Category: Case Studies

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Case Study: 80mm Diameter Hole in Cast Iron Wastewater Drain Pipe Repair at Hospital

80mm hole in a cast iron wastewater drain pipe undergoes repair with SylWrap HD Pipe Repair Bandage

15 minute drain pipe repair gets hospital bathroom out of a potential hole

An 80mm diameter hole in a cast iron drain pipe through which wastewater leaked out whenever a hospital bathroom was used is permanently sealed in a repair which needed the facility to close for just 15 minutes.

Case Study Data

Site
Hospital
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
80mm diameter hole in cast iron drain pipe

Products Used

Superfast Steel Epoxy Putty
Fast-working epoxy putty filled with steel which bonds to all pipe materials for sealing holes and cracks

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to form a thick, impact resistant sleeve

SylWrap Drain & Waste Pipe Repair Kit
Kit kept on-site containing all the products needed for instant repair of cast iron and plastic drain, waste and soil pipes

Case Study PDF

Case Study Details

The cast iron drain pipe ran horizontally in a roof space between two floors at the Victorian-era hospital. It was connected to a bathroom shared by multiple wards, handling wastewater from baths and sinks.

Corrosion caused a large 80mm hole to appear in the pipe. Whenever wastewater was expelled from the bathroom, significant amounts would pour out from the hole.

Corrosion caused an 80mm diameter hole to appear in the cast iron drain pipe

Not only was this causing damage inside the roof space, but it also posed a health risk. If the pipe could not be sealed immediately, the bathroom would have to be shut until a repair or replacement took place.

This would likely have taken a long time because of the potential bureaucracy involved and with many NHS trusts in England and Wales struggling to afford repairs or upgrades to their crumbling estates.

Water leaking from an 80mm hole in a cast iron drain pipe before a SylWrap repair
A strong stream of wastewater escaped the pipe whenever the bathroom was used

Thankfully, the hospital maintenance team were equipped with a SylWrap Drain & Waste Pipe Repair Kit. The Kit contains multiple products for sealing cracks and splits in cast iron and plastic drain, waste and soil pipes.

It comes in a robust red case which is easy to store on-site. As soon as the roof space leak was discovered, the maintenance team simply retrieved their Drain & Waste Kit and used the materials inside the seal the hole.

Superfast Steel Epoxy Putty was kneaded by hand and formed into a 110mm diameter disc, ensuring total coverage of the hole around all sides.

Whilst soft, the mixed Superfast Steel disc was positioned over the hole and pressed onto the pipe for maximum contact. The edges were firmly pushed into place and smoothed off to form a strong bond with the surface of the pipe.

Before the putty had fully hardened, SylWrap HD Pipe Repair Bandage was applied on top. The resin was activated using water and SylWrap HD wrapped and smoothed around a 300mm area with the hole at its centre.

SylWrap HD forced the gelled Superfast Steel further into the hole for a more effective seal. Within 10 minutes of mixing, the epoxy putty cured to form a material as hard as steel covering the hole.

SylWrap HD Pipe Repair Bandage used to permanently seal an 80mm hole on a cast iron drain pipe at a UK hospital
SylWrap HD Pipe Repair Bandage applied over Superfast Steel Epoxy Putty created a permanent, reinforced repair

The bandage began curing as soon as it was activated, needing less than five minutes to set. It provided an impact resistant protective sleeve around the entire pipe for a reinforced, permanent repair.

With the bathroom only needing to be shut for 15 minutes whilst the drain pipe hole repair took place, there was limited disruption to patients.

An inspection of the roof space several weeks later revealed no sign of leakage despite heavy use of the bathroom. The application had been a complete success with wastewater now fully contained.

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: Protection of Underwater Gas Pipe Network Laid Through River System

SylWrap HD Pipe Repair Bandage gives protection to an underwater gas pipe network running through the river system in Scotland

SylWrap pipe protection programme prevents gas pipelines across the Scottish river network from sleeping with the fishes

SGN and Sylmasta devise a pipe protection programme for underwater gas pipelines laid through the river network in Scotland after riverbed scour and erosion left them exposed and vulnerable to damage.

Case Study Data

Site
River network
Location
Scotland
Repair Type
Pipe reinforcement
Defect
Exposed gas pipes in rivers left vulnerable to impact damage

Products Used

SylWrap HD Pipe Repair Bandage
Composite repair wrap applied to submerged pipes which set rock-hard to form an impact resistant outer layer 6mm thick

Case Study PDF

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Case Study Details

Large sections of the gas pipe network in Scotland run through river and stream beds. Whilst these pipes are well buried during installation, changing conditions within waterways can still lead to exposure by riverbed scour and erosion.

