Three hundred not out – 300 joints are sealed in a leaking rainwater stack which threatened to derail the timeframe of an office block refurbishment
The refurbishment of a five-floor office block in central London is kept on track thanks to Sylmasta AB Original Epoxy Putty sealing 300 pipe joints in the repair of a 250-metre long internal cast iron rainwater stack leaking due to corrosion.
Case Study Data
Site London office block Location UK Repair Type Leaking repair Defect Corroded joints in cast iron rainwater stack
Products Used
Sylmasta AB Original Epoxy Putty Stick Waterproof epoxy putty with a two-hour work time for thorough leak sealing without the threat of curing before application is complete
With the entire office block stripped out as part of the refurbishment, the internal cast iron rainwater stack was accessed for the first time in many years. This revealed that 30-year-old rubber seals used to attach different sections of pipe together had begun to fail and would need replacing.
When these rubber seals were removed, the pipe ends underneath were discovered to be badly corroded where water had become trapped. Because of the uneven pipe surface, pitting and breaches caused by corrosion, it was now impossible to achieve a watertight seal.
The engineering company carrying out the office refurbishment tried new rubber seals, metal seals, pipe repair clamps and pipe repair clamps with teeth. When the joints continued to leak, it appeared the only option was to replace the entire 250 metres of pipework at considerable cost and with significant delay to the office refurbishment.
Sylmasta were called in to see if there was a better solution to repair the rainwater stack rather than total replacement. It was soon established the newly installed clamps could be removed and Wrap & Seal Pipe Burst Tape used to reconnect the pipe joints together, sealing them much more effectively.
However, the rainwater stack system running close to walls, floors and ceilings made it awkward in some areas to apply Wrap & Seal with the required 300 percent stretch. Removing every clamp would also be a time-consuming task.
It was instead decided to seal each clamp with Sylmasta AB Original Epoxy Putty Stick. Enough putty was cut from the 200g stick and kneaded by hand. Whilst soft, AB Original was forced into both ends of the clamp, filling the gaps between it and the corroded pipe surface.
AB Original Epoxy Putty was pushed between the newly installed clamps and the pipe surface, filling all gaps to seal the leaks
Once AB Original had hardened, it permanently sealed any leak paths. The repair was so effective that the engineering company decided to apply AB Original to all 300 joints on the rainwater stack, giving them full confidence the system would have no leaks once it was boxed back in and inaccessible.
The extended two-hour work time of AB Original allowed the engineers to thoroughly seal every joint at a reasonable pace without fear the putty would set before being properly applied.
120kg of AB Original was used for the repair. Supplying the epoxy putty in stick format eliminated the need to measure out separate components of Part A and Part B, making application quicker and more straightforward.
If you have an application you would like to enquire about, then please get in touch
Protection at the pumping station – corrosion prevention measures for a complex ductile pipe system
A water company take corrosion protection measures to avoid the future weakening of a 600mm diameter ductile pipe system with three outlets to isolation valves in an underground pumping station.
Case Study Data
Site Underground pumping station Location UK Repair Type Corrosion protection Defect 600mm ductile pipe showing early signs of surface damage
Products Used
Liquid Metal Epoxy Coating Brush applied coating which cures to a hard wearing, metallic surface for strengthening pipes and protecting against corrosion
SylWrap Pipe Repair Bandage Composite repair wrap with water activated resin which sets rock hard to encompass pipes with an impact resistant outer sleeve
Conditions inside the underground pumping station housing the pipework were damp, grimy and ripe for corrosion. Rainwater, dirt, sand and other contaminates were able to enter the chamber and settle on the pipework.
As a result, the ductile pipe system was beginning to show very early signs of exterior surface damage. This was of particular concern to the water company operating the pumping house because of the complexity of the pipework and the issues that would come in the event of heavy corrosion developing.
Diagram of the pipe system layout inside the underground pumping station
The main section of pipe entered the chamber through a wall. It was five metres long with three flanges at equal intervals. The three outlets branching off were two metres in length, had one flange each and a reducing spool to 200mm diameter at the isolation valves.
Carrying out any sort of leak repair or replacing sections of the system would present a serious challenge. Instead, the water company sought enhanced corrosion protection measures for the ductile pipe to lessen the chances of the line becoming breached.
Pipework in the chamber was showing early signs of surface damage
Rust and dirt were cleaned from the pipe before it was coated with Liquid Metal Epoxy Coating. Liquid Metal is brush applied and cures to form a smooth, metallic, hard-wearing outer surface which acts as a shield against external corrosion.
