Category: Damage Repair

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Case Study: Power Station Repair Damage to Alloy 20 Pump Lid Caused by Impeller

Ceramic Brushable Green Epoxy Coating is used to repair a badly damaged Alloy 20 pump lid at a power station water treatment plant

Keeping a lid on the cost of repair for a power station treatment plant pump in Puerto Rico

A power station in Puerto Rico repair a treatment plant pump lid made from Alloy 20 which would have cost $4000 to replace after it suffered extensive damage when an impeller fell out of place.

Case Study Data

Site
Power station treatment plant
Location
Puerto Rico
Repair Type
Damage repair
Defect
Gouged and scratched Alloy 20 pump lid

Products Used

Ceramic Brushable Green
Brushable epoxy coating used to repair surface damage and offer greater protection of the Alloy 20 pump lid

Case Study PDF

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Case Study Data

The pump lid came from a mud pool at the power station treatment plant. It was 500mm in diameter and made from Alloy 20 (nickel-chromium-molybdenum stainless steel) for its high chemical and corrosion resistance.

Extensive damage had been caused when an impeller blade came out of place and fell directly onto the lid, leaving numerous scratches and several very deep gouges across the surface.

A replacement lid would have cost $4000 and required shipping to Puerto Rico, potentially leaving the pump out of service for a significant amount of time and causing disruption to operations.

The power station instead used Ceramic Brushable Green Epoxy Coating to repair the pump lid. Ceramic Brushable is reinforced with silicon carbide, giving it a toughened, ultra-smooth finish.

It is painted onto surfaces which have suffered heavy surface damage or been weakened by corrosion and abrasion, restoring their strength and protecting the original part from further deterioration.

A pump lid made from Alloy 20 undergoes repair at a power station treatment plant after being damaged by an impeller
The pump lid having been fully repaired by Ceramic Brushable Green Epoxy Coating

The lid was removed from the pump. Part A and Part B of Ceramic Brushable Green were mixed and then applied via brush. The first few coatings were used to repair the damage by filling in the gouges and scratches, found mostly in the centre of the lid.

This was followed by additional layers being added across the entire 500mm area, creating a new reinforced surface over the original Alloy 20 to offer protection to the lid.

Once the final coating of Ceramic Brushable Green had begun to harden, the lid was turned on a lathe to finish it. The two colour tones on the complete repair show where the lid is angled towards the edge.

After a full cure had been achieved, the lid was fitted back in place and the water treatment plant could return to full service. The power station were extremely pleased with the application as it prevented a costly replacement which would have resulted in downtime at the site.

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: Underwater Wall Between River & Trout Farm Crack Repair

A crack in an underwater wall between a river and a trout farm undergoes repair with Sylmasta AB Original Epoxy Putty

River repair runs smooth – a crack in an underwater wall between a river and a trout farm is permanently sealed

The Environment Agency repair an underwater wall discovered to be cracked when a system monitoring how much water was being taken from a Yorkshire river by a local trout farm began returning inaccurate readings.

Case Study Data

Site
Sluice between river and trout farm
Location
Yorkshire, United Kingdom
Repair Type
Crack repair
Defect
700mm long crack in underwater wall

Products Used

Sylmasta AB Original Epoxy Putty
Super-strength epoxy putty effective underwater used to permanently seal holes and cracks

Case Study PDF

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Case Study Details

Trout farms in North Yorkshire are allowed to draw a limited amount of water from local rivers and streams. Extraction is normally controlled by a sluice connecting a farm to a river, which also enables the Environment Agency to monitor water levels to ensure no more than the permitted amount is taken.

Anomalies with data from one farm alerted the Environment Agency to a potential issue, initially believed to be with the sluice or the monitoring equipment. An inspection revealed that the problem was actually a 700mm long crack in a wall next to the sluice. The crack widened into a sizable hole as it reached the riverbed.

The sluice controlling the extraction of water from the river to the trout farm

Water from the river was now escaping through the crack and into the trout farm, making readings of the flow through the sluice completely inaccurate. The wall needed to be sealed to prevent water loss and ensure that the true level of water being taken by the farm could be recorded.

Sylmasta AB Original Epoxy Putty provided the ideal solution. AB Original is a ceramic-filled, high strength epoxy putty which cures underwater. It comes with a two hour work time, meaning that significant amounts of putty could be mixed to fill the crack without the threat of premature curing.

A 700mm long crack in an underwater wall prior to undergoing repair with Sylmasta AB Original Epoxy Putty
Significant levels of water were escaping from the river through the crack in the wall, seen here both above and below the waterline

An engineer from the Environment Agency attended the site with a large quantity of AB Original. Part A and Part B were kneaded in dry conditions. Once the putty had turned a uniform white colour and whilst it still remained soft, it was pushed into the crack.

