the entire line reinforced. The SylWrap sleeve surrounding the pipe prevented further external corrosion attacking the exterior and weakening the line, reducing the chances of future failure.

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: Using Epoxy Putty for Cracked & Damaged Brick Repair & Restoration

Brick repair carried out using epoxy putty to damaged brickwork suffering from lime blow

Another brick in the wall – How epoxy putty can be used to seamlessly repair cracked and damaged brickwork

When lime blow left numerous bricks at a housing estate in the south of England with cracks, holes and missing chunks, a building company in the UK hit upon the idea of using epoxy putty as a brick repair material.

Case Study Data

Site
Housing estate
Location
South of England
Repair Type
Brick face repair
Defect
Chunks of brick missing due to lime blow

Products Used

Sylmasta AB Original Epoxy Putty
Epoxy putty mixed with brick dust seamlessly filled and repaired holes, cracks and areas of damage

Case Study PDF

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Case Study Details

Lime blow occurs when clay bricks contain small amounts of lime. When the bricks are fired, this lime is converted to calcium oxide, also known as quicklime or burnt lime.

When calcium oxide mixes with water, it begins to slake in a highly vigorous process. Bricks which contain quicklime are therefore at risk or suffering from an eruption at their face when they become wet, causing chunks of brick to break away.

In a country like the United Kingdom where it rains a lot, lime blow is a frequent occurrence. Fortunately, it does not impact on the structural integrity of the brick. Some people even like the weathered, old fashioned look of bricks which have exploded.

The effect of lime blow however was not appreciated when the problem began happening frequently on a fairly new housing estate in the south of England. A building company were asked to find a cost effective and straightforward method of brick restoration, involving filling in the damaged areas.

Chuck of brick missing through lime blow prior to repair using epoxy putty
Chunk of brick missing due to lime blow

After consulting Sylmasta, it was decided to use an epoxy putty. Magic Sculp Sculpting Putty was used for a trial repair, after which the company approved Sylmasta AB Original Epoxy Putty for all future brick repair applications.

The putty was mixed by hand and then pushed into the holes and cracks in the brick face, filling in areas of damage. To ensure that the putty seamlessly matched the colour of the brick rather than the standard off-white it cured to, the putty was wetted once it had been applied to the wall and whilst still soft.

Dust was then taken from the brick undergoing repair and pushed into the putty, creating a material the exact same colour as the brick being repaired. To give the putty an identical texture to the existing brickwork, it was then spittled with a wire brush.

A section of brick missing a chunk because of lime blow undergoes a seamless repair and restoration using epoxy putty
Damaged section of brick repaired using epoxy putty mixed with brick dust

AB Original has a work time of two hours, after which it cures to form a solid material. So effective was the application that it is virtually impossible to tell where the area is on each brick that has undergone repair.

Using epoxy putty for brick repair is a practice that is growing in popularity across numerous sectors involved in construction. As well as builders and specialist brick restorers, Sylmasta also supply epoxy putty to facilities management companies, cable installers, DIY enthusiasts, gardeners and many more.

Any tradesperson or individual who may be required to fix a damaged brick – be it through lime blow, accidental damage or having to drill into brickwork – can easily fix holes, cracks and missing pieces using Sylmasta AB.

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 Leaking 150mm Steel 90 Degree Elbow Bend at a Quarry Wash Plant

A 150mm steel pipe elbow bend leaking at a quarry wash plant undergoes repair with a SylWrap Standard Pipe Repair Kit

When clamps don’t work – the repair of a 90 degree pipe elbow bend at a quarry wash plant

When a quarry in the UK was unable to repair a leaking 150mm steel pipe in their wash plant using a clamp due to the pinhole being located on a 90 degree elbow bend, they instead turned to Sylmasta for an alternative, versatile solution.

Case Study Data

Site
Quarry wash plant
Location
Hampshire, United Kingdom
Repair Type
No pressure pipe repair
Defect
Pinhole leak in a 150mm steel pipe elbow bend

Products Used

Superfast Steel Epoxy Putty Stick
Fast working steel epoxy putty used to seal the pinhole leak in the pipe

SylWrap HD Pipe Repair Bandage
Composite wrap applied over the sealed pinhole leak for reinforcing the repair and further protecting the pipe

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 150mm steel pipe was located in the wash plant of the quarry, passing across a lake. Wear and tear had caused a pinhole leak to appear in the line around 50mm away from a 90 degree elbow bend, leading foul water to escape into the lake below.

