Category: Case Studies

Posted on by

Case Study: 19th Century Lantern Restoration Using Superfast Steel Epoxy Putty

A 19th century lantern restoration undertaken using Superfast Steel Epoxy Putty Stick

Relighting a 19th century lantern – the restoration of a Victorian lamp made possible by Superfast Steel Epoxy Putty

Superfast Steel Epoxy Putty is used in the restoration of a lantern made by famous Birmingham lamp maker Arthur J. Poole and dated to the 1870s or 1880s, returning it to working order so that it could light up spaces as it did in its Victorian heyday.

Case Study Data

Repair Type
Restoration of a 19th century lantern
Defect
Broken candleholder and snapped door latch

Products Used

Superfast Steel Epoxy Putty Stick
Epoxy putty used to fabricate new parts and for high-strength adhesion of metal-to-metal and plastic-to-metal

Case Study PDF

Download

Case Study Details

Arthur J. Poole manufactured a huge range of candle-lit lanterns, lanterns for police offices, lamps for use on the railways, maritime signal lamps capable of transmitting Morse code, and copper coal buckets from his factory in the heart of Birmingham during the 19th century.

The lantern in question was candle powered, dating it to the 1870s or 1880s before paraffin became more widely used. For an item the best part of 120 years old and which had clearly spent most of its life as a working lantern, it was in remarkably good condition.

There were two areas which needed attention before it could be used once again. The lantern no longer had a latch to close the door in place. Whenever there was a breeze or the lantern swung as it was being carried by its handle, the door would swing open and the candle inside end up extinguished.

The original candleholder inside the lantern was small and designed for Victorian-era candles. The owner wanted to modify it to hold larger, modern day candles

The other problem was that original fitting for candles was designed for small, thin Victoria-era candles. The owner wanted to create a new platform capable of holding tea lights or other large candles, complete with a spike allowing it to slot into the existing fitting.

This was done using Superfast Steel Epoxy Putty. Superfast Steel comes in a pre-formatted 114g stick. The user cuts off the amount of putty required and mixes it by hand, instigating a chemical reaction between the resin and hardener.

Superfast Steel has a work time of around five minutes. Whilst soft, it can be shaped and formed as desired. Once cured, it offers super-strength adhesion between different substrates and forms a material as hard as steel.

Superfast Steel Epoxy Putty used to fabricate a new part in the restoration of a 19th century lantern
A new candleholder and spike were fabricated from Superfast Steel. The platform had already been painted black in this photo

To create a new candleholder, Superfast Steel was moulded into the required shape to make the platform. Once the putty platform had cured, the spike was shaped and added. Whilst soft, the spike was pushed into the existing fitting to ensure it was a perfect fit.

The spike easily bonded to the newly fabricated platform, creating a holder capable of supporting a modern candle inside the lantern and completing part one of the restoration.

The new candleholder enabled the lantern to hold a modern candle in place

To create a new handle for the door, a metal wire was bent into a T-shape by folding it in half, then bending the two ends at right angles. It was attached to the door via two plastic tubes which were bonded to the lantern using further Superfast Steel.

When the door was closed, this metal wire could now drop into an existing latch attached to the opposite side of the lantern, locking it in place and preventing the candle from blowing out.

A latch was made from a metal rod and plastic tube and attached to the lantern using Superfast Steel. All materials were then painted black to blend in seamlessly with the lantern
A 19th century lantern that underwent restoration using Superfast Steel Epoxy Putty Stick
The completed restoration

A coating of black paint was added to the wire, the plastic tubing and the Superfast Steel to complete the restoration at a cost of under £20.

The lantern is now lighting up a garden in East Sussex and ready for another 120 years of service. Arthur J. Poole himself would have been impressed.

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

Posted on by

Case Study: Snapped Nozzle on a 1500mm Seawater Cooling Line Repair & Reinforcement

A 1500mm line in a seawater cooling system undergoes repair after it began leaking from a broken off nozzle

Keeping it cool – the repair and reinforcement of a leaking 1500mm seawater cooling system supply line

A petrochemical plant in Saudi Arabia needed an urgent repair to the 1500mm main supply line in their seawater cooling system after a nozzle snapped off, leaving a 50mm hole discharging water 5 metres vertically at a pressure of 3 bar.

Case Study Data

Site
Petrochemical plant
Location
Saudi Arabia
Repair Type
Leak repair and reinforcement
Defect
Snapped nozzle in a 1500mm seawater cooling pipe

Products Used

Sylmasta AB Original Epoxy Putty
Epoxy putty with a long work time used alongside a PTFE plug to fill the 50mm hole left by the snapped nozzle

SylWrap HD Pipe Repair Bandage
Composite wrap reinforced the repair and was then applied around the diameter to strengthen the line

Case Study PDF

Download

Case Study Details

Seawater cooling systems allow water taken from the sea to be used for the cooling of machinery and other processes in industrial plants and factories.