The application began above the waterline, proceeding below it and then right the way down to where the crack met the waterbed. High-strength adhesion was achieved between the putty and the wall. Once cured, AB Original formed a rock-hard material to permanently fill the crack.

Sylmasta AB Original Epoxy Putty used to repair a crack in an underwater wall located alongside a river
AB Original was pushed into crack, curing to permanently seal the gap in the wall

After the repair was completed, water levels were carefully monitored. A very small leak remained, identified as being at the crack’s widest point near the riverbed. During the initial repair, it had been impossible to tell if all underwater areas in the wall had been sealed.

Further AB Original was applied at the base of the wall on a return visit. This brought the amount of water being drawn by the farm from the river back to expected levels, indicating that the crack had been successfully repaired.

Given the challenging nature of underwater repairs, the Environment Agency were delighted to have discovered such a versatile material capable of being effective underwater. They have since begun using AB Original for other applications and projects.

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: Fence Spurs Suffering from Concrete Cancer Filler Repair Using Epoxy Putty

Fence spur badly damaged by concrete cancer undergoes filler repair using Sylmasta AB Original Epoxy Putty

On the fence – installing replacement trellis provides the spur for a homeowner to repair posts suffering from concrete cancer

A homeowner installing a replacement trellis fence uses Sylmasta AB Original Epoxy Putty to repair damage to the original fence posts caused by concrete cancer, rather than having to undertake the mammoth task of replacing every spur.

Case Study Data

Site
Domestic property
Location
United Kingdom
Repair Type
Concrete filler repair
Defect
Fence spurs badly damaged by concrete cancer

Products Used

Sylmasta AB Original Epoxy Putty
Hard-wearing epoxy putty which offers excellent corrosion protection and can be used as a permanent repair filler

Case Study PDF

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Case Study Details

Concrete cancer occurs where steel reinforcements inside of concrete begins to corrode. This causes the steel to expand and as a result, the surrounding concrete to fall away and disintegrate.

Having been in place for 30 years, the fence posts were already badly damaged. When disturbed during the replacement of the trellis, they shed several more large chunks of material.

Concrete cancer had caused a fence spur to disintegrate, requiring a filler repair made with Sylmasta AB Original Epoxy Putty
Concrete cancer had caused parts of the fence spur to disintegrate, leaving the inner steel exposed and susceptible to further damage

Replacing every spur would have been a mammoth task and so the homeowner instead sought a means to repair the existing posts. They needed a material which would act as a concrete filler to repair the damage whilst at the same time offering greater protection against corrosion to lessen the impact of concrete cancer in future.

Sylmasta recommended the use of Sylmasta AB Original Epoxy Putty for the application. AB Original is a hard wearing, ceramic-filled putty with high corrosion and chemical resistance. It is suitable for indoor and outdoor use and comes with a two-hour cure for complex repairs.

The longer work time was particularly important for this application. Over 10kg of epoxy putty was needed to repair every concrete spur. Large quantities of putty could be mixed in one go and applied to significant areas of damage without the threat of premature curing.

Sylmasta AB is available in three colours as standard – white, grey and black. Grey was chosen for this repair because of its resemblance to concrete. Part A and Part B were mixed in equal measures. Whilst soft, the putty was pushed into the spur, filling cracks and replacing chunks of concrete which had been destroyed.

Sylmasta AB Original Epoxy Putty used as a filler to repair damage to a concrete fence spur caused by concrete cancer
AB Original Grey was applied to repair all damage and fill the missing concrete

AB Original adhered easily to the existing concrete. Once cured, it formed a rock-hard material to permanently repair the damage caused by concrete cancer. Had the homeowner wanted the putty to blend in more with the existing spurs, then they could have pushed concrete dust into the soft Sylmasta AB before it fully hardened.

This technique is found in the Sylmasta Brick Repair Kit, containing AB Original and brick dust. It is used for the seamless repair of bricks, filling in defects caused during construction work or by processes such as lime blow.

The repair of every concrete fence spur was completed in the homeowner’s spare time over several weekends. They were very pleased with the result. AB Original successfully repaired the damage caused by concrete cancer and improved the appearance of the fence posts, without taking the considerable amount of time replacing every spur would have.

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

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

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Case Study: Reinforcement of Heavily Corroded Steel Pipe to Avoid Future Leak Repair

A heavily corroded pipe in Saudi Arabia undergoes repair and reinforcement using epoxy putty

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 section 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

Case Study PDF

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Case Study Details

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.