Riverbed scour occurs when gravel, sand and rocks are washed away by fast-flowing water. The problem is intensified during floods, where rising water levels increase the speed of rivers and streams.

With climate change making extreme weather events more frequent, Scottish gas distribution company SGN have seen a sharp rise in the number of riverbed pipes on their network becoming exposed.

This poses a serious challenge. Without the covering and protection provided by the gravel and sediment of the riverbed, pipes are left open to impact from other debris carried by the water.

Such exposure increases the chances of surface damage which weakens the pipeline. Enough damage over time or from one big impact with a heavy object leaves the pipe at risk of being breached.

The problem of exposed pipes in riverbeds shows no signs of going away. Winter rainfall levels in Scotland increased by 19 percent in a decade between 2010-2019 compared to 1961-1990.

Knowing even more of their gas network will become exposed by riverbed scour in future years, SGN contacted Sylmasta looking for a protection method which could be applied to any submerged pipe in any river across Scotland.

Sylmasta recommended the use of SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water-activated resin which sets rock hard in minutes to form an impact resistant protective sleeve around pipework.

Before SylWrap HD could be used on the gas network, it had to receive several approvals from relevant industry bodies. This was handled by SGN with the process fast tracked through the system because of the importance of the project.

SylWrap HD also had to receive authorisation from the Scottish Environment Protection Agency before it could be used in natural waterways. SEPA tested SylWrap to ensure it would not impact or pollute the environment in any way.

Sylmasta then flew to Scotland to provide technical support for SGN with initial trial repairs, made to an exposed pipe in a shallow river around one-metre deep.

Contractors from SGN entered the water to wrap exposed gas pipes with SylWrap HD

Contractors entered the water and applied SYL616HD Bandages along the entire length of gas pipe. As soon as SylWrap HD was submerged, the resin began working.

The contractor worked quickly to wrap the bandage in a six layer repair. SylWrap HD easily cured underwater within minutes. Once set, it formed a 6mm thick shell protecting the pipe against future impact damage.

SylWrap HD Pipe Repair Bandage applied to protect submerged gas pipe in a river
SylWrap HD was wrapped and smoothed around the submerged pipe, curing quickly to form an impact resistant shield

Several different exposed pipes ended up being protected with SylWrap HD during the trial, including one in an area where visibility was made difficult due to reeds from a bank. At one point, a number of fish even swam around a newly-wrapped pipe to see what was going on.

SylWrap HD posed no danger to those fish or any other wildlife living in the river, as certified by SEPA. The bandage also has WRAS approval, meaning it has been approved as safe to use on pipes carrying drinking water.

Pipe submerged in a river and wrapped with SylWrap HD for protection attracts the attention of some fish
The completed repair attracted the attention of some intrigued fish

After the trial, one SGN contractor described working with SylWrap HD as “an absolute dream”. SGN were particularly pleased with how quick and easy SylWrap is to apply, as it would allow them to cover potentially hundreds of kilometres of pipework at a fast rate compared with alternative products.

SGN subsequently ordered over 500 SYL633HD Bandages for the river pipe protection programme to start immediately, helping to maintain the integrity of the Scottish gas network for 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: Homeowner DIY Repair of 25mm Lead Water Pipe Leaking Inside House Wall

A leaking 25mm vertical lead water supply pipe inside a wall of a house is sealed with a SylWrap Universal Pipe Repair Kit

Behind the wall – a leaking lead pipe repair prevents water damage until future replacement of the system

A homeowner in the United Kingdom makes a DIY repair to a vertical 25mm lead water pipe leaking inside the wall of their house by cutting away the drywall and using a SylWrap Universal Pipe Repair Kit.

Case Study Data

Site
Domestic property
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Leaking 25mm lead water supply pipe inside wall

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating repair tape which fuses to form a solid rubber band capable of sealing leaking lead pipes

SylWrap HD Pipe Repair Bandage
Composite repair wrap reinforced the repair by forming a rock hard, impact resistant sleeve around the pipe

SylWrap Universal Pipe Repair Kit
Wrap & Seal and SylWrap HD can be purchased together in the Universal Pipe Repair Kit

Case Study PDF

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Case Study Details

Homes constructed in the United Kingdom before the 1970s were often built with lead water pipes. Lead was particularly popular for pipework within walls, being malleable enough to shape into long lengths and durable enough to withstand containment.

A homeowner in the south of England noticed discolouration to a white wall close to a window during winter. They initially put it down to condensation and damp from the window.

But when summer arrived and the wall remained wet, they became suspicious of a potential leak. The drywall was removed to access the cavity, where they found a 25mm lead pipe running vertically which was weeping water.

