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
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
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
Preventing a chromic acid attack – SylWrap HD seals welded corners in a corroded tank repair
After new corners were welded in place during the repair and reinforcement of a badly corroded chromic acid tank at a factory in Argentina, SylWrap HD provided sealing security against any leaks in the welding.
Case Study Data
Site Chroming factory Location Argentina Repair Type Tank repair Defect Reinforcement and sealing of corroded tank corners
Products Used
SylWrap HD Pipe Repair Bandage Composite wrap used to encompass parts and structures which sets rock-hard for ultimate protection
The iron tank was at a chroming factory in Argentina. It held chromic acid and was used during the re-chroming process of piston parts for oil extraction pumps. It was 10 metres long, 1.5 deep and 1.5 metres wide.
After a long time in service, the tank was suffering from corrosion. The damage was particularly heavy in the corners. The factory decided to repair the chromic acid tank, which involved installing welded reinforcements to each inside corner.
Not wanting to risk the possibility of there being leaks in the welding which could cause a future escape of chromic acid, the factory used SylWrap HD Pipe Repair Bandage to provide additional sealing security to the corners of the tank.
New metal corners were welded to reinforce the corners of the tank. These were then covered in SylWrap HD
The normal method of application for SylWrap HD is to activate the resin, then wrap around the pipe or structure requiring repair whilst the bandage cures to form a rock hard material.
Wrapping was obviously not possible to the inside of the tank. Instead, the factory unwound their SylWrap HD and cut it into patches, making sure not to contaminate the bandage with dirt or grime.
These patches of SylWrap HD were then activated and smoothed as tightly as possible up the entire 1.5 metre length of the welded reinforcement, creating a watertight seal between the weld and the existing frame of the tank.
Complete repair with patches of SylWrap HD encompassing the welded corner, sealing any potential holes or cracks
SylWrap HD was applied to all four corners of the tank in this way. Within 10 minutes of application, it had completely set to encompass each welded corner and cover any gaps or holes which may have otherwise been left exposed.
The final stage of the tank repair saw an acid-resistant PVC covering added. Whilst SylWrap HD offers good resistance against chemicals including sulphuric acid (which is a stronger concentration than chromic acid), this additional step was taken with the aim of further protecting the entire tank from future corrosion and attack.
If you have an application you would like to enquire about, then please get in touch
Limiting leachate from landfill – a pipe stub undergoes encapsulation to further reinforce it after capping
A landfill site in Wales encapsulates a pipe stub and flange plate after capping to protect it against corrosion and a potential future failure, ensuring a decommissioned drainage system could not release toxic leachate into the environment.
Case Study Data
Site Landfill site Location South Wales Repair Type Encapsulation of pipe stub Defect Reinforcement of stub and flange plate after pipe capping
Products Used
Liquid Metal Epoxy Coating Brushable epoxy coated onto pipes and structures to create a metallic surface which protects the original metalwork from corrosion
SylWrap HD Pipe Repair Bandage Composite repair wrap with a water activated resin which sets in minutes to form a rock hard protective shell
A series of underground drainage pumps were found to not be working at the landfill site in South Wales. Drainage is vital on landfill as it is important that rainwater does not flood, gather or pool on the site unchecked to mix with other fluids, which will often be toxic.
Rainwater that does mix with landfill to dissolve environmentally harmful substances is known as leachate. Leachate must be collected and managed properly. If it is allowed to escape into soil, groundwater or surface water, it can have an acute and chronic impact on the environment, causing serious pollution.
Rather than carrying out a complicated and expensive repair of the pumps, it was decided to decommission and replace them with an entirely new drainage system. The old system needed all pipes to be capped off at the start of the network as part of the decommissioning process.
To further reinforce after capping, the landfill site wanted to protect and encapsulate the main pipe stub and its flange plate. This would save it from corrosion and a possible failure in the future, which could lead to the release of leachate.
Despite the pipe stub’s location in a difficult to access area, Liquid Metal was successfully applied
The stub was protruding around 300mm from a concrete wall, located towards the bottom of a chamber. There was very little space to manoeuvre within the chamber and various metal structures above the stub made access more difficult still. The flange plate itself had seven bolts and a tap which needed to be tightly sealed around.