Heavily corroded section of pipe before undergoing repair using the Sylmasta Pipe Refurbishment System
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.

Heavily corroded section of steel pipe having undergone repair with Sylmasta AB Original Epoxy Putty
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

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

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Case Study: Permanent Mortar and Pestle Repair Made Using Epoxy Adhesive

Repair of a granite mortar and pestle set using Sylmasta Rapid 5 Minute Epoxy Adhesive

Mortar and pestle repair – Rapid 5 Minute Epoxy Adhesives saves the grind of buying a new set

A high-strength, permanent repair using Rapid 5 Minute Epoxy Adhesive to a granite pestle cracked into two parts saves its owner from the grind of having to find a new mortar and pestle set for their kitchen.

Case Study Data

Repair Type
High-strength bonding
Defect
Granite pestle cracked into two pieces

Products Used

Sylmasta Rapid 5 Minute Epoxy Adhesive
Epoxy adhesive with a 5 minute work time for high-strength bonding between all materials, including granite

Case Study PDF

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Case Study Details

The mortar and pestle set was made of granite. The pestle had been cracked in two parts when it was dropped onto a granite kitchen worktop, leaving a break close to the base of the tool.

As the owner was rather fond of the pestle, they wanted to repair it rather than buy a replacement. To do so, they needed to find an adhesive capable of permanently bonding the two parts together and withstanding the rigour the tool went through when grinding ingredients.

A cracked granite pestle part of a pestle and mortar set before undergoing repair with an epoxy adhesive
The pestle had snapped into two parts

With traditional superglue ruled out as not being strong enough, they instead turned to epoxy adhesives. Sometimes known as structural or engineering adhesives, epoxies are used when high-performance, super-strength and powerful bonds are required.

Sylmasta Rapid 5 Minute Epoxy Adhesive was chosen due to its fast cure time and versatility in working effectively on a multitude of materials, including granite. Rapid 5 Minute comes with the two components that make up an epoxy adhesive – resin and hardener – kept separate.

Sylmasta Rapid 5 Minute Epoxy Adhesive applied to a granite pestle as part of a pestle and mortart repair
The bottom section was supported in an upright position by a piece of rubber. Rapid 5 Minute was then coated onto the top section

Both parts were extruded onto a piece of cardboard and then mixed together with a spatula for around 30 seconds. Once an even mix had been achieved, the spatula was used to apply a layer of adhesive where the break was on the top part of the pestle.

The bottom section of the pestle meanwhile had been placed on a piece of rubber for support and to keep it upright. The top part was pushed firmly against the bottom section as soon as the adhesive had been applied. Excess epoxy squeezed out from between the joint was wiped away with a tissue.

The two parts were pushed firmly together to create a high-strength bond

Rapid 5 Minute sets in around 3 to 5 minutes at room temperature. The top of the pestle was pressed against the bottom for this period of time, after which the owner was able to stop holding it in place as bonding had begun to take effect.

The pestle was left undisturbed for a further 30 minutes, allowing the epoxy adhesive to reach maximum properties. A full cure was achieved within 24 hours, after which the pestle could be used again in the kitchen.

The completed repair with no sign of crack or visible glue lines

With Rapid 5 Minute setting relatively clear, there were no obvious glue lines or evidence of a crack. To the unaware, the pestle had never been broken. Several years after the repair and the mortar and pestle set is still working perfectly.

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: Water Treatment Plant in Puerto Rico Repair Worn Pump Extracting from a Well

Ceramic Brushable Green Epoxy Coating used to repair a worn water well pump at a treatment plant in Puerto Rico

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
Brushable epoxy coating used to refurbish and repair the worn pump, restore it to original thickness

Case Study PDF

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Case Study Details

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 silicon 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.

Ceramic Brushable Green Epoxy Coating used to repair a well water pump which had become extremely worn at a treatment plant in Puerto Rico
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 overnight whilst the site was shut down to limit disruption and the cost was insignificant compared to fitting a new pump.

The treatment plant now monitors 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

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

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Case Study: Ceramic Mill Wheel Worn Shaft Repair & Rebuild After Replacement Deemed Impossible

A ceramic factory mill wheel shaft badly worn by abrasion undergoes repair and rebuild using Titanium Supergrade Epoxy Paste

No need to grin and bear wear and tear – the worn shaft repair to avoid a whole new mill wheel being installed at ceramic factory

After being told that disassembling a mill wheel to replace a damaged shaft was too complex and that the only solution was therefore a new wheel, a ceramic company in Mexico instead sought to repair the worn part without taking the system apart.