The entire main section of pipe, the three outlets, reducing spools and all six flanges were painted in Liquid Metal. The protective layer provided by the epoxy coating was then further reinforced using SylWrap Pipe Repair Bandage.
SylWrap Bandage is a composite wrap with a water-activated resin. It is wrapped and smoothed around pipework, curing in minutes to provide a rock-hard, impact resistant layer of protection.
The engineers carrying out the repair wrapped all sections of the pipe system in four layers of SylWrap, running the Bandage as close to the flange plates as possible to ensure maximum coverage.
The completed repair with final coating of Liquid Metal painted onto SylWrap Bandage
Despite the space constraints where the pipe ran close to the floor, the engineers were still able to successfully apply SylWrap around the bottom of the line. Once SylWrap had been applied, another coating of Liquid Metal was added over the top as an additional corrosion prevention measure.
With the repair completed, the water company could now be satisfied that the two coatings of Liquid Metal and several layers of SylWrap Bandage would offer robust protection for the ductile pipe against corrosion.
If you have an application you would like to enquire about, then please get in touch
The alcohol line repair which had a sugar mill in Costa Rica raising a glass of guaro to the SylWrap Pipe Repair Contractor Case
Having a SylWrap Pipe Repair Contractor Case on site enabled a sugar mill in Costa Rica to make an instant live leak pipe repair when a pinhole was discovered in an alcohol line running vertically up a tower.
Case Study Data
Site Sugar mill Location Costa Rica Repair Type Live leak pipe repair Defect Pinhole leak in 70mm alcohol line
Products Used
Wrap & Seal Pipe Burst Tape Self-amalgamating silicone repair tape seals live leaks by fusing together to form a solid rubber band
A SylWrap Pipe Repair Contractor Case contains enough products to seal up to six live leaks, making it the ideal kit to keep on-site for rapid response to emergences. The sugar mill had approved its use several years earlier, since when repairs had been made to multiple sections of pipework.
These included 90 degree elbow bends in elevated pipelines and a particularly challenging Y-joint leaking from the exact point where three separate pipes connected. Most of these pipes carried hot water.
Previous repairs made by the mill using Contractor Cases
The leaking alcohol line was 70mm in diameter and transported alcohol juice extracted from sugar cane during fermentation, which would eventually be used in the production of spirits including rum and guaro, the official liquor of Costa Rica.
It ran vertically up the tower, with the leak developing in a weakened section as the line passed through a circular hole in one of the upper floors. Alcohol juice was left spraying through the pinhole at around two bar pressure.
Alcohol juice spraying out of the pinhole leak in the pipe
As the pipe could not be isolated, Wrap & Seal Pipe Burst Tape was used as the leak sealant. Wrap & Seal is made from self-amalgamating silicone. When stretched by up to three times its length as it is wrapped around a pipe, the Tape fuses to form a solid rubber band capable of sealing live leaks .
Despite the space constraints around the pipe where it passed through the hole in the floor, the engineer making the repair managed to stretch the Tape to a suitable length so that it amalgamated successfully.
Wrap & Seal Pipe Burst Tape sealed the live leak
Once the engineer was satisfied the leak had been fully arrested and alcohol was no longer escaping, a SylWrap HD Pipe Repair Bandage was applied over the top to reinforce the Wrap & Seal.
SylWrap HD is a composite repair wrap containing a water activated resin. As it was wrapped and smoothed around the Wrap & Seal, it cured to form a rock-hard protective sleeve over the pipe.
SylWrap HD reinforced the repair with an impact resistant layer of protection
Both Wrap & Seal and SylWrap HD have WRAS approval, meaning they are safe to use with drinking water. The sugar mill were therefore reassured that neither product would affect the alcohol juice inside the pipe.
Because the plant already had all the products required to repair the pipe on-site in their Contractor Case, it took less than 20 minutes to seal the alcohol line from the moment the pinhole was discovered.
Only a minimal amount of alcohol juice escaped thanks to the speed and ease of the repair. All systems remained fully operational, meaning there was no disruption whilst the application took place.
Had a Contractor Case not been available, a much greater quantity of juice would have been lost. The mill may have even been forced to shut down the leaking section until such time as it could be repaired at significant cost both financially and to production.