After cutting away the drywall, the homeowner discovered a leaking lead water pipe

Long-term, the homeowner planned to remove the lead pipe because of the associated health risks. But whilst waiting for that to happen, they needed to repair the pipe inside the wall to prevent further water damage.

Water supply through the pipe could be turned off via the property’s external stopcock. Sealing an offline leak would normally mean using a SylWrap Standard Pipe Repair Kit.

However, the softness and oxidised surface of lead means epoxy putty struggles to adhere cohesively to it. Sylmasta therefore always recommend the SylWrap Universal Pipe Repair Kit for sealing lead pipes even when there is no pressure.

The Universal Kit comes with Wrap & Seal Pipe Burst Tape, which can repair lead because it is made from self-amalgamating silicone and bonds to itself more than the substrate.

Despite the space constraints inside the wall, Wrap & Seal was successfully stretched by the maximum three times its length as it was wrapped around the leak area. This enabled it to fuse into a solid rubber band, exerting pressure over the leak to contain pipe content.

Despite the space constraints inside the wall, the lead pipe was successfully repaired using Wrap & Seal and SylWrap HD Bandage

The repair was then overwrapped with a SylWrap HD Pipe Repair Bandage. The water activated resin turned the bandage rock-hard within minutes. It formed an impact resistant protective shell around the pipe for a reinforced repair.

Completing the application took under 20 minutes. Water supply to the house was turned back on and the lead pipe inspected regularly over the next two days for any sign of leakage. It remained bone dry, indicating a successful repair.

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

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

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Case Study: Rotted Bay Sash Window Frame Repair & Restoration

Rotted bay sash window reframe undergoes repair and restoration using AB Original Epoxy Putty as a filler

Sharing a window on how to seamlessly repair and restore a rotted bay sash frame

A bay sash window frame which had rotted after only eight years due to severe weathering and poor preparation by the installer undergoes repair and restoration by the homeowner using Sylmasta AB Original Epoxy Putty.

Case Study Data

Site
Domestic property
Location
England
Repair Type
Wood repair
Defect
Heavily rotted bay sash window

Products Used

CA3 Penetrating Superglue
Very low viscosity cyanoacrylate superglue stabilises wood by wicking deep into soft damaged fibres and turning them rock hard

Sylmasta AB Original Epoxy Putty
Epoxy putty which is easy to shape and mould when used as a filler to rebuild missing sections of damaged wood

Case Study PDF

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Case Study Details

When installed eight years earlier, the bay sash window was brand new. Thanks to severe weathering and poor preparation by the installer, one sharp corner had become heavily rotted in just eight years.

The rot first softened the wood, then caused cracks to appear before chunks of timber eventually fell away. It left very obvious and unsightly damage visible to all visitors and passers-by.

Wanting to repair the bay sash window, the homeowner contacted Sylmasta for advice. A restoration plan was formulated involving cleaning, stabilising and then rebuilding the damaged corner.

All loose rotted timber was removed from the bay sash window frame as the first stage of repair. Any remaining fragile wood was then stabilised using CAE3 Penetrating Cyanoacrylate Superglue.

The extreme low viscosity of CAE3 makes it as thin as water. This allows CAE3 to penetrate porous surfaces, wick into cracks and flow easily into small and hard-to-access areas.

When CAE3 was applied to the bay sash window corner, it permeated deep into the damaged fibres of the frame. It cured rapidly to turn all wood which had been left soft and fragile by rot into a rock-hard material ready to be rebuilt with epoxy putty.

AB Original Epoxy Putty applied to rebuild and repair the heavily rotted corner of a bay sash window
Once rot had been removed and the remaining wood stabilised, Sylmasta AB Original Epoxy Putty was applied to fill all gaps in the corner

It was decided to use Sylmasta AB Original Epoxy Putty. AB Original was chosen for its two-hour work time, allowing the homeowner to mix, shape and apply the putty carefully without the worry of it curing off quickly.

AB Original was kneaded by hand and applied direct to the frame. It easily adhered to the stabilised wood. Enough putty was added until all the missing wood was filled and replaced, leaving the damaged corner rebuilt.

Epoxy putty smoothed off with a metal spreader during the repair of a rotted bay sash window frame
AB Original was smoothed off with a metal spreader. Once cured, it left a rebuilt corner

Before curing, the putty was smoothed off using a metal spreader and a little water. Once it had fully hardened, it was lightly sanded down and then painted the same white colour as the sash window for a seamless restoration.

Seamless repair of a rotted bay sash window frame completed using Sylmasta AB Original Epoxy Putty
The cured AB Original was painted to seamlessly match the colour of the bay sash window, leaving no signs of any repair

The homeowner had never handled epoxy putty before making the repair. They said afterwards they liked how straightforward an AB Original Stick was to use, simply by cutting off the amount of putty required and mixing by hand.