Case Study Data

Site
Ceramic factory
Location
Mexico
Repair Type
Damaged part rebuild
Defect
Mill wheel shaft badly weakened by abrasion

Products Used

Titanium Supergrade Epoxy Paste
Epoxy paste with high compressive strength and extreme temperature resistance for repairing and rebuilding worn parts


Case Study Details

The 150mm shaft was part of a mill wheel at a production plant operated by a company specialising in ceramic, glass and concrete manufacturing. Such abrasive work had left the shaft suffering from extreme wear after years of service.

When the company consulted experts about replacing the shaft, they were told it was too complex. To remove the damaged part and fit a replacement, the entire wheel would have to be disassembled. The size and weight of the wheel meant that this was impossible.

The shaft on the mill wheel had been damaged by abrasion

Even if the wheel could be taken apart, there was a danger that once dismantled it may be reassembled incorrectly and fail to work. There was nobody with the technical knowledge to carry out such an application because it had never been tried before.

The company were therefore told that the only solution was to remove the existing wheel and fit an entirely new system. Given that the only fault was with the shaft and the rest of the wheel was in good working order, this seemed like an unnecessary waste of time and resources to the company.

A worn shaft attached to a ceramic factory mill wheel prior to undergoing repair using Titanium Supergrade Epoxy Paste
The shaft could not be replaced without disassembling the wheel

Instead, they sought a method of repairing the worn shaft without taking the system apart. Sylmasta recommended the use of Titanium Supergrade Epoxy Paste to rebuild the outside of the shaft, which had been worn away and damaged by abrasion.

Titanium Supergrade was chosen because of its high compressive strength. It also offers extreme temperature resistance up to 250°C. It is reinforced with corrosion-resistant metal platelets which give it a smooth finish.

The shaft underwent an extreme mechanical clean prior to repair

An extreme mechanical clean was carried out to the shaft prior to the repair. This removed rust, dirt, grime and other materials which had coated the part over its life.

As soon as the preparation was completed, Part A and Part B of the epoxy paste were mixed together. Titanium Supergrade has a work time of three hours, allowing for careful application without the threat of premature curing.

Titanium Supergrade Epoxy Paste was mixed and applied to the shaft

Once successfully mixed, the paste was applied around the entire shaft. A putty knife was used to first push it into imperfections on the shaft, filling all areas of damage.

After the damage had been repaired, further paste was applied to rebuild the shaft by several millimetres. When abrasion now occurred, it would be the new material formed by Titanium Supergrade wearing away, rather than the metalwork of the original shaft.

  • Damaged shaft worn down by abrasion in a ceramic mill after undergoing repair and rebuild with Titanium Supergrade Epoxy Paste
Completed repair with the shaft thickened and rebuilt

In this way, Titanium Supergrade offers a long-term solution. Further epoxy paste can be applied to rebuild the worn shaft again when the existing repair wears through, keeping the part operational for as long as the wheel remains in service.

A full cure was achieved in 24 hours, after which the system went back into operation. The repair helped the company save a huge amount of money compared to the suggested solution of replacing the entire mill wheel.

The company are now planning to use Titanium Supergrade to rebuild other worn machine parts across their production facilities instead of replacement wherever possible.

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: Rapid 5 Minute Epoxy Adhesive Used to Repair Broken Ceramic Teapot Lid

Repair of a broken teapot lid made of ceramic using Sylmasta Rapid Epoxy Adhesive

Tea for two – Rapid 5 Minute Epoxy Adhesive keeps a teapot brewing with the repair of a ceramic lid cracked into two pieces

A ceramic teapot lid cracked into two pieces when it was accidentally dropped on a hard floor undergoes a permanent repair using Sylmasta Rapid 5 Minute Epoxy.

Case Study Data

Repair Type
High-strength bonding
Defect
Ceramic teapot lid broken into two pieces

Products Used

Sylmasta Rapid 5 Minute Epoxy Adhesive
Epoxy adhesive with a 5 minute work time for high-strength, accurate bonding between materials

Case Study PDF

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Case Study Details

The ceramic teapot lid was broken when accidentally dropped onto a hard floor. Fortunately, it cracked into two pieces rather than shattering into many, meaning that it could be repaired relatively easily.

Sylmasta Rapid 5 Minute Epoxy Adhesive was chosen for the job of glueing the teapot lid back together. As an epoxy adhesive, Rapid 5 Minute offered much stronger bonding power than a traditional superglue.