If you have an application you would like to enquire about, then please get in touch
Cottages counter corrosion – the Sylmasta Pipe Refurbishment System is used to repair and reinforce a water supply line shared by eight properties
Four cottages in a terrace of eight in London use the Sylmasta Pipe Refurbishment System to repair and reinforce their respective sections of a 48 metre long shared water supply pipe weakened and breached by corrosion.
Case Study Data
Site Terraced cottages Location London, UK Repair Type Leak repair and pipe reinforcement Defect Heavily corroded 48 metre long steel shared water supply pipe breached in places
Products Used
Superfast Aqua PW Epoxy Putty Stick Fast working, WRAS approved epoxy putty with excellent wet surface adhesion used to seal leaks in pipework
Liquid Metal Epoxy Coating Brush applied coating which cures to a hard wearing, metallic surface for strengthening pipes and protecting against corrosion
SylWrap HD Pipe Repair Bandage Composite repair wrap with water activated resin which sets rock hard to encompass pipes with an impact resistant outer sleeve
The row of eight terraced cottages were built in the middle of the 19th century. They were connected to the public water network at a later date, which led to a somewhat unusual setup involving an above-ground shared supply pipe.
This steel pipe connected with a water main underground at one end of the terrace. It rose up the side of the first cottage and was then fixed at a height of around three metres to the back wall of all eight properties, along which it ran for 48 metres.
The height of the line meant it was surrounded by extensions built onto the cottages, downpipes, guttering and other installations and improvements added to the buildings over time. Access to certain sections was therefore severely restricted.
Lagging being removed from the section of pipe climbing up the side wall. The line then ran for 48 metres along the back of the cottages.
Each cottage was responsible for the section of pipe outside their property, giving them around six metres to maintain and upkeep. Lagging had been added around all 48 metres of the line to protect it during winter.
Unfortunately, low-quality insulation material was used which soaked up moisture like a sponge, causing water and condensation to become trapped against the steel. Over time, this led to heavy corrosion and a weakening of the pipe.
When temperatures in London dropped as low as -8°C in an unusually cold spell and water inside the pipe froze, the brittle metalwork was unable to cope. Several cracks appeared outside one cottage, requiring repair.
The lagging was removed from the leaking section to access the pipe, at which point the extent of the corrosion problem became clear. The other seven cottages were inevitably going to suffer from bursts on their sections in future if something were not done.
Corrosion covered the pipe where it ran along the back wall of the cottages
Initially, the cottages contacted their water company for help. Because the pipe was a shared supply line and not part of the public network, the water company said they had no responsibility for it. It was therefore down to the eight property owners to find a solution themselves.
The cottages were quoted £22,000 to replace the entire line. Some of the property owners did not wish to contribute £2,750 towards the cost, preferring instead to take a chance their section would not burst.
It next became clear that replacing individual sections of pipe for those cottages wanting to avoid future leaks would not be practical either. New fittings would struggle to connect with old, brittle pipes not being replaced.
Installation would also be disruptive to those cottages not undertaking work, with shared electrical boxes and satellite dishes having to be taken out of service whilst new sections of pipe were fitted.
With no common route forward found, the cottage with the leaking section contacted Sylmasta for advice on sealing the holes on their part of the line. At this point, the owner also explained the complications caused by the shared water supply pipe and the concern about how it might deteriorate further.
Sylmasta suggested that in addition to sealing the cracked section of pipe outside one cottage, their Pipe Refurbishment System be used to reinforce individual sections along the line for those property owners wanting protection against future leaks.
Two cottages requested their sections be attended to, and so Sylmasta sent an approved contractor to London to carry out the repair and strengthening of the shared water supply pipe.
Superfast Aqua PW Epoxy Putty sealed the holes in the section of pipe which had burst
Once the lagging had been removed, the first stage of the Pipe Refurbishment System involved application of the leak sealant – in this case, Superfast Aqua PW Epoxy Putty.
Superfast Aqua PW was chosen for its excellent wet surface adhesion to alleviate concerns the pipe may have been weeping water. It has WRAS approval, meaning it is certified as safe to come into contact with potable water.
Aqua PW is supplied in a pre-measured 114g stick. The required amount of putty was cut from the stick, kneaded by hand and then pushed into the cracks and damage in the pipe whilst soft. Within 20 minutes, it cured to form a rock-hard sealing material.
Liquid Metal could be easily painted onto difficult-to-access areas of the pipe
The second stage of the Pipe Refurbishment System saw Liquid Metal Epoxy Coating applied to strengthen the line and protect it from corrosion. Liquid Metal was painted on by brush to sections of the pipe outside every cottage who wanted their part of the line reinforced.