Normally when pipework failed on site, the quarry would fit a pipe repair clamp over the problem area. This was not possible in this case because of the location of the leak area being so close to the elbow.

Seeking a more versatile repair method capable of being effective on the bend, the quarry contacted Sylmasta. Once it was established that pressure could be easily shut off, a SylWrap Standard Pipe Repair Kit was delivered to the site.

A leaking elbow bend on a 150mm steel pipe at a quarry wash plant before undergoing repair with a SylWrap Standard Pipe Repair Kit
The steel pipe was leaking close to an elbow bend

The pipe was cleaned as best it could be before the repair began. Superfast Steel Epoxy Putty Stick was used to seal the pinhole. The required amount of putty was cut from the stick and kneaded by hand.

After around two minutes of mixing and whilst still soft, the putty was pushed into the hole in the pipe. Within 10 minutes it had hardened, forming a material as hard as steel which now filled the pinhole.

To further reinforce the repair, a SylWrap HD Pipe Repair Bandage was applied around the leaking section. SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes.

Completed repair of a 150mm steel pipe on an elbow bend
Completed repair finished with a SylWrap HD Pipe Repair Bandage

SylWrap was wrapped and smoothed around the pipe, curing to form an impact resistant sleeve. This would help protect the pipe from future breakages, a common occurrence due to the abrasive nature of operations at the quarry.

The entire application was completed in under 30 minutes by a member of the operations team at the quarry. No training was required; they simply followed the instructions provided with the Kit to make a permanent pipe elbow bend repair.

Since the repair, the quarry group have taken further stock of SylWrap Pipe Kits, knowing them to be capable of making more versatile repairs than heavy, bulky pipe repair clamps.

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: Desalination Plant Partially Buried 3000mm FRP Discharge Return Pipe Repair

A 3 metre diamete FRP desalination plant discharge pipe underoges repair in Saudi Arabia

Pipeline in the sand – how a composite patch repair helped seal a partially buried three metre diameter FRP pipe in Saudi Arabia

Problems during the installation of a three metre diameter FRP discharge pipe at a desalination plant in Saudi Arabia had caused gaps to appear between connecting rings on the line, which had to be sealed in a repair carried out whilst the pipe remained partially buried.

Case Study Data

Site
Desalination plant
Location
Saudi Arabia
Repair Type
Leak repair
Defect
Gaps between rings in a 3000mm FRP discharge return pipe

Products Used

Sylmasta AB Original Epoxy Putty
Epoxy putty used to seal gaps between the ring and the pipe through which water was escaping from a join in the FRP pipe

E190 Brushable Epoxy
Brushable epoxy resin coated onto strips of Fibreglass Tape to create a composite patch repair to reinforce the putty

Fibreglass Tape
Fibreglass Tape soaked with E190, after which it cured to form a rock hard material reinforcing the initial repair

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

Case Study PDF

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Case Study Details

The three metre diameter FRP (fibreglass reinforced plastic) pipe was to play a crucial role at the plant, returning discharge water not turned into fresh water during the desalination process to the Red Sea.

Problems during the installation of the line meant that one section of the pipe was not connected properly. It was only when the system was fully pressurised and water began escaping that the issue was noticed.

The three metre diameter FRP pipe prior to undergoing repair

Even though flow was immediately shut off, the amount of water passing through the pipe meant that the chamber housing the problem section became flooded and had to be drained.

Once drained, a scaffold was erected around the pipe and pressure turned back on with minimal flow rate to properly identify what was causing the leak.

It was discovered that gaps had appeared at both ends of a 310mm wide ring connecting sections of the line together. These gaps had to be sealed before the line could be put into service.

  • Water excaping from a 3 metre FRP pipe in Saudi Arabia before the line underwent a Sylmasta repair
Water escaping between gaps in a join in the pipe

The system was again shut off to enable the repair of the gaps using Sylmasta AB Original Epoxy Putty. After being kneaded by hand, AB Original was pushed into the gaps between the connecting ring and the rest of the pipe and left to harden.