The ceramic teapot lid had cracked into two pieces. Epoxy Adhesive was applied to the entire white break area on the smaller piece

Its longer working time also allowed for careful application of the adhesive along the complex shape of the break, and for the two pieces to then be fitted together more accurately. With superglue came the risk of an instant cure and misalignment, after which it would be too late to rectify the error.

Rapid 5 Minute is supplied with the two epoxy adhesive components – resin and hardener – stored separately. These were extruded onto a flat and stable surface which could be easily disposed of afterwards (an empty cereal box) and mixed together with a stirrer.

After 30 seconds, an even mix had been achieved. The epoxy was then spread using the stirrer over the entire break joint of the smaller piece of the teapot lid. Once the adhesive had been applied, the two parts of the lid were pressed together and carefully adjusted for a seamless fit.

A ceramic teapot lid having undergone repair using Sylmasta Rapid 5 Minute Epoxy Adhesive
Completed repair of the teapot lid

The two parts of the teapot lid continued to be pushed together for five minutes, the functional cure time of the epoxy. Once the adhesive had begun to bond, the lid no longer required pressure to keep the parts together.

It was left undisturbed for 30 minutes for the epoxy adhesive to achieve maximum properties. A full cure was achieved after one hour. The teapot could then be reunited with its lid following the successful repair.

The structurally strong bonds provided by Rapid 5 Minute will last for a very long time – providing nobody drops the teapot lid onto a hard floor to damage the ceramic again.

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: Dairy Delivery Truck 466 International Engine Cracked Timing Cover Repair

The repair of a crack in a 466 International engine timing cover made using Industrial Metal Epoxy Paste

The delivery truck timing cover repair which meant no crying over spilt milk for a dairy in Puerto Rico

Replacing a delivery truck’s 466 International engine timing cover after it developed a hairline crack was set to cost a milk company in Puerto Rico $1000 until Sylmasta formulated a faster, more cost-effective repair method.

Case Study Data

Repair Type
Timing cover repair
Defect
Crack in 466 International engine timing cover

Products Used

Industrial Metal Epoxy Paste
Epoxy paste used to fill the crack, permanently sealing it to prevent any further oil escaping

Case Study PDF

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Case Study Details

The delivery truck belonged to a milk company in Puerto Rico. Oil was discovered to be leaking from the timing cover of the vehicle’s 466 International engine. Once opened, a hairline crack was discovered in the casing.

A replacement cover would have cost $1000. Delivery of the part was estimated to take up to a week. The company needed the truck to be back in service as soon as possible and so they sought a faster, more cost-effective repair.

The opened timing cover during inspection
A crack developed in a 466 International Engine timing cover which then underwent repair with Industrial Metal Epoxy Paste
A hairline crack discovered in the centre of the metalwork

Sylmasta technicians were able to formulate a repair method for the timing cover, involving a degree of preparation followed by the use of Industrial Metal Epoxy Paste. Instructions were sent to the engineer, who had been asked to find a solution by the company.

Before the application of the paste began, Sylmasta recommended that the ends of the crack were drilled. This was to relieve stress concentration and prevent the crack from spreading further.

Repair instructions, showing the V-shaped grooves to be cut along the top and bottom of the crack and the overlap of epoxy paste

A coarse 3-square file was used to cut a V-shaped groove along the length of the crack, widening the gap in both the top of the metalwork and underneath. This increased the available surface area to which Industrial Metal could bond. The V-grooves were then degreased to remove contamination.

Part A and Part B of Industrial Metal were mixed in the instructed ratio. A spatula was used to force the paste into the crack, completely filling both V-grooves. The paste was also overlapped by 20mm either side of the crack to ensure full adhesion.

Crack in 466 International timing cover undergoes repair using Industrial Metal Epoxy Paste
The crack seamlessly filled in and repaired once Industrial Metal had cured

Industrial Metal has a work time of 60 minutes, allowing it to be carefully applied to the crack without the worry of premature curing. A full cure was achieved in 24 hours, after which the paste set to form a solid metallic material which seamlessly filled and repaired the crack.

One day after the application had been completed, the delivery truck was back on the road with the timing cover no longer leaking. The company were very pleased with the technical advice offered by Sylmasta, the speed and ease with which they had been able to complete the repair – and obviously, the cost saving.

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: Superfast Steel Epoxy Putty Used to Fix Rust Holes on a Classic Car

Superfast Steel Epoxy Putty used to fix rust holes in the metal frame of a steel car

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

Products Used

Superfast Steel Epoxy Putty Stick
Metal repair putty used to permanently fill rust holes and help prevent further corrosion

Case Study PDF

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Case Study Details

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 Epoxy Putty used as a metal filler in the fix of rust holes on a classic car
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

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