They also appreciated not having to rush the putty application because of the longer work time, and that AB Original did not sag or lose shape as it was applied to the bay sash window corner.

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

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

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Case Study: Worthington Simpson Pump Repair Seals Pinhole Leaks in Casing

Liquid Metal Epoxy Coating used to repair and refurbish a corroded and leaking Worthington Simpson pump

No replacement parts, no problem – repair and refurbishment keeps historic Worthington Simpson Pump operational

The inside of a Worthington Simpson pump head – old enough that replacement parts no longer exist – undergoes repair after the removal of corrosion via shot-blasting left multiple pinhole leaks in the casing.

Case Study Data

Site
Engineering company
Location
Warwickshire, UK
Repair Type
Pump repair
Defect
Pinhole leaks in heavily corroded Worthington Simpson pump head casing

Products Used

Superfast Steel Epoxy Putty Stick
Fast working epoxy putty which cures within 10 minutes for quickly sealing small holes and leaks in metalwork

Liquid Metal Epoxy Coating
Brush applied coating forms a robust metallic surface when painted onto parts and surfaces to shield against corrosion

Case Study PDF

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Case Study Details

Worthington Simpson were a British pump manufacturer founded in 1785. They operated independently until merging in 1967 with American companies Wagner Electric and Studebaker Corporation, becoming a subsidiary of Studebaker-Worthington.

In their heyday, Worthington Simpson supplied pumps for most municipal waterworks throughout Great Britain. They later worked with the Royal Air Force and the Royal Navy.

The demise of Worthington Simpson has made getting hold of replacement parts for older pumps virtually impossible. Repair and refurbishment is therefore the only option to keep systems operational.

GEM Integrated Solutions are an electrical and mechanical engineering company in the United Kingdom specialising in motor and pump repair.

They were asked by the owner of a now-obsolete Worthington Simpson pump to refurbish the corroded pump head, for which spare parts no longer exist.

The pump was disassembled so that the inside of the head could be shot-blasted to remove all traces of rust, dirt and grime. But when the pump was then pressure tested after the repair, it was found to be leaking.

Heavily corroded inside of an old Worthington Simpson pump before repair and refurbishment with Liquid Metal Epoxy Coating
Heavy corrosion was removed from the inside pump head via shot-blasting

Shot-blasting had turned the head porous by creating several pinholes in the casing, through which water sprayed out in small volumes when the pump was pressurised. This was not something which GEM had experienced before.

An attempt to patch weld over a pinhole was unsuccessful, leaving GEM needing an alternative method to seal the casing and successfully complete the Worthington Simpson pump repair for their client.

They used two 114g Superfast Steel Epoxy Putty Sticks to fill all pinholes in the pump. Small amounts of epoxy putty were cut from the stick, mixed by hand and then pushed flat onto the casing over every pinhole.

Within 10 minutes of application, Superfast Steel cured to form a rock-hard material covering all leaks. No water could now escape the pump.

Liquid Metal Epoxy Coating applied to a Worthington Simpson pump to repair casing damaged by pinhole leaks and corrosion
After shot-blasting left pinhole leaks, the pump was sealed with Superfast Steel before being reinforced with three layers of Liquid Metal

Liquid Metal Epoxy Coating was then used to completely seal the casing and give the metalwork inside robust protection against future corrosion, extending the lifespan of the pump.

Three coatings of Liquid Metal were painted onto the casing. Once cured, this provided a 3mm thick reinforced metallic layer which covered the pump interior.

Worthington Simpson pump reassembled after repair using Sylmasta products
GEM’s client were delighted with both the fully working pump and that its lifespan had been significantly extended thanks to the protection provided by Liquid Metal

Fluid inside the pump was now fully contained and with the original metalwork shielded from water contact by Liquid Metal, it will now be many years before the inside casing shows any sign of corrosion again – much to the delight of the client.

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: Cast Iron Waste Pipe U-Bend Crack Repair Above Hospital Corridor

A cast iron pipe U-bend with a hairline crack at a UK hospital is sealed with a SylWrap Drain & Waste Pipe Repair Kit

Ladder-top repair stops leaking cast iron waste pipe driving hospital staff around the U-bend

From the top of a ladder, a maintenance worker makes a repair in under 15 minutes to a hairline crack in a cast iron waste pipe U-bend within a cramped roof space above a hospital corridor.