Liquid Metal coated onto the pipe to form a new metallic outer surface
Once cured, Liquid Metal formed a smooth, metallic, hard-wearing outer surface around the pipe to act as a shield against external corrosion. Should the brittle steel be breached from the inside by freezing temperatures in future, the Liquid Metal shell will contain the contents of the pipe.
The cottages who did not wish for their sections of pipe to be reinforced were left with the original lagging and corroded pipe, contrasting with the refurbishment provided by Liquid Metal
SylWrap HD Pipe Repair Bandage was added as the final stage of the Pipe Refurbishment System, to provide the shared water supply pipe with another layer of protection. SylWrap HD is a composite repair wrap with a water-activated resin which sets rock-hard in minutes when wrapped and smoothed around pipework.
The pipe was given further protection using SylWrap HD Pipe Repair Bandage
Nine SylWrap Bandages were applied per cottage to build up thickness to four layers, with the application taking place whilst the Liquid Metal remained tacky to improve adhesion to the pipe. Once cured, SylWrap HD formed an impact resistant shell encompassing the pipe.
In addition to the two planned repairs, a third cottage owner asked for their section to be reinforced, having seen how straightforward and cost-effective the process was. Their part of the pipe had not been as badly weakened by corrosion and therefore required only Liquid Metal for suitable strengthening.
All three cottages were completed in a single day, since when a fourth has requested the approved contractor return and attend to their part of the pipe with whatever treatment necessary depending on its condition beneath the cladding.
Lagging added to complete the repair
Those cottages who used the Sylmasta Pipe Refurbishment System will now head into winter confident their sections of the shared water supply pipe will not be weakened further by corrosion or breached. The approved contractor then installed new lagging to replace the original insulation which had to be removed.
In the unlikely event that water and condensation again became trapped underneath the lagging, the barrier between moisture and the original metalwork provided by Liquid Metal and SylWrap HD would make future corrosion virtually impossible.
If you have an application you would like to enquire about, then please get in touch
Repair and refurbishment helps a portable toilet company avoid flushing two working luxury trailer units down the drain
Holding tanks with the capacity to store 3000 litres of wastewater underneath two luxury portable toilet trailers undergo repair and strengthening after the metalwork became weakened by corrosion, causing numerous holes to appear.
Case Study Data
Site Luxury Portable Toilet Trailer Location United Kingdom Repair Type Tank repair and refurbishment Defect Heavy corrosion to two wastewater storage tanks
Products Used
Sylmasta AB Original Epoxy Putty Epoxy putty pushed into holes and cracks in tanks and pipes, where it will cure to a rock-hard material which permanently seals leaks
Liquid Metal Epoxy Coating Brush applied coating which strengthens and protects metalwork by forming a new metallic, hard-wearing surface
Case Study PDF
Case Study Details
Luxury portable toilet trailers are mobile restroom facilities used for large outdoor occasions, such as music festivals and sporting events. They include flushing toilets, urinals, sinks with running water, mirrors and lighting, offering a much more comfortable experience than standard portable toilets.
Toilet trailers require no connection to permanent plumbing. Instead, the wastewater they produce is stored in holding tanks between the floor of the restroom and the undercarriage of the trailer. When the event has finished, the tanks are drained and the wastewater taken to a treatment site before the trailer is moved onto its next destination.
Constructing a portable toilet trailer is expensive, and so when one of the United Kingdom’s leading suppliers discovered holes starting to appear in the wastewater holding tanks of two of their units, they contacted Sylmasta for advice on whether a repair was feasible.
Damage to the underneath of the first portable toilet trailerThe second trailer was suffering from more extensive corrosion and surface damage
The plumbing, fixtures and fittings in each of the trailers were otherwise in perfect working order. The company therefore wanted to avoid decommissioning the two trailers if the holes in the wastewater tanks could be plugged and the weakened metalwork strengthened against future damage.
Sylmasta recommended a two-stage repair, starting with Sylmasta AB Original Epoxy Putty and finished with Liquid Metal Epoxy Coating. The first trailer was jacked up, enabling access underneath the wastewater holding tank. The metalwork was then ground down to remove rust, dirt and grime.
AB Original Black was supplied in stick format for the plugging of the holes. An AB Original Stick combines the resin and hardener pre-measured rather than in a tub of Part A and a tub of Part B, eliminating the need for weighing out and mixing separate components. This makes a repair quicker and easier.