AB Original was chosen as its two hour working time allowed larger quantities of putty to be mixed in one go without the worry of premature curing.

This was a particularly important consideration because of the size of the pipe being repaired and the temperature on-site in Saudi Arabia. Sylmasta recommend AB Original to most clients working in hotter climates.

  • Sylmasta AB Epoxy Putty used to repair and seal gaps in a 3 metre diametre FRP pipe in Saudi Arabia
Sylmasta AB Original was pushed into the gaps to seal the line

The second stage of repair would normally involve reinforcing the AB Original with a SylWrap HD Pipe Repair Bandage to create a rock hard, impact resistant layer of protection.

However, with the bottom of the FRP pipe remaining buried, it was not possible to wrap SylWrap HD around the line in this application. Even if the line had been completely accessible, its size would have made effective wrapping extremely difficult.

Instead, Sylmasta E190 Brushable Epoxy Resin and Fibreglass Tape were used to build a composite patch repair over the ends of the connecting ring which had been earlier sealed with AB Original.

Fibreglass Tape wrapped over the pipe which had been coated with E190 Brushable Epoxy
  • Sylmasta E190 Brushable Epoxy is coated onto Fibreglass Tape to reinforce and repair a 3000mm FRP pipe in Saudi Arabia
Coating the Tape with further E190 created a composite patch repair

E190 was painted onto the pipe and strips of Fibreglass Tape of the required length cut off and placed over the epoxy. The E190 soaked through the Tape, attaching it to the pipe.

Another coating of E190 was painted over the top of the Fibreglass Tape, with the open weave of the Tape allowing significant amounts of epoxy to saturate the fabric.

The resin-soaked Fibreglass Tape now constituted a composite wrap similar to a SylWrap Bandage, the crucial difference being that it could be layered over areas requiring repair rather than wrapped.

Multiple layers of Fibreglass Tape were applied over each other and soaked with E190. The repair continued in this manner until the last layer of Fibreglass Tape was covered with a final coating of E190 and left to cure.

  • A composite patch repair made using Fibreglass and E190 Brushable to an FRP pipe in a desalination plant
The completed repair with all cracks sealed and the problematic section of line reinforced

E190 has a work time of 30 minutes and a full cure of 24 hours. The reinforcement of the pipe was completed within 36 hours, after which the line could be returned to service.

Once it had been established that the FRP pipe was no longer leaking and the repair had therefore been a success, the line was buried. It was now ready to serve the desalination plant after construction of the facility was finished.

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: CAE1500 With a Miracle Decoration Repair to Save a Family’s Christmas

A Christmas decoration repair made using CAE1500 High Viscosity Superglue

All I want for Christmas… is Sylmasta to repair a priceless decoration passed through generations of a family

When a decoration which had been in a family for generations was accidentally snapped in two, it was down to Sylmasta CAE1500 High Viscosity Superglue to provide a repair to save Christmas.

Case Study Data

Repair Type
Christmas decoration repair
Defect
Wise man from nativity scene snapped in two

Products Used

CAE1500 High Viscosity Superglue
High viscosity superglue with a bond time of between 10 and 45 seconds to non-absorbent materials

Case Study PDF

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Case Study Details

It is not all fixing major pipelines and other infrastructure at Sylmasta. Sometimes an application of real importance comes along, like the repair of a priceless Christmas decoration passed through generations of a family which had been accidentally snapped in two.

The ornament in question was one of the Three Wise Men from a nativity scene. In the annual tradition of getting the Christmas decorations out of the loft, he had become broken and meaning he was no longer able to join Mary, Joseph, Baby Jesus, the wee donkey and the rest on display.

A broken Christmas decoration before undergoing repair with Sylmasta CAE1500 High Viscosity Superglue
The Christmas decoration had been snapped cleanly in two

Christmas would not be Christmas without the full nativity set, and so the family desperately sought a means of repairing the wise man. Sylmasta CAE1500 High Viscosity Superglue was chosen for the application on account of its slightly longer cure time and versatility.

CAE1500 is a cyanoacrylate superglue which offers strong bonding between materials including ceramic, porcelain, plastic, metal, wood, paper and some fabrics. Its thickness means that when used on non-absorbent surfaces, it has a bond time of between 10 and 45 seconds.