Case Study Data

Site
Hospital
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Hairline crack in cast iron waste pipe U-bend

Products Used

CrackSeal Pipe Sealant
Sealant extruded directly into cracks in cast iron pipework, where it hardens almost instantly to fill the damage

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to create a reinforced sleeve around pipework

SylWrap Drain & Waste Pipe Repair Kit
Specialist Kit containing products for repairing low-pressure cast iron and plastic waste, sewer and drain pipes

Case Study PDF


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Case Study Details

Damp patches were noticed in ceiling tiles above a busy corridor in the hospital. A maintenance worker climbed up a ladder, removed the tiles and accessed the roof space above to investigate.

They found a complex network of cast iron pipework. One of these pipes came down through the ceiling, into a U-bend followed by a 90-degree elbow before connecting with two other waste pipes via a Y-joint.

The problem was found to be a hairline crack across the U-bend located directly above the Y-joint. Wastewater was seeping through this crack, corroding the three pipes at the Y-joint where they met below and dripping further down to discolour and damage the ceiling tiles.

Hairline crack in a cast iron pipe U-bend through which wastewater was leaking at a UK hospital before undergoing repair
After accessing the roof space, a hairline crack was discovered in a cast iron pipe U-bend

To replace the cracked U-bend, every pipe connected to it – including the Y-joint – would have needed to be removed to gain enough access.

The cash-strapped NHS trust responsible for the hospital could not afford the cost of effectively taking the entire system out of operation.

Research by the maintenance team led them to the SylWrap Drain & Waste Pipe Repair Kit, which is already used by several NHS trusts in England for making fast, straightforward and cost-effective repairs to leaking cast iron and plastic pipework on their estates.

All the products in the Drain & Waste Kit are lightweight enough to be applied from the top of a ladder. The repair started by using CrackSeal Pipe Sealant to fill the crack in the U-bend.

Using a standard sealant gun, CrackSeal was extruded directly into the crack. As a moisture curing sealant, it began to harden almost instantly. Within 10 minutes, it had formed a skin to leave the pipe fully sealed.

CrackSeal was then reinforced using SylWrap HD Pipe Repair Bandage. Although the U-bend was a difficult geometry to wrap the bandage around, the worker managed to apply it effectively.

The resin in SylWrap was activated using water and the bandage wrapped and smoothed around the U-bend. Once the U-bend was covered, wrapping continued vertically to cocoon the entire repair area.

Cast iron pipe U-bend with hairline crack undergoes repair at a UK hospital with SylWrap Pipe Repair Bandage
The crack was sealed with CrackSeal and then reinforced with SylWrap HD, despite the lack of space left by the complex network of pipes in the roof

SylWrap set rock-hard within minutes of application, providing the entire leak area with an impact-resistant protective sleeve capable of containing any future leaks should the weakened U-bend become breached in future.

The worker completed the cast iron U-bend repair in under 15 minutes and with little disruption to the hospital, other than the corridor being out of use whilst they were up the ladder.

With the Drain & Waste Pipe Repair Kit containing enough products to seal multiple cracks and holes in different types of pipework, the hospital now have CrackSeal, Superfast Steel Epoxy Putty, SplitFill Epoxy Adhesive and SylWrap HD Bandages on-site in an easy-to-store case for use when future leaks occur.

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: Complex in UAE Approves SylWrap for Chilled Water System ABS Pipe Repair

An ABS pipe leaking at a joint undergoes repair to show SylWrap is effective in chilled water cooling systems

Keeping cool under pressure – SylWrap passes testing for repair of chilled water system ABS pipe joints

Superfast Aqua PW Epoxy Putty and SylWrap HD Pipe Repair Bandage undergo rigorous pressure testing by an engineering company to receive approval for use sealing ABS pipe joints in a chilled water cooling system at a luxury complex in the UAE.

Case Study Data

Site
Luxury complex
Location
United Arab Emirates
Repair Type
No pressure pipe repair
Defect
Leaking ABS pipe flange in chilled water cooling system

Products Used

Superfast Aqua PW Epoxy Putty Stick
Epoxy putty with specialist high underwater adhesion formulation for sealing pipes when the surface is wet

SylWrap HD Pipe Repair Bandage
Composite wrap cures to form a thickened, reinforced layer which restores pipework integrity

Case Study PDF

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Case Study Details

Chilled water and district cooling systems are used throughout the United Arab Emirates to provide an energy efficient method of air conditioning.

Water is stored and cooled in a central plant. It is then pumped around buildings, complexes and even entire districts via vast pipe networks operating at between 5 and 7 bar pressure.

Some of these systems provide air conditioning to hundreds of different homes and workplaces from a large-scale plant. The Empower Business Bay plant in Dubai for example serves 188 multi-use buildings and skyscrapers. Future expansion is planned to take that number over 300.

Other leisure complexes and skyscrapers have private chilled water systems, supplying air conditioning for their own facilities. This is the case with the Burj Khalifa, which has 34 kilometres of pipework circulating cooled water around the 830-metre tall building.