A significant number of holes underneath trailer one sealed with AB Original Black Epoxy Putty.Holes underneath trailer two sealed with AB Original Black
The required amount of putty to fill a hole was cut from the stick and kneaded by hand. Once the putty had turned a uniform black colour but was still soft, it was pushed into the hole. After two hours, AB Original cured to form a rock-hard sealing material. Every hole in the tank was permanently filled in this way.
Once all the holes had been attended to, the entire bottom of the trailer – an area 1.3 metres by 2.5 metres – was painted with Liquid Metal Epoxy Coating. Also painted were the metallic box and pipe fitted to the bottom of the holding tank, through which wastewater was removed. Two coatings of Liquid Metal were brush applied, curing to form a smooth, metallic, hard-wearing surface.
This new surface repaired and strengthened the weakened metalwork to increase structural integrity. It acted as a protective shield against further external corrosion and encased the wastewater tank in a new outer shell, capable of containing the wastewater if the original metalwork became fully breached in future.
Trailer one coated with Liquid Metal to complete the repairTrailer two having been reinforced and refurbished with Liquid Metal
After the repair of the first toilet trailer was completed, the second was jacked up and fixed by following the exact same process. Each trailer could go back into service 24 hours after the second coating of Liquid Metal had been applied.
In total, 10kg of AB Original and 10kg of Liquid Metal were used to repair the two portable toilet trailers at a cost of under £800, representing a huge saving on replacing the units. The company are now planning to use the repair method on other units when they become weakened by corrosion, potentially extending the lifespan of their entire fleet by up to 10 years.
If you have an application you would like to enquire about, then please get in touch
Water fountain repair cracked – putting the pieces of a favourite garden ornament back together
A tiered composite stone water fountain in a Welsh garden undergoes a DIY repair after winter temperatures caused water left inside the upper bowl of the ornament to freeze, cracking it into multiple pieces.
Case Study Data
Site Garden Location Wales Repair Type High-strength bonding and stone repair Defect Composite stone water fountain cracked into multiple pieces
The water fountain consisted of two tiers and was made from composite stone. When winter temperatures in Wales plummeted below -10°C, the upper bowl cracked into several pieces due to water inside it freezing.
When Spring arrived, the owner of the water fountain decided to try and repair and restore their favourite ornament. Not only did the upper bowl need to be bonded back together, but there were numerous other cracks and missing sections requiring attention.
Crack lines show the significant damage across the entire upper bowl of the fountain
Sylmasta advised that Rapid 5 Minute Epoxy Adhesive be used first to reassemble the fountain. Rapid 5 Minute creates high-strength, permanent bonds between many materials, including composite stone.
The five-minute cure meanwhile is long enough for parts to be carefully assembled and rearranged if necessary before the adhesive sets, at the same time as requiring minimal holding or clamping.
Rapid 5 Minute comes with the two components that make up an epoxy adhesive – resin and hardener – kept separate. The 25ml cartridge extrudes the parts in equal measures, after which they are mixed together for around 30 seconds with a spatula.
The fountain owner extruded the epoxy onto a piece of cardboard for mixing. The mixed adhesive was then applied using the spatula to one of the surfaces to be bonded, and the pieces pushed together and held in place.
The two largest pieces of upper bowl after the cracks caused it to completely come apart
Any overspill of epoxy was thoroughly cleaned off the stonework. Rapid 5 Minute exposed to sunlight can yellow with age, which would have looked unsightly against the pale coloured fountain.
After five minutes, the stonework no longer needed to be held together as Rapid 5 Minute had begun to set. The fountain was left undisturbed for a further 30 minutes, allowing the epoxy adhesive to reach maximum properties.
Once the upper bowl had been reassembled, any remaining cracks and missing sections were filled in using Sylmasta AB Original Epoxy Putty. AB Original is a hard wearing, waterproof, ceramic-filled putty which bonds to all materials.
It offers a two-hour work time, enabling the putty to be mixed, moulded into shape and applied without any worry about premature curing. It is suitable for use in interior or exterior settings and achieves a full cure in 24 hours.
Cracks and missing chunks were filled with AB Original, which can just about be identified as the off-white colour down the centre of the stonework
The putty was kneaded by hand until a uniform colour. It was then shaped and formed to replace missing areas of stonework and pushed into cracks. For shallow cracks, the surface of the curing putty was wetted whilst still pliable to create a type of slurry which could be worked further in.