The petrochemical plant were extracting from the Red Sea. A nozzle on the 1500mm diameter main line supplying the cooling system had snapped off from the flange, causing a jet of pressurised water to shoot 5 metres into the air from a 50mm hole.

An engineer fitted a PTFE plug to the leaking line

When this seawater returned to ground, it saturated the surface of the pipe. This had caused visible external damage, discolouration and mould to form. The petrochemical plant were concerned over a potential catastrophic weakening of the line.

Losing so much water also had a serious impact on the efficiency of the cooling system. The plant therefore decided to call in a maintenance team to attempt to fix the problem as a matter of urgency.

The supply line was shut off whilst the repair took place. The application began by securing the hole left in the pipe by the snapped nozzle with a plug made from PTFE.

Sylmasta AB Epoxy Putty used to repair a seawater supply line by fixing a PTFE plug in place
AB Original Epoxy Putty was used to permanently fix the plug in place, creating a watertight seal

To create a watertight seal around the PTFE plug and fix it in place permanently, the nozzle was then encompassed using Sylmasta AB Original Epoxy Putty.

AB Original is a smooth-setting putty capable of bonding to all materials, including wet surfaces. It has a two-hour work time, allowing for more careful application without the worry of premature curing.

This longer cure time is particularly useful in hot climates such as Saudi Arabia, where higher ambient temperatures make epoxy putties set faster.

SylWrap HD Pipe Repair Bandage applied to a snapped nozzle in a seawater supply line repair
The exposed top of the plug and AB Original were encompassed with SylWrap HD

Further reinforcement of the exposed top of the plug and the surrounding AB Original was provided by SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets rock in hard in minutes.

Seven layers of SYL412HD Bandage were wrapped and smoothed around the nozzle, creating an impact resistant outer layer. It completely sealed the hole, forming a repair easily capable of withstanding the pressure the cooling system operated at.

SylWrap HD Pipe Repair Bandage being applied to a 1500mm seawater supply line
Further SylWrap reinforced the weakened section of pipe around the plug

When the pipe was put back into service, the engineers noticed during their inspection that the pipe around the nozzle had indeed been weakened, as the petrochemical plant suspected.

Although no major leaks were present, the surface could be seen bubbling with air and water. The engineers therefore decided to reinforce the entire area of pipe underneath the nozzle by wrapping the 1500mm diameter with four layers of SYL616HD Pipe Repair Bandage.

Repair and reinforcement of a 1500mm seawater supply line after a nozzle snapped off
The repair was completed in two hours, leaving the line sealed and strengthened

SylWrap HD cured to form a thick, rock-hard robust shell encompassing the pipe and strengthening the weakened outer wall. The line was now well protected from external damage or future breaches.

Completing the repair of the nozzle and the reinforcement of the line took less than three hours. 24 hours later and AB Original had reached maximum properties, allowing the seawater cooling system to operate at full capacity once 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

Posted on by

Case Study: Live Leak Pinhole Repair on 150mm Elbow at Pumping House in Malaysia

A SylWrap Live Leak repair made to a pinhole leak on a 6 bar 150mm elbow joint with a pinhole leak

Fixing an elbow – a pumping house in Malaysia stays operational thanks to a SylWrap live leak repair

When a 150mm steel pipe elbow in a Malaysia pumping house developed a pinhole leak through which water was spraying out at 6 bar pressure, the company responsible for the facility turned to Sylmasta for a rapid live leak repair.

Case Study Data

Site
Pumping house
Location
Malaysia
Repair Type
Live leak repair
Defect
Pinhole leak in 150mm steel pipe elbow joint

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating repair tape formed a solid rubber band to seal the live leak on the elbow joint

SylWrap HD Pipe Repair Bandage
Composite repair wrap applied to reinforce the initial repair by curing to form an impact resistant protective sleeve

SylWrap Universal Pipe Repair Kit
Kit with Wrap & Seal and SylWrap HD for making a single, permanent live leak pipe repair

SylWrap Pipe Repair Contractor Case
Contains enough products to make up to six live leak repairs, now approved for use on Kuala Lumpur’s vast network

Case Study PDF

Download

Case Study Details

The steel pipe was an important part of the system at the pumping house, operated by a water company. A pinhole leak had appeared on an elbow joint weakened by corrosion where two sections of metalwork joined together.

Because the leak was on an elbow, a repair clamp could not be fitted. The pipe could not be taken out of operation for repair or replacement due to its importance to operations at the pumping house.