CAE1500 High Viscosity Superglue applied to a wise man ornament in a Christmas decoration repair
CAE1500 High Viscosity Superglue was applied to the bottom piece of the wise man

This allows a small window for parts being glued together to be adjusted to ensure that they are correctly fitted; something which becomes more difficult or even impossible with superglue which bonds instantly.

CAE1500 Superglue was carefully applied directly to the break on the bottom half of the wise man. Once this had been done, the two pieces were pushed back together and held in place for around 20 seconds whilst CAE1500 worked its magic.

Completed repair of a wise man Christmas decoration
The completed repair with no visible glue or crack line

Excess superglue which had been squeezed out of the joints during bonding was wiped away before it had the opportunity to fully cure, leaving a wise man who had been perfectly healed with no visible glue or crack line.

The decoration repair had been a complete success and the wise man could be returned to the nativity scene, ready to play his part in celebrating Christmas for many years to come.

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: Refurbishment & Repair of Power Plant Condenser Unit Deformed by Corrosion

A cast iron face deformed by corrosion in a power station condenser unit undergoes repair and refurbishment using Sylmasta Ceramic Supergrade Abrasion Resistant Epoxy Paste

Putting a new face on it – the cast iron face of a turbine cooler condenser unit deformed by corrosion undergoes repair and refurbishment

Replacing a turbine cooler condenser unit because of a cast iron face deformed by heavy corrosion was not a cost-effective solution for a power plant in Puerto Rico, so they instead turned to Sylmasta for a repair and refurbishment method.

Case Study Data

Site
Electrical Power Plant
Location
Puerto Rico
Repair Type
Metal repair & corrosion resistance
Defect
Turbine cooler condenser unit deformed by corrosion

Products Used

Ceramic Supergrade
Epoxy paste used to rebuild the deformed cast iron face via the creation of a new corrosion and abrasion resistant surface

Case Study PDF

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Case Study Details

The condenser was part of the turbine cooler at the electrical power plant operated by the Puerto Rico Power Authority. It was used to condense steam back into water and had been in operation for approximately 20 years.

There were two components of the condenser. The tubes were made from bronze and the face was made from cast iron. Having been exposed to steam and water for over two decades, the cast iron face had become heavily corroded and deformed.

The corroded, deformed face of the cast iron condenser prior to repair

Replacing the condenser would have been an extremely costly exercise compared to the value of the turbine cooler as a whole, which itself would need replacing within the next 5 to 10 years.

Parts were no longer made for this particular type of condenser because of its age, and so a replacement face would have had to be specially fabricated and then shipped to Puerto Rico.

Rather than install an expensive new condenser with a lifespan of 20 years for a turbine that would have to be condemned long before that, the Power Authority instead sought a way of keeping the condenser in operation until such time as the whole turbine needed replacing.

Sylmasta recommended the use of Ceramic Supergrade Abrasion Resistant Epoxy Paste for the repair and refurbishment of the condenser, to rebuild the deformed face and offer protection from future corrosion and wear.

Ceramic Supergrade is filled with silicon carbide for ultimate surface hardness and an extremely smooth finish. It is applied to worn or damaged surfaces to rebuild, or to new equipment to protect parts from abrasion, corrosion and chemical attack.

Before the application began, the condenser was cleaned as best it could be, with traces of rust and grime removed. Rods were inserted into every tube hole in the face, covering them so that they did not become inadvertently filled with epoxy paste.

Ceramic Supergrade Epoxy Paste used to rebuild the cast iron face of a condenser unit damaged by heavy corrosion in a repair and refurbishment application
Ceramic Supergrade built a new, ultra-smooth layer with high corrosion and abrasion resistance over the original deformed cast iron face

Ceramic Supergrade was then applied to the face around these rods. The epoxy paste filled in imperfections in the cast iron as it was built up to create a new, waterproof, surface on top of the original deformed face with high resistance to abrasion and corrosion.

The 60 minute work time of Ceramic Supergrade allowed large quantities of the paste to be mixed and applied carefully without the threat of premature curing.

A full cure was achieved in 24 hours, after which the condenser could be returned to the turbine and the system put back into operation following a successful epoxy paste rebuild. The high-wear resistance of Ceramic Supergrade would keep the condenser in service for many more years.

