Category: Case Studies

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Case Study: Landscaping Materials Company Repair & Protect Warehouse Metal Pallets

Ceramic Brushable Blue Epoxy Coating is used to repair metal pallets damaged by impact, abrasion and wear

Ceramic Brushable Blue helps a landscaping materials supplier lay a path to metal pallets protection

A landscaping materials company use Ceramic Brushable Epoxy Coating to repair and protect metal pallets at their central warehouse left damaged by years of having heavy and abrasive items like driveway paving, garden slabs and natural stones stacked on them.

Case Study Data

Site
Landscaping materials supplier warehouse
Location
United Kingdom
Repair Type
Metal repair and protection
Defect
Metal pallets damaged and worn by storage of abrasive, heavy materials

Products Used

Ceramic Brushable Epoxy Coating
Epoxy coating reinforced with silicon-carbide which protects metal surfaces against wear, abrasion and impact

Case Study PDF

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Case Study Details

As one of the biggest suppliers of landscaping materials in the United Kingdom, the company had a vast central warehouse storing items which were then sent to distributors around the country.

These materials included driveway paving, garden slabs, kerbs, edges, porcelain, natural stone and bricks. All were stacked and stored on metal pallets.

The weight of these materials, their abrasive nature and the impact from moving them on and off the metal pallets meant that over time, the metalwork began to show visible signs of wear.

Removing all existing pallets from the warehouse and installing replacements would have been a time-consuming and expensive task.

The landscaping company therefore contacted a mechanical engineering specialist who used and distributed Sylmasta products for advice. They suggested Ceramic Brushable Blue Epoxy Coating to repair the metal pallets in the warehouse.

Ceramic Brushable is reinforced with silicon-carbide for hardness and an ultra-smooth finish. It is painted onto parts and surfaces to create an outer layer with extreme resistance to abrasion, corrosion, chemical attack, cavitation, erosion and pitting.

Ceramic Brushable Blue was painted onto the top parts of the metal pallet which came into contact with landscaping materials

Two coatings of Ceramic Brushable were applied to the top part of the pallets which the landscaping materials sat on. It cured to form a hardened shell, protecting the original metalwork against abrasion and impact damage caused by the materials.

Initially, only a few pallets were treated as a trial run to test the performance of Ceramic Brushable. Six months later and there were no visible signs of damage to any of the coatings applied during the trial.

Metal pallets in a landscaping materials supplier warehouse are coated with Ceramic Brushable Epoxy to repair them after impact and abrasion damage
Once cured, Ceramic Brushable formed a silicon-carbide reinforced layer which was ultra-smooth and offered high resistance against impact and abrasion

Satisfied with the performance of Ceramic Brushable, the landscaping company purchased 10kg to repair and protect more metal pallets throughout the warehouse.

They are also now considering opting for a two-layer wear indicator coating, whereby a topcoat of Ceramic Brushable Green or Black is applied over the existing Blue.

When the Blue layer begins to show through, it will indicate a new topcoat of Green or Black is required to maintain suitable protection levels for the pallet.

Having a clear system showing when to reapply Ceramic Brushable will help the company continually extend the lifespan of its metal pallets for years to come.

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

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

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Case Study: Heat Exchanger Plenum Chamber Corrosion Protection at Power Plant

Corrosion protection given to the inside of a heat exchanger water box using Liquid Metal Epoxy Coating

Productivity improved at power plant as corrosion protection for heat exchanger removes annual repair requirement

Having spent many years annually reapplying a standard epoxy coating to the inside of a heat exchanger plenum chamber, a power plant in Thailand seek a more robust corrosion protection method to improve system efficiency and reduce downtime.

Case Study Data

Site
Power plant
Location
Thailand
Repair Type
Corrosion protection
Defect
Heavily corroded metalwork and parts inside heat exchanger plenum chamber

Products Used

Liquid Metal Epoxy Coating
Brush applied coating which cures to a hard wearing, metallic layer protecting surfaces and parts against corrosion

Case Study PDF

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Case Study Details

A plenum chamber – sometimes known as a water box – is found at the end of a heat exchanger. It supplies and directs the flow of water through the tubes of the heat exchanger.

Conditions inside a plenum chamber are perfect for galvanic corrosion and cavitation. Extreme temperatures, high pressure and unpurified water passing through the box leave the metalwork under constant attack and requiring frequent repair.

The power plant had spent many years using a standard epoxy coating to protect the plenum chamber. The rate of corrosion meant a new coating had to be applied annually.