A pinhole leak on an elbow joint in a Malaysia pumping station prior to undergoing a live leak repair
The pinhole was located on an elbow
A pressurised jet of water escaping from a 150mm pipe elbow in a Malaysia pumping station
Pressurised jet of water spraying from the pinhole leak

The water company’s maintenance team therefore used a SylWrap Universal Pipe Repair Kit to carry out a live leak repair which would be effective on the 150mm elbow operating under 6 bar pressure.

Wrap & Seal Pipe Burst Tape was used to seal the pinhole leak in the pipe. Wrap & Seal is a self-amalgamating waterproof repair tape. It stretches by 300 percent and fuses to form a solid rubber band over holes and cracks in pipework, containing pipe content.

Wrap & Seal Pioe Burst Tape used to repair a pinhole leak on a 150mm pipe elbow in Malaysia
Wrap & Seal Pipe Burst Tape was stretched by its maximum 300 percent
Wrap & Seal successfully sealed the pinhole leak

Once the Tape had successfully sealed the hole in the pipe, it was overwrapped with a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets rock hard in minutes.

The Bandage was wrapped around the elbow and smoothed down whilst water from a bucket was poured over it at sporadic intervals. Once cured, SylWrap HD provided an impact resistant shell around the elbow, preventing any future leaks or bursts.

Within 30 minutes of the application starting, the maintenance team had successfully repaired the elbow with no interruption to operations at the pumping house.

SylWrap HD Pipe Repair Bandage used to reinforce a repair on a 150mm elbow joint in a Malaysia pumping station
SylWrap HD Bandage was used to reinforce the repair
The repair was completed in less than 30 minutes

Both Wrap & Seal and SylWrap HD are WRAS approved, meaning they are certified as safe to use on pipes and fittings carrying drinking water according to British Standards.

Numerous other successful pipe repair applications have since been made in Malaysia using Wrap & Seal and SylWrap HD supplied in a SylWrap Pipe Repair Contractor Case.

This has led the Case to be approved for carrying out leak repairs across Kuala Lumpur’s vast pipe network, reducing water loss at a time when Malaysia is facing a growing water crisis.

Each Contractor Case contains enough products to make up to six live leak repairs on pipes of all diameters and types without the need for any training.

The Case can be easily stored on-the-van, providing a lightweight and more versatile alternative to carrying around heavy, bulky pipe repair clamps.

When leaks and bursts on the water network are identified, a contractor simply has to reach for the Case on their van to repair the problem in under 30 minutes.

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

Posted on by

Case Study: Repair of a Leaking 200mm Fuel Oil Line Pressure Resistant to 44 bar in Libya

Sylmasta repair a 200mm underground oil fuel line in Brega, Libya suffering from a crack caused by heavy corrosion

Fuel for thought – a high pressure, high temperature pipe repair keeps an oil line in Libya operating

Heavy corrosion caused a small crack to appear in a 200mm fuel oil line buried underground in Libya, leaving the pipe requiring a repair that could withstand pressure fluctuations up to 44 bar and temperatures up to 70°C

Case Study Data

Site
Underground fuel oil line
Location
Brega, Libya
Repair Type
Leak repair
Defect
Small crack in 200mm pipe

Products Used

Wrap & Seal Pipe Burst Tape
Multiple tapes were used for creating a thick, tough rubber band over the leak capable of withstanding extreme pressure

SylWrap HD Pipe Repair Bandage
Composite repair wrap formed an impact resistant protective shell over the initial repair, reinforcing the line

SylWrap Pipe Repair Contractor Case
Contains multiple Wrap & Seals and SylWrap HD Bandages to carry out up to six live leak repairs

Case Study PDF

Download

Case Study Details

The town of Brega serves as a major export hub for Libyan oil, being home to one of the five oil terminals operating in the eastern half of Libya. It is also the starting point of the 670 km Brega-Khoms Intisar gas pipeline.

A 200mm fuel oil line required repair after it was found to be leaking underground
Excavation revealed that the pipe was in poor condition

Heavy corrosion had caused a small crack to appear in a 200mm fuel oil line buried underground. Once the pipe had been excavated for inspection, it became clear that it was in terrible condition, badly pitted and covered in escaped oil.

To add to the complexity of the application, the line experienced pressure fluctuations up to 44 bar and at operated at temperatures of up to 70°C. Any repair had to be able to withstand these extremes.

Oil leaking from a damaged 200mm fuel pipe line in Brega, Libya
The leak area was a small crack caused by corrosion

Prior to the application, the pipe was cleaned as best as it could be. Oil and dirt was removed and the surface smoothed off to enable a good connection between the line and Wrap & Seal Pipe Burst Tape, which made up the first stage of the repair.

Wrap & Seal is a self-amalgamating repair tape which stretches by 300 percent. As it is wrapped around a pipe, it fuses to form a solid rubber band over holes and cracks.