To help disguise larger sections of AB Original, powdered dust from the stonework was pressed into the putty. This took it from its standard off-white towards and towards the colour of the fountain, helping the repaired areas blend in.
Once the repair was completed, the water fountain retuned to full working order
The fountain owner even discovered that painting yoghurt onto the fountain helped further disguise the repair by encouraging lichen and moss to grow. The distressed touch this added was in keeping with the original stone.
Once the repair and restoration had been completed, the end result was a robust and fully watertight upper bowl. The fountain could go back into use for the summer with any visitors to the garden none the wiser that just a few months earlier, it had been cracked into multiple pieces.
If you have an application you would like to enquire about, then please get in touch
Soil pipe sealing – Wrap & Seal forms a rubber ring to repair a porcelain toilet
A homeowner carries out a DIY pipe repair to a porcelain soil pipe which developed a hairline crack around its entire diameter after an unstable bathroom floor caused the toilet to shift away from the wall it was connected to.
Case Study Data
Site Bathroom Location United Kingdom Repair Type Leak repair Defect Hairline crack in porcelain soil pipe
Products Used
Wrap & Seal Pipe Burst Tape Self-amalgamating silicone repair tape which formed a watertight rubber ring to encompass and seal the pipe
Case Study PDF
Case Study Details
The porcelain soil pipe connected the bowl of the toilet with the sewer pipe behind. The increasingly unstable bathroom floor meant that whenever anyone sat on the toilet, it tilted forward and pulled the pipe away from its fixed connection to the back wall.
Eventually, the stress being put on the pipe by the frequent movement of the toilet caused a hairline crack to appear around the entire diameter, through which water dripped whenever the toilet was flushed. This had the potential to make the floor even more unstable.
The crack caused by movement of the toilet pulling the porcelain soil pipe away from its connection to the bathroom wall
The homeowner was planning a full bathroom renovation to address the floor issue, which would include replacing the toilet. They therefore wanted a quick, easy and cost-effective DIY method to repair the porcelain soil pipe until sad renovation took place.
There were several challenges with the repair. The crack was too thin to force epoxy putty into and was located on a bend in a difficult position, close to the back wall and with minimal space between the pipe and floor.
The continued movement of the toilet also had to be taken into account. Any repair needed to offer a degree of flexibility, as rigidly fixing the pipe back in place would leave the potential for cracks to develop elsewhere.
Sylmasta recommended encompassing as much of the pipe as possible with Wrap & Seal Pipe Burst Tape to create a watertight rubber ring bonded to the porcelain. This would seal the leak, allow the pipe an element of movement to reduce stress, and prevent water escaping from any other cracks which developed elsewhere in the porcelain.
Wrap & Seal Pipe Burst Tape created a rubber ring around the entire leak area, sealing the crack
Wrap & Seal is made from self-amalgamating silicone which fuses to itself to form a solid rubber band as it is wrapped around a pipe. One 50mm x 4m tape was enough to cover the leak and the surrounding area susceptible to future cracks.
Despite the space constraints between the back wall, the floor and the toilet bowl, the homeowner was able to stretch the tape to three times its length whist wrapping, creating maximum tension.
The tape easily fused, fully sealing the leak and preventing any more water escaping when the toilet was flushed. Completing the porcelain soil pipe repair took less than 15 minutes and cost under £30, including delivery of the Wrap & Seal Pipe Burst Tape.
If you have an application you would like to enquire about, then please get in touch
Combined Liquid Metal and SylWrap HD repair combined heat and power system natural gas pipe
An industrial plant repair and refurbish a three metre section of steel pipe carrying natural gas in a combined heat and power system after water trapped between the line and an incorrectly installed PVC tape caused heavy corrosion.
Case Study Data
Site Industrial Plant Location Puerto Rico Repair Type Pipe refurbishment Defect Three metre section of corroded 100mm steel pipe in CHP system
Products Used
Liquid Metal Epoxy Coating Brush applied coating which cures to form an ultra-smooth, hard wearing, metallic surface over pipes and structures
SylWrap HD Pipe Repair Bandage Composite repair wrap with a water activated resin which sets rock hard to encompass pipes with an impact resistant outer sleeve
The pipeline was 100mm in diameter and ran for 365 metres through the plant, carrying natural gas produced by a combined heat and power system. It was hung on a series of U-shaped supports welded to I-beams suspended from the roof of the building.