Arch Services were appointed by the site to find a solution. Arch are a Sylmasta approved contractor for major projects and after consultation with Sylmasta technicians, a method for reinforcing the pipe stub after capping was formulated.
Liquid Metal created a new corrosion resistant shield for the flange plate and stub
Liquid Metal Epoxy Coating was first used to protect the pipe stub and flange plate. Liquid Metal is a brushable epoxy which cures to form a new metallic surface when painted over pipework and other structures. It offers excellent protection against corrosion and chemicals by acting as an external shield.
Several coatings of Liquid Metal were painted all over the pipe stub and flange plate. Whilst the final coating had gelled but remained a little tacky, the stub was then encapsulated with SylWrap HD Pipe Repair Bandage.
The entire stub was encapsulated with SylWrap HD Pipe Repair Bandage to complete the repair
A SYL633HD bandage was used. The resin was activated with water and the bandage wrapped around the stub and smothered over the plate. More water was applied to smooth the wrap, which cured to form a rock-hard, impact resistant covering of the stub.
Arch said after the successful completion of the application: “Given the protruding bolts and cramped application position, this was not a ‘pretty’ repair. But it absolutely did the job!” The site now had full confidence that the capped pipe would not fail in future.
If you have an application you would like to enquire about, then please get in touch
Rebuild after rust – a heavily corroded steel pipe undergoes repair and reinforcement before the line was breached
An industrial site in Saudi Arabia use two stages of the Sylmasta Pipe Refurbishment System to reinforce a 2 metre long section of heavily corroded steel pipe before the line was breached and required a complex leak repair.
Case Study Data
Site Industrial site Location Saudi Arabia Repair Type Pipeline reinforcement and protection Defect Heavy corrosion to a 600mm patch causing a serious weakening of the line
Products Used
Sylmasta AB Original Epoxy Putty Two part epoxy putty offering excellent protection against corrosion and chemical attack used to rebuild the weakened area
SylWrap CR Pipe Repair Bandage Composite repair wrap specially formulated to prevent corrosion and strengthen pipes in aggressive environments
The steel pipe was suffering from a 600mm patch of very heavy corrosion to its external surface. It was only a matter of time until the pipe was breached, at which point the site would have been forced to shut off the line whilst either the leak was sealed or a new section was installed.
To avoid this, it was decided to rebuild and strengthen the line before corrosion could eat all the way through the metalwork. The first stage of repair involved rebuilding the area weakened by corrosion, bringing it back up to full specification.
Heavy corrosion to the pipe looked like to breach the line in the near future
Because the corrosion was impacting only a relatively small area of pipe, it was decided to use Sylmasta AB Original Epoxy Putty to fill in the damage and restore the integrity of the line. Had the damage been on a much larger scale, an epoxy paste like Industrial Metal would have been applied using a hand tool.
Sylmasta AB is a super strength putty filled with ceramic to make it harder wearing. A two hour work time means it is more suitable for warmer climates like Saudi Arabia, where the cure is often accelerated by the natural temperature.
AB Original offers excellent protection against corrosion and chemical attack. In chemically aggressive environments, it can be used as a sacrificial layer to protect pipes and metalwork.
Sylmasta AB was applied across the entire corroded section, restoring the integrity of the line
The two parts of the putty were mixed by hand in equal measures. It was then pushed down onto the pipe, where it cured to strengthen the heavily corroded areas by increasing the thickness of the pipe back towards its original specification.
Once the putty had cured, SylWrap CR Corrosion Protection Wrap was applied over the top to further protect the repair. SylWrap CR is a black-coloured composite repair bandage incorporated with highly effective corrosion inhibitors.
It has been specially formulated to protect pipes, metalwork and other structures in harsh and aggressive environments against corrosion. SylWrap CR was activated with water and then wrapped and smoothed along a 2 metre section of the pipeline.
The pipe was reinforced with SylWrap CR to complete the repair
Within minutes, it began to cure rock hard. Once set, SylWrap CR formed an impact resistant shell around the pipe to further strengthen it from future attack and remove the prospect of a breach in the line.
Completing the repair from the first kneading of Sylmasta AB to the finished application of SylWrap CR took half a day. The line remained in operation throughout, meaning there was no disruption to the site and the reinforcement cost a fraction of a future leak repair or replacement of an entire section of the line.