Multiple tapes can be applied over each other, where they will amalgamate together in the same way. The more Wrap & Seal used, the tougher the rubber mass becomes and the higher the pressure resistance of the repair.

One of the first Wrap & Seal applied to the pipe. Multiple tapes were used to form a repair with high pressure resistance

A total of six 50mm x 4m Wrap & Seal tapes were used to build a repair with the required pressure resistance. The tape was then overwrapped with SylWrap HD Pipe Repair Bandage.

SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes. It provides an impact resistant protective shell to pipes and structures, increasing life span and hoop strength.

200mm fuel oil line in Brega, Libya undergoes leak repair using a Sylmasta Pipe Repair Kit
The line was reinforced using SylWrap HD

Four SylWrap HD Bandages were used to cover the repair area, reinforcing the fuel oil line before it was reburied. Each bandage cured within five minutes of application.

Wrap & Seal has a maximum service temperature of 200°C and SylWrap HD withstands up to 250°C, leaving the repair capable of withstanding both the temperature and pressure extremes of the pipeline.

Completed repair prior to the line being reburied

It took under two hours to complete the application, notwithstanding the time to excavate and inspect the pipe. The repair was a cost-effective and less time-consuming alternative to replacing the damaged section, which would have left the line out of operation for a prolonged period.

The maintenance team who carried out the job in Brega have since gone onto use Sylmasta products to make numerous repairs to other oil lines in the region, taking advantage of the ease and convenience offered by the SylWrap range.

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

Posted on by

Case Study: Repair of a Cracked Copper Pipe in a Camper Van Boiler System

A copper pipe in a camper van boiler system undergoes repair using Superfast Copper Epoxy Putty and a SylWrap HD Pipe Repair Bandage

Carry on camping – a difficult-to-access copper pipe in a camper van boiler system undergoes repair

A camper van owner manages to repair a crack in a copper pipe located within the van’s boiler system, despite the leak area being extremely difficult to access

Case Study Data

Site
Camper van boiler
Location
United Kingdom
Repair Type
Leak repair
Defect
Crack in a copper pipe

Products Used

Superfast Copper Epoxy Putty Stick
Fast-working epoxy putty mixed by hand and applied over the crack in the copper pipe to seal the leak

SylWrap HD Pipe Repair Bandage
Composite repair bandage applied around the entire pipe to reinforce and protect the initial repair

SylWrap Standard Pipe Repair Kit
Superfast Epoxy Putty and SylWrap HD are supplied together in the Standard Pipe Repair Kit

Case Study PDF

Download

Case Study Details

The boiler system provided heat and hot water to the camper van. A deep crack appeared in a copper pipe located underneath the cover of the boiler, causing a pressurised jet of water to spray out whenever the boiler was turned on.

Problematically, the crack was located at a point where the pipe angled towards the back casing of the boiler. It faced towards the side of the casing with access extremely limited.

A crack in a copper pipe which was part of a camper van boiler system before undergoing repair using a Sylmasta Pipe Repair Kit
A jet of water escaped the copper pipe whenever the boiler was put into operation

The confined space meant there was no room to fit a pipe repair clamp, nor apply Wrap & Seal Pipe Burst Tape with enough stretch for it to self-amalgamate effectively.

Because the boiler could be turned off, Sylmasta recommended to the camper van owner that they use Superfast Copper Epoxy Putty Stick to plug the crack in the pipe.

Superfast Copper comes in an easy-to-use, pre-measured 114g stick. It has a work time of around five minutes, enabling rapid repairs to be made to copper and other non-ferrous metals.

Superfast Copper Epoxy Putty being applied to repair a crack in a pipe which formed part of a camper van boiler system
Superfast Copper applied to the crack in the pipe

Before application began, the pipe was cleaned and dried to aid the adhesion of the putty to the metalwork. The required amount of putty was cut from the stick and kneaded by hand until it turned a uniform copper colour with no streaks.

Whilst soft, the putty was pushed into the crack in the copper pipe. It quickly hardened, sealing the hole. Enough putty was used to cover the section of pipe both above and below the crack to improve the chances of success by creating a totally watertight seal.

The entire section of pipe was then reinforced by applying a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes to provide an impact resistant layer of protection.

Superfast Copper Epoxy Putty used to seal a hole on a copper pipe in a camper van boiler system
Superfast Copper and SylWrap HD successfully sealed the crack

Typically, SylWrap HD would be wrapped tightly around the pipe. The space constraints meant that this could not be done effectively in this particular application, and so the bandage was cable tied to the pipe whilst it cured.

Once the copper pipe repair was completed, the boiler was turned back on. Water was no longer escaping from the crack, denoting a successful repair and saving a considerable amount of money for the camper van owner compared to the cost of replacing the pipe.