When originally installed, the pipe had been wrapped with a protective PVC tape. Unfortunately, incorrect application of the tape had left a three metre section where it was possible for water and condensation to become trapped between the tape and the line.
Removal of the yellow PVC tape revealed very heavy corrosion to the steel pipe
This had led to heavy corrosion, which was particularly prevalent at the bottom of the pipe and the area where the section in question rested on its U-shaped support. The weakened three metres of the natural gas pipe now required strengthening and repair before the steel became breached.
Th pipe was cleaned of paint and grime before repair of the corroded surface
The plant decided to use the Sylmasta Pipe Refurbishment System to bring the damaged section of the line back up to specification, by reinforcing the metalwork and giving the pipe greater protection against future corrosion.
First, the U-Shaped support was cut away from the I-beam to enable better access to the corroded area. The PVC tape was removed and rust, grime and paint ground off. Alcoholic cloths were then used to remove any remaining residue from the grinding process.
Liquid Metal was brush applied across the three metres of the pipe suffering from corrosion
To repair the damage and restore the pipe exterior, the three metre section was coated in Liquid Metal Epoxy Coating. Liquid Metal is brush applied and cures to form a smooth, metallic, hard-wearing outer surface which acts as a shield against external corrosion and chemical attack.
The 90 minute gel time of Liquid Metal allowed significant amounts of epoxy to be mixed and painted on without the threat of premature curing. A SylWrap HD Pipe Repair Bandage was then wrapped around the area of the line which had contact with the U-shaped support.
SylWrap HD was wrapped around the area of the pipe which came into contact with the U-shaped support, which was to be welded back in place to the I-beam above
SylWrap HD is a composite repair wrap with a water-activated resin. It was applied whilst the Liquid Metal remained tacky and cured within minutes to form a rock-hard, impact resistant outer shell around the pipe. This further increased the thickness of the weakened section and provided an additional layer of protection.
A second layer of Liquid Metal was applied across the three metre section, including over the SylWrap HD. Although an additional coating on top of the composite bandage is not a required step of the Sylmasta Pipe Refurbishment System, the plant wanted to make the line look aesthetically pleasing with a final metallic finish.
A second Liquid Metal coating was applied over the SylWrap, the U-support welded back in place and the pipe fixed to it via a support clamp
Once the pipe had been refurbished, the removed U-shaped support was welded back to the I-beam. The line was then fixed to the U-shape via a new pipe support clamp fitted to prevent movement caused by vibration. The clamp was also coated in Liquid Metal.
Refurbishing the pipe was carried out with no impact to operations at the plant. It prevented an expensive and disruptive future repair or replacement being needed when corrosion eventually ate through the line.
The ultra smooth finish provided by Liquid Metal compared to the pitting caused by corrosion
The plant were very happy with the outcome and how easy their maintenance team found the application. They are now intending to use Liquid Metal to extend the lifespan of other pipes and structures at both this facility and across other sites.
If you have an application you would like to enquire about, then please get in touch
Saddle up for a complex repair – sealing a leaking welded saddle joint with a 20mm step using Wrap & Seal Pipe Burst Tape
A 150mm steel pipe connected to a pumping house in Malaysia which was leaking from both ends of a welded saddle joint is sealed in a successful repair built up and over a 20mm step between the line and the joint.
Case Study Data
Site Pumping house Location Malaysia Repair Type Live leak repair Defect Leaking saddle joint on a 150mm steel pipe with a 20mm step
Products Used
Wrap & Seal Pipe Burst Tape Self-amalgamating silicone repair tape which sealed up and over the leaking saddle joint weld
The 150mm steel pipe ran water out of the pumping house. The saddle joint had been welded in place to reinforce a capped tee and sat approximately 20mm higher than the original line. One end of the joint was suffering from heavy corrosion.
Water had been found seeping from both ends of the joint, leaving the pipe surface noticeably wet and the ground beneath the pipe sodden. The pipe could not be isolated or replaced because this would involve shutting down the pumping station.
Several repair attempts had failed, including a clampOne end of the saddle joint was suffering from heavy corrosion whilst water was seeping from both
Several repair attempts had been made using different methods by the water company operating the facility, including the use of a clamp and epoxy putty, but none had been successful. The pipe had therefore been left to leak.