Sylmasta were contacted by an engineering company responsible for a private chilled water system at a luxurious complex containing over 500 apartments, a leisure centre, shops, restaurants and a 5-star hotel.

They were looking for a quick and straightforward repair method for sealing any leaking joints in the ABS pipe network which pumped cooled water around the complex. Rapid response time was essential to ensure the efficiency of the air conditioning system.

An engineering company in the UAE build an ABS pipe rig to test SylWrap for the repair of chilled water cooling pipes in the UAE
The engineering company built several ABS pipe test rigs with an intentionally weakened flange end for repair using Superfast Aqua PW and SylWrap HD

To evaluate Sylmasta products, the company built several test rigs with 50mm, 100mm and 150mm ABS pipes. Each rig was one-metre long and connected with stub flange sets and MS end flanges.

One side of the flange ends was made intentionally weak so that it would begin leaking when pressure was increased. The pipe was filled with water through a valve. Once it was full, pressure was applied.

At 4 bar, a leak was noticed at the weakened flange end. The area was instantly cleaned and then sealed using Superfast Aqua PW Epoxy Putty. Aqua PW was chosen for its high underwater adhesion properties, enabling it to bond to the ABS even though the pipe surface was wet.

Enough putty was cut from the stick for application all around the weak flange plate. The putty was kneaded by hand and applied to the pipe whilst still soft. Within 20 minutes, it cured to form a rock-hard, waterproof material permanently bonded to the ABS and covering all leak spots to restore pipeline integrity.

SylWrap HD Pipe Repair Bandage applied to an ABS pipe identical to those found in chilled water cooling systems in UAE
SylWrap HD was wrapped over a 250mm section of pipe either side of where the flange was leaking through

SylWrap HD Pipe Repair Bandage was then wrapped over a 250mm section of the pipe either side of the leak. It cured to create a thickened, impact-resistant sleeve around the leak, further enhancing the seal provided by Superfast Aqua PW.

The repair was left for 90 minutes to reach working strength and then pressure tested. Pressure was gradually increased towards 8 bar, reflecting the maximum the chilled water system at the complex reached.

Throughout each of the three pressure tests to the different sized rigs, the gauge was monitored for any significant drops or irregular fluctuations.

Once 8 bar had been exceeded, the repair was left for 18 hours. When the pipe was inspected again, there were no visible cracks, leaks, deformations or signs of damage.

The repair successfully held over 8 bar pressure for 18 hours

Based on the visual inspection and pressure test results, the engineering company concluded the SylWrap repair to have successfully restored the functionality and integrity of the ABS pipe.

In their report compiled after all 50mm, 100mm and 150mm tests had been completed, the company wrote: “The repair material was applied correctly and adhered well to the pipe surface.”

“The pressure test demonstrated the repair’s ability to withstand the specified pressure without any signs of leakage, failure, or abnormal pressure fluctuations.”

“We therefore consider this repair a suitable solution for any leakage on ABS pipes in chilled water cooling systems.”

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: Leaking HVAC Cooling Tower Repair at Production Facility in USA

A leaking HVAC cooling tower undergoes repair at a production facility in the USA

Chill out, Sylmasta have got this – leaking cooling tower repair restores efficiency to HVAC system

After several failed repair attempts, a leaking HVAC cooling tower at a production facility is sealed within a matter of hours using a combination of Superfast Aqua PW Epoxy Putty and Industrial Metal Rapid 5 Minute Epoxy Paste.

Case Study Data

Site
Production facility
Location
United States
Repair Type
Leak repair
Defect
Leaking cooling tower in HVAC system

Products Used

Superfast Aqua PW Epoxy Putty
Fast working epoxy putty specially formulated for high-strength adhesion to wet and underwater surfaces

Industrial Metal Rapid Epoxy Paste
Epoxy paste with a 60-minute functional cure for quickly rebuilding significant areas of damage

Case Study PDF

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Case Study Details

Temperature control at the production facility was provided by a HVAC system. Water which had absorbed heat from inside the building was pumped to a cooling tower located on the roof.

This warmed water was exposed to air inside the tower, leading to heat being rejected into the atmosphere via evaporation. The re-cooled water was then pumped back into the building and the whole process repeated.

After water was seen leaking from the cooling tower, the HVAC system was shut off, and the tower drained and accessed. A long crack was discovered in the floor, with significant amounts of concrete either side having crumbled away.

The floor of the cooling tower was leaking through a hairline crack with severe damage to the concrete either side

With the effectiveness of the HVAC system determined by the amount of water cooled, any loss from the tower through leakage was extremely damaging to efficiency.

The manufacturer of the HVAC system admitted they had never seen a fault like this before. Several repair attempts were made using their normal tried-and-tested methods, but these failed before they contacted a Sylmasta distributor for advice.