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

Posted on by

Case Study: Bahrain International Airport Repair of Leaking Step Joint on 100mm UPVC Pipe

A leaking 100mm UPVC pipe at Bahrain International Airport undergoes a live leak repair using a SylWrap Pipe Repair Contractor Case

Flying high – the live leak repair of a 100mm UPVC pipe step joint which kept a system operational at Bahrain International Airport

When a 100mm UPVC pipe which was part of an important system at Bahrain International Airport began leaking from a step joint, a quick-and-easy live leak repair method was required as shutting down the line was not an option.

Case Study Data

Site
Airport
Location
Bahrain
Repair Type
Live leak repair
Defect
Leaking step joint on a 100mm UPVC plastic pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape which sealed up and over the leaking step joint

SylWrap HD Pipe Repair Bandage
Applied over the sealed step joint to reinforce the repair by providing a rock hard, impact resistant layer

SylWrap Pipe Repair Contractor Case
Products were supplied as part of a Contractor Case, capable of making up to six live leak repairs

Case Study PDF

Download

Case Study Details

UPVC is a strong and versatile pipe material which is assembled using a solvent cement to bond pieces together. Sometimes, these bonds can loosen and begin leaking, which is what happened to the 100mm pipe at Bahrain Airport.

The leak in question was through a step joint connecting two sections of pipe together. The pipe could not be shut off for a repair because of the importance of the airport system it supported.

This meant that the normal method Sylmasta recommend to clients for sealing a leaking step – by using a Superfast Epoxy Putty Stick to plug the gaps between the joint and the pipe – would not be effective because the pipe was wet.

  • Wrap & Seal Pipe Burst Tape being used to repair a step joint on a UPVC Pipe at Bahrain International Airport
The pipe was leaking from behind the left hand side of the joint

The airport therefore had to use Wrap & Seal Pipe Burst Tape as their sealing material. Wrap & Seal is a self-amalgamating silicone repair tape which stretches by 300 percent, fusing to form a solid rubber band over leak areas.

Using Wrap & Seal on a step is not as straightforward as wrapping a straight section of pipe. To create a repair capable of sealing the step between the 100mm UPVC pipe and the sleeve, the maintenance team carrying out the application began wrapping approximately 100mm away from the joint.

  • Wrap & Seal Pipe Burst Tape applied to a step joint on a 100mm UPVC pipe as part of a live leak repair
A ridge was created using Wrap & Seal to seal up and over the step

After approaching the sleeve by overlapping the Tape by 50 percent, they then built up layers of Wrap & Seal immediately next to the joint. This created a ridge. When this ridge reached near-level height with the step, the application of the Tape continued for a further 50mm across the step joint to fully encompass it.

Two 50mm x 4m Wrap & Seals were required before it was established that water had stopped escaping the joint and the leak was fully sealed. The repair was then completed by applying a SylWrap HD Pipe Repair Bandage over the Tape.

SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes. The Bandage was wrapped around the pipe and smoothed down using water poured onto the pipe from a bottle. It cured to provide an impact resistant, protective shell.

  • SylWrap HD Pipe Repair Bandage used to reinforce a 100mm UPVC pipe leaking from a step joint
The repair was completed with a SylWrap HD Bandage

The entire repair was carried out in less than 30 minutes whilst the pipe remained in operation. The two Wrap & Seal Tapes and SylWrap HD Bandage were supplied to the maintenance team as part of a SYL-PRO-633 Pipe Repair Contractor Case.

A Contractor Case contains enough products to make up to six live leak repairs on pipes of all types and diameters. The Case is easy-to-store on site and transport, ensuring that everything needed to fix a leaking pipe is close to hand and enabling repairs to be made as soon as problems are identified.

Following the success of the 100mm UPVC pipe repair, the maintenance team have since gone onto use Contractor Cases at the Airport to fix 150mm and 200mm pipes suffering from similar problems.

Case Study Video

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

Posted on by

Case Study: Creating an Abrasion Resistant Surface for Pug Mill Extruder Barrels

Ceramic Brushabkle Blue Epoxy Paste created an abrasion resistant surface for worn aluminium barrels in a pug mill putty extruder

Putty in their hands – Ceramic Brushable provides an abrasion resistant surface coating to improve pug mill putty extruder efficiency

Aluminium barrels in several pug mill putty extruders suffering from both abrasive wear and a rough initial finish are given an ultra-smooth, abrasion resistant surface coating to improve their efficiency

Case Study Data

Repair Type
Abrasion Protection
Defect
Worn aluminium barrels in pug mill putty extruders

Products Used

Ceramic Brushable Blue Epoxy Coating
Ceramic-filled epoxy coating painted onto surfaces and parts to create a smooth, abrasion resistant layer

Case Study PDF

Download

Case Study Details

Silica-filled putty was extruded from the pug mills via aluminium barrels. Over time, the silica in the putty had caused abrasive wear to the surface of the barrels as it passed through.