Whilst on a visit to Malaysia, a technician from Sylmasta was asked to accompany a engineering team to inspect the pipe and see if a solution could be formulated. They recommended using Wrap & Seal Pipe Burst Tape to start a repair on the original steel pipe and build it up and over the weld, encompassing and sealing either end of the saddle joint.
The pipe was cleaned and prepared before repair
First, an angle grinder was used to sand down the pipe, clean it of loose material and remove corrosion. A first Wrap & Seal Tape was then applied directly next to the step. Wrap & Seal is made from self-amalgamating silicone and stretches by three times its length, fusing together to form a solid rubber band.
Wrap & Seal application started on the pipe next to the saddle, was built up until level with the step and then continued across onto the joint
With each rotation, the Tape moved closer to being level with the top of the saddle joint. The application continued until enough Wrap & Seal had been applied to bridge the 20mm step between the pipe and the saddle.
Once this had been achieved, Wrap & Seal was applied 50mm across the saddle to achieve a good connection. It was then returned to directly over the edge of the joint.
Once Tape had been built up and over the saddle, wrapping continued immediately over the leak area The finished repair with both ends of the saddle joint sealed
Here, a ridge was created directly over the leak area to increase the pressure resistance of the repair. It was estimated that three Wrap & Seal Tapes needed to be used to seal one end, after which the process was repeated at the other end of the saddle joint.
Because the welded saddle joint had been seeping water slowly, the only way to check whether the application had been effective was to inspect several days later. When the pipe surface was found to be dry, the repair was deemed a success.
If you have an application you would like to enquire about, then please get in touch
Replacement? Hold your horses – the repair of a burst copper pipe which had a horse shower running again in no time
When freezing winter weather led a copper pipe in a portable horse and dog shower to burst, it required a quick and simple repair method capable of being effective inside the cramped space of the unit.
Case Study Data
Site Portable horse and dog shower Location United Kingdom Repair Type Leak repair Defect Split in copper pipe caused by freezing temperatures
Showerking are a Sussex-based supplier of portable hot shower units designed for horses and dogs. Units are typically stored in unheated outbuildings. Although designed to handle winter weather, copper pipe in the unit which has not been fully drained becomes prone to bursting during periods of exceptionally cold weather.
When temperatures in the United Kingdom dropped as low as -15°C, several Showerking owners reported burst pipes which rendered their units unusable. If they turned the shower on, water would spray out of the large crack created in the copper pipe.
Freezing temperatures had created a split in the copper pipe
Fortunately, Showerking had already contacted Sylmasta about the possibilities of pipe repair for horse showers. The SylWrap Standard Pipe Repair Kit provided the most suitable method as units would be turned off in the event of leaks or bursts, meaning no pressure to the pipe.
It had been established that the smallest Standard Pipe Repair Kit (SYL-106-NP) was ideal for application because of both the cramped space inside the unit and the difficult shape of the pipework. There were many bends which were unrepairable with a clamp.
Through the relationship between Showerking and Sylmasta, users whose horse showers had suffered burst pipes were directed to the exact product they needed to fix the problem, and had the straightforward repair process explained to them.
Superfast Copper Epoxy Putty was used to cover the split
Loose material was removed from the burst copper pipe before repair. Superfast Copper Epoxy Putty Stick was then used to seal the crack. Enough putty to cover the crack was cut from the stick and kneaded by hand until it turned a uniform colour.
Whilst soft, the putty was pushed onto the pipe, encompassing the entire crack. This completed the first stage of the repair. The second stage involved applying a SylWrap HD Pipe Repair Bandage over the Superfast Copper.
The repair was finished with reinforcement via a SylWrap HD Pipe Repair Bandage
SylWrap HD is a composite repair wrap with a water-activated resin which sets rock hard. The bandage was wrapped and smoothed around the pipe as the Superfast Copper began to harden, forcing the putty into the crack to create a permanent, watertight seal.
Within five minutes of SylWrap HD being applied, the bandage had cured to form a rock hard shell reinforcing the pipe, and which also offered protection from expansion in the future. The completed repair was resistant to 30bar, making it more than capable of holding the pressure the horse shower unit operated at.
The repair took less than 30 minutes from start to finish and the SYL-106-NP Standard Pipe Repair Kit cost under £25 including delivery, returning the £180 Showerking unit to service the same day.
For more information about portable horse and dog showers, please see the Showerking website.
If you have an application you would like to enquire about, then please get in touch
Cookies are used to ensure you are given the best experience on our website. By continuing to browse the site you are agreeing to our use of cookies.OkPrivacy policy