Because the tower floor was still saturated with water, Superfast Aqua PW Epoxy Putty was used to fill the crack. Superfast Aqua PW is specially formulated for high underwater adhesion.

Whereas other repair compounds might have struggled to form an effective bond, Aqua PW easily adhered to the wet concrete.

Superfast Aqua PW Epoxy Putty was forced into the crack, forming a rock-hard material in around 20 minutes to seal the leak

After the surface had been prepared via grinding with an abrasive disc, the putty was mixed by hand and forced into the crack. It hardened within 20 minutes, curing to form a solid material which sealed along the entire leak area.

With the leak sealed, attention turned to repairing the significant damage left where the concrete floor had crumbled away, using Industrial Metal Rapid 5 Minute Epoxy Paste.

Industrial Metal Rapid was chosen for its fast 60-minute functional cure time, which would enable the cooling tower to go back into service more quickly than if standard grade Industrial Metal were used.

Industrial Metal Rapid 5 Minute Epoxy Paste rebuilt areas of the floor around the crack where the concrete had crumbled away

The epoxy paste was mixed using a putty knife before being used to rebuild the missing floor around the crack. It filled the damaged area with a smooth, metallic-like material offering excellent corrosion resistance to further enhance the sealing power of Aqua PW.

Within three hours of the leaking cooling tower repair starting, the HVAC system was operating at full efficiency again. Impressed by the ease and speed of the repair, the HVAC manufacturer is now using Sylmasta products for a wider range of applications.

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 Underground Clay Drainage Pipe Cracked During Building Work

A cracked underground clay drainage pipe undergoes repair using a SylWrap Standard Pipe Repair Kit

An underground clay pipe repair prevents a home drainage system going to pot

Accidental impact and ground movement during building work left an underground 100mm clay drainage pipe with two cracks requiring repair, one of which was severe enough to almost split the pipe into two separate parts.

Case Study Data

Site
Domestic property
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Two cracks in underground 100mm clay drainage pipe

Products Used

Superfast Steel Epoxy Putty Stick
Fast working steel epoxy putty which sets rock hard inside cracks and holes, sealing leaks

SylWrap HD Pipe Repair Bandage
Composite wrap reinforced the repair with a rock hard sleeve which also helped hold the pipe back together

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

Clay was a popular material for drainage pipes in the United Kingdom from the early 20th century until the 1970s, when plastic became more widely used due to being easier and cheaper to fabricate and install.

High resistance to corrosion and chemical degradation gives clay extreme durability and longevity, with an estimated lifespan of anywhere between 60 and 100 years. This means many UK homes built before the 1970s are still serviced by working clay pipes.

One weakness of clay pipes, however, is they are susceptible to damage from root ingress and ground movement – which often only becomes obvious when a patch of ground becomes noticeably waterlogged from an underground leak.

A homeowner was carrying out building works when an area of their garden began suffering from this problem. After digging down, they discovered a dislodged 100mm clay pipe with two areas of significant damage.

The first and most severe was a crack next to a junction almost splitting the pipe into separate parts. The junction and uneven surface meant it would not be possible to reassemble the pipe using a repair clamp.

The clay pipe had a significant crack next to a junction with a smaller hairline crack along its top

Across the top of the pipe was a hairline crack, representing the second damaged area. There was no pressure and the homeowner was keen to avoid the cost and disruption which would come with replacing the pipe.

They therefore used a SYL-412-NP SylWrap Standard Pipe Repair Kit to seal the leaks and attach the pipe back together. Before the repair, enough room was dug out underneath the pipe to allow clearance for it to be wrapped.

The two cracks were then filled with Superfast Steel Epoxy Putty. Enough putty was first mixed by hand to cover the hairline crack. It was then pushed firmly down across the top of the pipe, curing within five minutes to form a rock hard material covering the leak.

Superfast Steel Epoxy Putty used to repair cracks in an underground clay drainage pipe
Superfast Steel was used to seal the two cracks in the pipe

For the larger crack, more putty was mixed and forced into the gap between the two sections of pipe. Once it had set, Superfast Steel bridged the crack with a watertight material bonded to both pieces.

The pipe was then overwrapped with SylWrap HD Pipe Repair Bandage. The fast-working resin in SylWrap HD was activated with water and the bandage wrapped along the entire length of the exposed pipe.

SylWrap HD cured to form a rock-hard, impact resistant protective shell. It reinforced the repair and helped hold the two broken pieces of clay pipe back together.