The site were therefore very pleased that they opted for strengthening the steel pipe before their corrosion problem could develop into a much bigger issue.
If you have an application you would like to enquire about, then please get in touch
Troubled bridge over water – the repair and refurbishment of a dilapidated steel pipe bridge crossing the Rhonda River
Sylmasta and Arch Services repair and refurbish a dilapidated 20-metre long pipe bridge crossing the Rhonda River in Porth, South Wales, helping to save Dwr Cymru Welsh Water from an expensive replacement of the heavily corroded structure.
Case Study Data
Site Pipe bridge Location Porth, South Wales Repair Type 300mm steel pipe bridge repair Defect Significant cracking and weakening of line caused by corrosion
Products Used
Liquid Metal Epoxy Coating Brush applied to coat pipes and structures with an ultra-smooth, hard wearing, metallic surface
SylWrap CR Pipe Repair Bandage Composite repair wrap specially formulated to prevent corrosion and strengthen pipes in aggressive environments
Sylmasta were contacted by Dwr Cymru Welsh Water for advice on repairing and extending the lifespan of a dilapidated pipe bridge crossing the Rhonda River in Porth, South Wales. The bridge was gravity fed and made up of a 300mm diameter, 20 metre long steel pipe rested inside an angle-iron structure for support and protection.
For such a complex project, it was recommended that the four-stage Sylmasta Pipe Refurbishment System be used as a starting point. A final decision on the repair elements required would be decided once the pipe had been fully inspected.
Dwr Cymru official contractors appointed Arch Services of Porth to carry out the work, and it was agreed that Sylmasta would keep in close communication throughout the project to deal with any questions that might arise.
The steel pipe was covered in corrosion, which had eaten through in places
On inspection, the pipe was discovered to be totally covered in corrosion. This had eaten completely through the steel in several places along the top of the pipe, leaving large holes in the brittle surface.
As these holes were too large or delicate to be repaired with epoxy putty, Arch decided to use fibreglass patches layered over the cracked sections of pipe to seal the leaks. The entire pipe was then coated with Liquid Metal Epoxy Coating.
Liquid Metal is a metal-filled, brushable epoxy. After being coated onto the pipe, it cured to form a smooth, metallic, hard-wearing surface. Several layers of Liquid Metal were used to create an impermeable skin around the original pipe, preventing any further corrosion to the steel and ensuring fluids could no longer escape.
Liquid Metal created an ultra-smooth, hard-wearing metallic surface around the pipe
The 90 minute gel time of Liquid Metal allowed significant amounts of epoxy to be mixed without the threat of premature curing. Arch Services used a roller to apply each coating to a 1mm – 2mm thickness, also painting with Liquid Metal the corroded steel hoops and beams which held the pipe in place.
To further reinforce the pipe and reinstate its integral strength, it was wrapped with four layers of SylWrap CR Corrosion Protection Wrap. SylWrap CR is a composite repair bandage incorporated with highly effective corrosion inhibitors.
SylWrap CR was carefully applied along the length of the pipe, further reinforcing the repair
It has been specially formulated for the prevention of corrosion and the protection and strengthening of pipes, metalwork, and other structures in harsh and aggressive environments.
SylWrap CR was applied to the pipe whilst the final coating of Liquid Metal remained tacky. The resin in SylWrap CR was activated with water and the bandage tightly wrapped and smoothed around the pipe.
The completed repair along the 20 metre length of the pipe
Within minutes, SylWrap CR cured to form a rock-hard, impact resistant shell around the pipe. Arch Services were particularly careful in ensuring that no area of the pipe was left without SylWrap CR. This required precision application close to the steel hoops.
The final result was a very smart pipe bridge now well protected from future corrosion and reinforced against breaches by Liquid Metal and SylWrap CR. Arch Services have subsequently become Sylmasta’s approved contractor for similar projects after their excellent documentation of the process and attention to detail.
If you have an application you would like to enquire about, then please get in touch
Pump it up – the repair which allowed a water treatment plant to keep pumping water from their below ground well
Sylmasta provide a long-term repair solution for a water treatment plant in Puerto Rico, whose pump extracting from a below ground well had become heavily worn due to minerals and sediment in the water.