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: Steel District Heating System Pipe Suspended in Ceiling Live Pinhole Leak Repair

A steel pipe in a district heating system leaking from a pinhole undergoes a live leak repair using a SylWrap Pipe Repair Contractor Case

Saved from substantial district heating damage – the energy company rewarded for equipping all their vans with a SylWrap Pipe Repair Contractor Case

A pinhole leak in a 50mm steel pipe suspended in the ceiling as part of a building’s district heating system required an urgent live leak repair when escaping, pressurised water began causing substantial damage to surrounding surfaces.

Case Study Data

Site
Public building
Location
United Kingdom
Repair Type
Live leak pipe repair
Defect
Pinhole in a 50mm steel district heating system pipe

Products Used

SylWrap Pipe Repair Contractor Case
The energy company responsible for the district heating system equip every van with a Contractor Case

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape used to seal the leak on the pipe despite the difficulty in gaining access to the ceiling

SylWrap HD Pipe Repair Bandage
Composite wrap applied to encapsulate the repaired section with an impact-resistant, protective sleeve

Case Study PDF

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Case Study Details

The district heating system was operated by a United Kingdom based company who specialise in installing and maintaining sustainable energy generation systems in public buildings, residential developments, factories and manufacturing sites.

Because of the importance of pipes to these systems, Sylmasta already had an established relationship with the company prior to the repair. Each of the company’s vans are equipped with a SylWrap Pipe Repair Contractor Case in case of emergencies, enabling contractors to make up to four live leak repairs as soon as problems are identified.

A pinhole leak in a 50mm steel pipe in a district heating system prior to being repaired with a SylWrap Pipe Repair Contractor Case
Water jetting from the pipe was causing substantial damage to surfaces and surrounding pipework, both above and below

The repair in question was to a large pinhole leak in a section of 50mm pipe suspended in the ceiling of the building. Pressurised water was jetting out in numerous directions, causing substantial damage to surfaces and surrounding pipework both above and below the leaking pipe.

Flow could not be turned off, as this would have involved shutting down heating across the entire building. A live leak repair to the district heating system was therefore necessary, using lightweight materials which could be easily carried and applied from the top of a ladder used to reach the ceiling.

From the Contractor Case, Wrap & Seal Pipe Burst Tape was used to successfully seal the leak. Despite the difficulty in accessing the pipe caused by the minimal space to work in the ceiling cavity and the surrounding pipes, Wrap & Seal was still stretched by 300 percent, amalgamating to form a solid silicone band over the steel pipe.

Wrap & Seal successfully applied to seal the pinhole

The entire section was then encapsulated with a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets rock hard in minutes. Once cured, it reinforced the pipe from any future breakages.

After seeing the extent of the damage that escaping water managed to cause in the short space of time between the leak being identified and the Contractor Case arriving on site, the company were appreciative of their partnership with Sylmasta.

Had a Contractor Case not been so readily available, then this could easily have turned into a major incident for the district heating system and the building. Instead, the company’s reputation was enhanced for the swift manner in which they reacted to and repaired the problem.

Completed repair of a steel pipe in a district heating system suspended in the ceiling of a building
The repair was completed by encapsulating the entire section with SylWrap HD

The company have since used their Contractor Cases to make live leak repairs to pipes in various systems they operate made from aquatherm, a semi-rigid polypropylene material.

Aquatherm pipe is popular because it does not react with water, preventing leaching, corrosion, scaling and erosion – major causes of water contamination and long-term pipeline failure.

Once thought to be foolproof, it is now known that failures can happen in aquatherm. Reasons for this include excessive clamping, elevated temperatures, extreme vibrations, flow velocity, water pressure and chemistry, or the presence of copper ions.

There is also the danger posed when a section of aquatherm pipeline has been repaired by inserting copper or iron pipe, leading to different coefficients of thermal expansion and severe cracks.

In the event of any failures in aquatherm piping, the presence of Contractor Cases across the company’s fleet of vehicles means that leaks and bursts can be attended to instantly, instead of suffering delays waiting for materials or parts to be delivered.

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: 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

Case Study PDF

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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 silicon 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