SylWrap HD Pipe Repair Bandage applied to an underground clay drainage pipe to reinforce the line after it cracked
The pipe was overwrapped with a SylWrap HD Bandage to complete the repair

The homeowner said afterwards that the repair worked perfectly and that the product was great. Completing the repair took under 30 minutes and cost less than £50, representing a huge saving compared with removing the pipe and installing a replacement.

With many clay pipes installed before the 1970s now beginning to reach the end of their natural lifespan, repairs such as this are set to become more common in the UK over the coming 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: SylWrap Leak Repair Passes ASME PCC-2 402-III Qualification Standard

Superfast Aqua PW Epoxy Putty and SylWrap HD Pipe Repair Bandage are successfully tested to be ASME PCC-2 402-III compliant

Leak repair made using Sylmasta products withstands 30 bar pressure in qualification tests for ASME PCC-2 402-III

Superfast Aqua PW Epoxy Putty and SylWrap HD Pipe Repair Bandage make a leak repair qualified to ASME PCC-2 Appendix 402-III – Validation for Repair of Leaking Component by withstanding 30 bar pressure in multiple tests.

Case Study Data

Site
Sylmasta HQ
Location
United Kingdom
Repair Type
Leak repair
Defect
25mm hole in 110mm diameter carbon steel pipe

Products Used

Superfast Aqua PW Epoxy Putty
Fast working epoxy putty which bonds to wet surfaces with WRAS approval for sealing holes and cracks in pipes

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to reinforce pipework with a thickened, impact resistant sleeve

Case Study PDF

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Case Study Details

ASME PCC-2 Appendix 402-III – Validation for Repair of Leaking Component is a test which assesses the ability of a composite pipe repair system for sealing leaking pipes, tanks and vessels containing non-hazardous fluids operating below 10 bar.

To qualify for ASME PCC-2 402-III, a repair must successfully seal a leaking pipe which has been fully breached, restore pressure-retaining capability to the line and show it will not degrade or be compromised over time under service conditions.

It is a standard widely used across many industries – such as water utilities – to give confidence that repairs on the public supply network will be strong and long-lasting.

ASME PCC-2 402-III is also applicable to other industries where high-pressure water pipes are used – such as desalination plants and cooling systems at oil refineries, power stations and food and beverage production.

Testing took place at Sylmasta HQ in the United Kingdom. A 25mm hole was cut into a 110mm diameter carbon steel pipe. The leak needed to be sealed before being subjected to three separate pressure tests up to 30 bar.

A 25mm hole was cut into a steel pipe for testing

Superfast Aqua PW Epoxy Putty was used to plug the hole in the pipe. To improve adhesion, the pipe was abraded first. This removed any traces of rust, dirt or grime. It also created a textured surface for the repair to grip onto.

The putty was mixed by hand and formed into a disc around 75mm in diameter, ensuring total coverage of the leak. It was placed over the hole and pushed firmly down onto the pipe for maximum contact.

Superfast Aqua PW seals a 25mm hole in a carbon steel pipe to qualify for ASME PCC-2 401-III standard
Superfast Aqua PW Epoxy Putty was formed into a disc and fixed over the hole

At the edges, the putty was smoothed off using a little water to remove any step from the surface. It was allowed to cure for around 10 minutes until gelled but not hardened.

SylWrap HD Pipe Repair Bandage was then used to reinforce Superfast Aqua PW. The composite repair wrap was activated with water and applied over an area approximately 225mm, with the leak at its centre.

As SylWrap HD was wrapped and smoothed over the putty, it helped force Superfast Aqua PW further into the hole for a more effective seal. SylWrap HD set rock hard within minutes, curing to form a thick, rock hard, impact-resistant sleeve around the pipe.

SylWrap HD reinforced the pipe with a rock hard, impact resistant sleeve

The repair was left for 24 hours to achieve maximum properties before pressure testing. This involved increasing pressure through the pipe at a steady rate for more than 30 seconds until 30 bar was reached.

After 60 seconds of the pipe being pressurised at 30 bar, the repair was inspected for any visible leakage. This test was carried out on three separate occasions.

With no leak or defect detected during any of the three pressure tests, repairs made using Superfast Epoxy Putty and SylWrap HD are qualified to meet ASME PCC-2 402-III standard.

A SylWrap Pipe Repair withstands 30 bar pressure to be qualified for ASME PCC-2 401-III - Validation for Repair of Leaking Component
The repair was pressure tested three times, withstanding 30 bar on each occasion

In addition to qualifying for ASME PCC-2-402-III, Superfast Aqua PW and SylWrap HD both have WRAS approval – meaning they are certified as safe for use on pipes and fittings carrying drinking water.

For repairs to be fully ASME PCC-2 402-III compliant, installers must undergo training and certification on using Sylmasta products for leaking pipe repair. To find out more, please email sales@sylmasta.com

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