Conditions inside the plenum chamber were perfect for galvanic corrosion and cavitation

This involved shutting down the system, disassembling the heat exchanger, applying the coating and then putting it all back together. It was a disruptive process which resulted in significant downtime for the plant.

It was therefore decided to find a more robust, effective coating to protect the plenum chamber which did not require yearly reapplication. The plant analysed conditions inside the water box and came up with a specification for their ideal epoxy coating.

Temperature resistance had to be as a high as 149°C with long-term performance at operational temperatures of 25–40°C. It needed to be resistant to pH 8-10 and pressure up to 3 bar. Most importantly, the plant wanted a coating strong enough to last several years at least.

Tubes within the water box and a condenser faceplate were also heavily corroded

Taking these requirements into consideration, Sylmasta recommended using Liquid Metal Epoxy Coating to protect the inside of the plenum chamber, the tubes within the water box and its condenser faceplate.

Liquid Metal is metal-filled, meaning it offers superior corrosion resistance and enhanced durability by creating a thicker, more resilient layer. The cured material has Shore D hardness in excess of 80 and a maximum service temperature of 150°C.

Before application, the metal surface was thoroughly cleaned to remove rust, other contaminants and any traces of the previously applied standard epoxy coatings.

Liquid Metal Epoxy Coating applied to the internal metalwork of a heat exchanger plenum chamber for corrosion protection
Liquid Metal provided a robust protective layer to the internal metalwork of the plenum chamber

Liquid Metal was then painted onto the areas requiring protection using a brush. Three coatings 1mm thick were applied. Liquid Metal has a 90-minute gel and a four hour re-coat time. The entire repair was completed over two days.

Once the final coating had cured, the original metalwork inside the heat exchanger plenum chamber, tubes and the condenser faceplate were covered with a 3mm thick metallic layer, offering ultimate protection against corrosion and cavitation.

Liquid Metal Epoxy Coating used to give corrosion protection to tubes inside a power plant heat exchanger
Corrosion protection given to a condenser faceplate in a heat exchanger at a Thailand power station
Liquid Metal was also applied to the tubes inside the water box and the condenser faceplate

Six months after the repair, the manager of the engineering company responsible for maintenance at the plant contacted Sylmasta with an update.

“I had a good experience with Liquid Metal. We have looked at the heat exchanger and condenser again and the coating has fully performed and protected from corrosion very well.”

“We now want to use Liquid Metal on 22 blowdown tanks at this plant and more systems at other power plants in Thailand where we run maintenance.”

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

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

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Case Study: Repair of Leaking Expansion Joint Fitted to Water Main Pipe on UK Road Bridge

A leaking expansion joint on a 225mm steel water main pipe undergoes repair with Wrap & Seal Pipe Burst Tape

Contracting a leak from an expansion joint – Wrap & Seal repair keeps water supply strong between two counties

A water company in southwest England repair a leaking aluminium expansion joint fitted to a 225mm steel water main pipe, running the length of a suspension bridge carrying a major A road over a river.

Case Study Data

Site
Road suspension bridge
Location
United Kingdom
Repair Type
Expansion joint repair
Defect
Leaking expansion joint fitted to a 225mm steel water main pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating repair tape which fuses to form a solid rubber band, containing high pressure leaks

SylWrap Pipe Repair Contractor Case
Three PB-50x4m Wrap & Seal Tapes were used from a Contractor Case containing enough products to make up to six pipe repairs

Case Study PDF

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Case Study Details

The 335-metre-long suspension bridge linked Devon and Cornwall with the main helping transport water between the two counties. The aluminium expansion joint was fitted to reduce stress on the steel pipe caused by the movement of the bridge.

After it became known the pipe was leaking, a team of engineers accessed the pipe. It ran beneath the road deck of the bridge in a severely constrained space.

The steel water main ran beneath the bridge road deck in a severely constrained space

They discovered a split in the expansion joint between two bellows, through which water was now flowing out. Comparing the position of the fitting from its previous mandatory safety inspection revealed it had moved and contracted significantly.

For this reason, the water company needed a flexible live leak repair solution which could seal the leaking expansion joint but also allow for future movement of the fitting.

The expansion joint was leaking through a split between the final two bellows on the righthand side

They therefore decided to use Wrap & Seal Pipe Burst Tape for the application. Wrap & Seal self-amalgamates as it is wrapped around a pipe, forming a rubber band which exerts pressure over the leak to contain pipe content.

On the day of the repair, the expansion joint had contracted to the point of failure. Whilst this meant the engineers were not battling a stream of water, it reduced the available space between the bellows into which Wrap & Seal could be applied.