This wear combined with the initial rough cast finish of the aluminium had caused the flow rate of putty from the pug mills to slow dramatically, impacting on efficiency.

A badly worn putty extruder had become inefficient because of abrasion
Barrels in the putty extruders were suffering from heavy wear

To help the extruders run more efficiently, a means of improving the flow rate through the barrels by filling in existing damage and creating an ultra-smooth finish was sought.

After researching cost and ease of repair, machining the barrels was ruled out as it would have been difficult, expensive and too time consuming.

Instead, it was decided to paint the aluminium barrels in every putty extruder with a low friction coating for increased extrusion rate. The coating used in the repair also needed to be abrasion resistant to protect the aluminium from further wear.

Ceramic Brushable Blue is an easy to use epoxy coating used to create abrasion resistant surface to machines, parts and surfaces of all materials
Ceramic Brushable Blue was easy to mix and apply to the extruder barrels

Ceramic Brushable Blue was the obvious solution. It is ceramic-filled and reinforced with silicon carbide for ultimate hardness. It is used on both new and old machines and parts in highly abrasive environments.

Coating new surfaces with Ceramic Brushable Blue provides a toughened, reinforced layer of protection from wear, extending the lifespan of parts.

When used on older machine parts and surfaces such as the putty extruder barrels, Ceramic Brushable Blue repairs damaged areas as well as offering protection against abrasion.

Ceramic Brushable Epoxy Coating applied to provide an abrasion resistant surface to a putty extruyder to improve efficiency
The epoxy coating gave a low friction surface to the barrels

Ceramic Brushable Blue was easy to apply. The parts were mixed and then the coating painted on using a conventional paintbrush. The 90 minute work time allowed larger quantities of epoxy to be mixed and applied in one go without the threat of premature curing.

It took one day to coat every pug mill putty extruder barrel with the required amount of Ceramic Brushable Blue. A full cure was achieved 24 hours after the final coat, meaning that there was minimal disruption to production.

Sylmasta Ceramic Brushable Epoxy Coating used to create an abrasion resistant surface for a pug mill putty extruder aluminium barrel
Ceramic Brushable Blue provided a low friction, ultra-smooth finish

The non-stick, smooth finish of Ceramic Brushable also enabled quicker and easy cleaning of the barrels. Less time needed for the maintenance of the extruders resulted in even greater efficiency for the pug mills.

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

Posted on by

Case Study: Repair & Refurbishment of a 19th Century Pit Wheel at Mordiford Mill

A 19th century cast iron pit wheel in Mordiford Mill, Herefordshire undergoes repair and refburbishment with Sylmasta AB Epoxy Putty

Big wheel keeps on turning – the repair and refurbishment of a 19th century pit wheel using Sylmasta AB Epoxy Putty

When the repair and refurbishment of a 19th century pit wheel required a waterproof, corrosion resistant material to protect the cast iron wheel from water and help bond two protective steel hoops for reinforcement, Sylmasta had the ideal solution.

Case Study Data

Site
Mordiford Mill
Location
Herefordshire, United Kingdom
Repair Type
Corrosion protection, water ingress prevention & high strength bonding
Defect
Cracked & weakened 19th century cast iron pit wheel

Products Used

Sylmasta AB Original Epoxy Putty
Water resistant epoxy putty with high strength adhesion and a long work time for complex and larger applications

Case Study PDF

Download

Case Study Details

Mordiford Mill is a 19th century tall stone corn mill in Herefordshire. A water wheel connects to a three metre diameter cast iron pit wheel which drives iron machinery and two pairs of stones.

The Mill ceased grinding flour in 1935. Over 80 years later and the Mill’s latest owner was undertaking a long-term refurbishment project to make it turnable again. One of the most challenging aspects of this was the repair of the pit wheel.

Pit Wheel at Mordiford Mill suffering from numerous cracks and breaks before refurbishment and repair with Sylmasta AB Epoxy Putty
The pit wheel was suffering from cracks and breaks in several places

Corrosion and the passage of time had weakened the castings of the wheel. Both the inner and outer castings had been unusually thin for a pit wheel when they were originally installed in the 1800s, and two generations of previous repair attempts had been unable to suitably reinforce them.

The wheel was cracked and broken in various places. Calculations indicated sudden impacts such as a cog breaking would cause the casting to break apart again – possibly irreparably.

Sylmasta AB Epoxy Putty applied to a 19th century cast iron pit wheel in Mordiford Mill, Herefordshire
Sylmasta AB being applied to the outer casting of the wheel

Replacement was not a viable option because the cost of doing so exceeded the budget of the project. The only way to get Mordiford Mill operating again was by finding a repair and refurbishment method for the pit wheel.