Case Study Data
Site Water treatment plant Location Puerto Rico Repair Type Damage repair Defect Heavily worn pump extracting water from a well
Products Used
Ceramic Brushable Green Brushable epoxy coating used to refurbish and repair the worn pump, restore it to original thickness
The large water pump was used by the water treatment plant to extract water from a well. The water was then distributed around the entire site for various purposes, making the pump central to operations.
This natural groundwater contained minerals, sediments and impurities which caused deterioration to the pump. Over time, the pump became so worn and degraded that there was a substantial risk of bursting.
A burst would have been a disaster for the plant. Operations would have needed to be shut down and a replacement pump fitted. This would have been a costly and time-consuming exercise, potentially involving the fabrication of a new pump and its shipping to Puerto Rico.
Before the water well pump reached the stage whereby it needed to be replaced, the treatment plant decided to repair and reinforce the system using a hard-wearing, abrasion resistant coating.
Ceramic Brushable Green Epoxy Coating was used for the application. Ceramic Brushable is reinforced with silicone carbide, giving it a toughened, ultra-smooth finish.
It is painted onto surfaces which have suffered heavy damage or been weakened by corrosion and abrasion, restoring their strength and protecting the original part from further damage.
The well pump repaired and strengthened with Ceramic Brushable Green
The two parts of the epoxy coating were mixed in the prescribed ratios and then brushed onto the pump. The 90 minute gel time of Ceramic Brushable enabled more epoxy to be mixed and applied without the threat of premature curing.
Four coatings were used, each between 1mm and 2mm thick. This built up a substantial, reinforced shell around the worn pump to restore the weakened metalwork to its original thickness.
With a recoat time of around four hours, it took two days to complete the repair. The application took place over night whilst the site was shut down to limit disruption and the cost was insignificant compared to fitting a new pump.
The treatment plant now monitor the pump on a regular basis for future wear caused by corrosion and erosion. When there are concerns that it is becoming too weak, further coatings of Ceramic Brushable are added to restore integrity.
Speaking about the process, the maintenance manager at the plant said: “The pump deteriorates very soon but coating it in Ceramic Brushable helps a lot.” In this way, Sylmasta have provided a cost-effective and long-term solution.
If you have an application you would like to enquire about, then please get in touch
How to fix rust holes on a classic car in a repair time (nearly) as quick as a lap of Silverstone
When rust holes developed on a classic car, the owner turned to Superfast Steel Epoxy Putty as a cost-effective, quick and easy way to permanently fix the problem.
Case Study Data
Repair Type Metal filler repair Defect Rust holes in classic car
The classic car had developed a rust hole. Corrosion had eaten away at a section of the inside car door where the window mechanism was anchored, causing it to fail.
As a DIY enthusiast, the car owner wanted to find a quick, cost-effective and easy method to permanently fix the rust hole. The owner required a lightweight, metal filler material which would offer resistance to water, temperature extremes and future corrosion.
Heavy corrosion had caused significant rusting to the inside door of the car
They decided to use Superfast Steel Epoxy Putty Stick for the application. Superfast Steel sets in under 10 minutes and makes permanent repairs to damage in steel, iron and other ferrous metals.
Before the repair began, the metalwork was cleaned and prepared as best as it could be. Dirt, grime, and rust were removed. Moisture repellant spray was used to drive moisture and grease out from the crack and leave a fine lubricating film to protect against corrosion.
The area was cleaned prior to repair
Once preparation was completed, the required amount of Superfast Steel Epoxy Putty was cut from the 114g stick and kneaded by hand. Whilst soft, the putty was pushed into the hole in the metalwork, where it was shaped and moulded around the screw.
Within 10 minutes, the putty had begun to harden into a material sharing the look and feel of steel. Maximum properties were reached after an hour, leaving the hole filled and the damage caused by corrosion repaired.
Superfast Steel filled the hole. Once fully cured, it was painted red to match the car
Once cured, the putty was filed and painted red to appear uniform with the rest of the metal frame. The total cost of the rust hole repair was less than £20, including delivery of the Superfast Steel Stick.
The Superfast and Sylmasta AB ranges of epoxy putties are used frequently across various sections of the motoring industry, including classic car repairs such as this one and in Formula One.
Lightweight yet robust repair materials which are straightforward to use and effective quickly provide the sort of speedy repairs required when it comes to fixing damage on cars.
If you have an application you would like to enquire about, then please get in touch
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