It was decided to strap both the inside and the outside of the wheel with steel hoops to encompass the 19th century ironwork. This would reinforce the pit wheel, ensuring it had adequate protection from future impacts.

Repair and refurbishment of a pit wheel at Mordiford Mill
Steel reinforcement hoop applied over Sylmasta AB and held in place with clamps

These steel hoops could not be welded to the pit wheel because of the dangers associated with welding old cast iron, which tends to explode due to air pockets within the iron. No welder would guarantee a result as success of such a process is less than 50 percent.

Welding would also have left gaps between the steel hoops and the uneven, damaged casting of the wheel. Water entering these gaps would potentially collect inside them, leading to further corrosion of the original cast iron.

Once the putty had cured, the steel hoop was screwed into place

As a water-resistant material capable of high-strength bonding, Sylmasta AB Original Epoxy Putty provided the ideal solution for encompassing the cast iron to prevent water ingress at the same time as aiding the adhesion of the steel hoops to the wheel.

Prior to the application of Sylmasta AB, the casting was cleaned with a needle gun and a wire brush on an angle grinder. This removed rust, grime and dirt from the surface.

The long work time of Sylmasta AB meant that large quantities could be mixed in one go without the worry of premature curing. The putty was applied to the outside casting of the wheel first, after which large sections of the steel hoop were fitted over the putty and held in place using clamps.

Steel hoop screwed into place on the outside casting

The steel hoop was then screwed in place and the clamps removed. The entire process was repeated to the inside casting, although this was slightly more challenge because of the spokes of the pit wheel connecting with the casting.

To overcome this, the application was broken down into smaller sections between each spoke. Sylmasta AB was applied and a small section of steel hoop added, clamped and screwed, before moving onto the next section on the inner wheel.

Clamps fitted to hold a smaller section of steel hoop to the inside of the pit wheel in-between spokes

Once completed, the original pit wheel was successfully reinforced with a steel casing that would last for many years and the presence of Sylmasta AB meant that no corrosion caused by trapped water could attack the ironwork.

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

Posted on by

Case Study: Reinforcement of Weakened Pipe Elbow Joint on 100mm 22 bar Sulphuric Acid Line

A 100mm pipe elbow undergoes reinforcement after the sulphuric acid line it was part of was found to have degraded by 21mm thickness

Chemical romance – the repair and reinforcement of a sulphuric acid line pipe elbow found to have degraded in thickness by 21mm

A pipe elbow on a 100mm sulphuric acid line operating under 22 bar pressure which had degraded from 22mm thickness to just 1mm undergoes urgent repair and reinforcement in Saudi Arabia.

Case Study Data

Site
Petrochemical Refinery
Location
Saudi Arabia
Repair Type
Pipeline reinforcement
Defect
Weakened elbow joint on a 100mm sulphuric acid line

Products Used

Industrial Metal Epoxy Paste
Applied to the elbow joint to strengthen it via the creation of a shell resistant to corrosion and chemical attack

SylWrap HD Pipe Repair Bandage
Applied over Industrial Metal for further reinforcement by encompassing the elbow with a rock hard protective sleeve and increased hoop strength

Case Study PDF

Download

Case Study Details

The petrochemical refinery produces over 140 million barrels of petroleum products and 5 million tons of petrochemical products every year, including naphtha, kerosene, gasoline, diesel and fuel oil.

During a routine inspection, a 100mm sulphuric acid line operating under 22 bar pressure was found to have degraded to only 1mm thickness from 22mm on an elbow joint. This required urgent attention before the line failed.

The scale of production at the site meant that the petrochemical company were keen not to have to shut down the line to replace the weakened section, as this would severely impacted on output.

They therefore needed a flexible method of reinforcement for making an effective repair to the elbow on the sulphuric acid line which, for example, a pipe repair clamp would not have been capable of.

A pipe elbow in a line carrying sulphuric acid undergoes repair using Sylmasta Industrial Metal Epoxy Paste
The elbow joint was reinforced using Industrial Metal Epoxy Paste

The petrochemical refinery consulted an engineering company with whom Sylmasta work with in the region, and they decided to apply Industrial Metal Epoxy Paste to the elbow to strengthen it.

Industrial Metal is reinforced with corrosion-resistant metal platelets which provide excellent protection against corrosion and chemical attack, creating a tough outer shell around pipes and structures.

Industrial Metal Epoxy Paste is applied to a pipe elbow joint in Saudi Arabia to reinforce a weakened 100mm sulphuric acid line
Industrial Metal applied to the elbow using a putty knife

The epoxy paste was spread over the area requiring reinforcement using a putty knife. The 60 minute work time allowed for a large quantity of paste to be mixed and applied without the threat of premature curing, an especially important consideration given the hot climate.

If the remaining 1mm degraded further and the original line was breached, its contents would now be contained by a casing with high chemical and corrosion resistance surrounding the elbow provided by the cured Industrial Metal.

To further reinforce the elbow, SylWrap HD Pipe Repair Bandage was applied over the Industrial Metal. SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in 30 minutes.

It provided an impact resistant layer of protection over the elbow, increasing the hoop strength of the line until such time as a replacement could be conveniently carried out.

Repair completed with SylWrap HD for increased hoop strength

Whilst the reinforcement took place, the pressure was reduced to 8 bar with only a minor amount of disruption to operations at the site. 24 hours after the repair had been completed, the line was restored to its normal 22 bar pressure..

The petrochemical refinery were delighted with the ease and speed of repair made possible by Sylmasta. Regular inspections of the line showed that there had been little to no decrease in the strength of the repair over two years later.

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

Posted on by

Case Study: 650mm Ductile Iron Pipe Located in Pit Undergoes Live Leak Coupling Joint Repair

A 2 metre section of 650mm pipe buried in an inspection chamber was discovered to be leaking, excavated and then sealed using SylWrap pipe repair products

Coupling goals – the challenging repair of an iron water pipe discovered to be leaking from coupling joints in a disused pipe inspection chamber

A 2 metre section of 650mm ductile iron pipe buried in a former underground inspection pit is excavated by a UK water company to undergo repair after it was found to be leaking from two coupling joints.

Case Study Data

Site
Inspection Pit
Location
United Kingdom
Repair Type
Live leak repair
Defect
650mm ductile iron pipe leaking from coupling joints

Products Used

Wrap & Seal Pipe Burst Tape
Multiple self-fusing silicone repair tapes used for building up a repair to seal the coupling joints

SylWrap HD Pipe Repair Bandage
Reinforced the coupling repair and fortified the pipe from further deterioration before it was reburied

SylWrap Pipe Repair Contractor Case
Contains multiple Wrap & Seals and SylWrap HD to carry out up to six live leak repairs

Case Study PDF

Download

Case Study Details

The pit had originally been an inspection chamber housing a valve. Many years ago, the valve had been replaced with a two metre section of straight ductile iron pipe attached to the existing pipe carrying mains water via two coupling joints.

After the straight section was fitted, the whole chamber had been filled in with earth and covered over, where it remained forgotten. That was until the water company responsible for the pipe rediscovered it during maintenance work.

Contractors discovered a 2 metre long section of 650mm ductile iron pipe buried in what used to be a valve chamber was leaking
The 2 metre section of pipe with raised couplings at either end

Soil within the pit was found to be extremely muddy, suggesting that the pipe was leaking in the chamber. After excavating the entire pit to investigate further, the water company discovered that the pipe was in poor condition with slight seepage from both couplings.

The water company decided to seal the couplings to prevent further leakage. Each coupling was 80mm wide but 100mm higher than the 650mm pipe, presenting contractors with an awkward ridge that the repair needed to wrap over.

There were also challenges with the clearance in the pit. The two couplings gave only 35mm underneath in which to work. Conditions within the chamber meant that any repair material wrapped around the pipe would be in danger of picking up mud and dirt off the floor.

Coupling joints on a 650mm ductile iron pipe were leaking before undergoing a leak repair using SylWrap Pipe Repair products
Raised couplings were 100mm higher than the pipe

To overcome this, a polythene sheet was squeezed underneath the pipe. For sealing the couplings, multiple Wrap & Seal Pipe Burst Tape were used to build a repair over and around the couplings.

Wrap & Seal is made from self-amalgamating silicone which fuses to form a solid rubber band for live leak repairs. Separate Tapes will also fuse to each other, this being how the repair was built up and the difficult ridge shape of the coupling sealed.

Each coupling and the surrounding area was then encompassed with a SYL1266HD SylWrap Pipe Repair Bandage. SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes to provide an impact resistant layer of protection.

  • A 2 metre section of pipe in a valve chamber leaking from coupling connections undergoes repair
The completed repair with both couplings encapsulated with SylWrap HD

SYL1266HD Bandages are 300mm wide, giving them more than enough coverage to be moulded around the raised coupling. With the reinforcement provided by SylWrap, the water company could rebury the pipe safe in the knowledge that the leaks were sealed and the pipe had been suitably fortified to prevent further deterioration.

Both Wrap & Seal and SylWrap HD have WRAS approval, meaning that they are certified to British standards as safe to use on pipes carrying drinking water. Because the pipe carried mains water, it was a legal requirement that any repair materials used had to be WRAS approved.

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