Engineers apply Wrap & Seal Pipe Burst Tape during the repair of a 225mm steel water pipe expansion joint
Wrap & Seal was wrapped between the bellows, over the split in the joint

The versatility of Wrap & Seal still made a repair possible. Despite the space constraints, the engineers were able to stretch the tape by its maximum 300 percent to achieve full amalgamation.

Multiple Wrap & Seals wrapped on top of each other fuse together in the same way, increasing pressure resistance. Three PB-50x4m Wrap & Seals were applied until no more water was seeping from the pipe, leaving the engineers satisfied the leak had been fully arrested.

Wrap & Seal Pipe Burst Tape used to repair a leaking expansion joint on a 225mm steel water main pipe
The completed repair left a solid rubber band compacted over the leak, containing pipe content

By the time the repair was complete, a solid rubber band had been compacted over the leak, filling the gap between the two bellows. Measurements were then taken of the expansion joint, so a replacement could be made and fitted at a later date.

The three PB-50x4m Wrap & Seal Tapes used in the repair came from a SYL-PRO-50-150 SylWrap Pipe Repair Contractor Case, a product the water company had recently approved to be carried by all engineers for use on their network.

A Contractor Case is easily stored on-site or on a van and contains enough Wrap & Seal, Superfast Steel Epoxy Putty and SylWrap HD Pipe Repair Bandages to make up to six WRAS approved live leak repairs.

Feeding back to Sylmasta after the expansion joint repair, the engineers said: “The SylWrap Contractor Case was extremely useful in the scenario. Having a variety of products within the repair pack provided plenty of options to us once the problem had been fully evaluated.”

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

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

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Case Study: Bilge Pipe Leaking Through Corroded Welded Joint Repair On Board Superyacht

SylWrap Pipe Repair Kit used to seal a pinhole leak in a steel bilge pipe onboard a superyacht

The seventy pound bilge pipe repair which kept a multimillion dollar superyacht sailing safely

A leaking bilge pipe on board a multimillion dollar superyacht undergoes repair after corrosion at a welded joint caused a hole to appear in an area of the steel line where it was impossible to fit a clamp.

Case Study Data

Site
Superyacht
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Hole in a steel bilge pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape fuses to form a solid rubber band, sealing high pressure leaks

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to reinforce and protect repairs

SylWrap Pipe Repair Contractor Case
Products supplied in a Contractor Case, enabling up to six live leak repairs to be made to pipes of different diameters

Case Study PDF

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Case Study Details

Bilge pumps are one of the most important systems on any boat for keeping the vessel dry and safe. Water naturally collects at the lowest point on board a boat from everyday sources like rainwater, waves when sailing rough seas and spray.

The bilge pump removes this excess water and other fluids which may have found their way to the bottom of the vessel – such as engine oil – by pumping it through a series of pipes and out via an exit hole in the hull.

This prevents flooding impacting the balance of the boat and causing overflow into other areas. Oily water coming into contact with machinery or electrics in the engine room for example can cause serious problems, potentially destroying a boat’s system.

In the event of a hull breach, a bilge pump removing water as it is being taken onboard buys time to slow or repair the leak. If major damage is obtained, the bilge pump allows for safe evacuation by helping keep the vessel afloat for longer than would otherwise be possible.

Corrosion had caused the leak in the superyacht bilge pipe by attacking the steel at a welded joint. The subsequent hole was close to a 90-degree elbow and the hull of the boat.

It was also surrounded by other pipes and equipment, making it impossible to repair with a clamp. With water jetting out the pipe whenever the bilge pump went into operation, the hole needed to be urgently sealed until a new pipe could be fabricated and installed.

Hole caused by corrosion in a bilge pipe onboard a superyacht leaking before a SylWrap repair
Corrosion attacking a welded joint had caused a hole to appear in the steel bilge pipe

The superyacht were sent a SylWrap Pipe Repair Contractor Case, from which Wrap & Seal Pipe Burst Tape was used to seal the leak. Wrap & Seal is a self-amalgamating repair tape with a unique tapered profile which stretches by three times its length.

As it was wrapped around the pipe, it fused to form a solid rubber band capable of containing the water sent through the line by the bilge pump at around 2 bar pressure.

The repair was then reinforced using a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin. It was wrapped and smoothed around the pipe, curing in minutes to form a rock hard, impact resistant sleeve.

SylWrap HD Pipe Repair Bandage used to seal a leaking bilge pipe onboard a superyacht
The pipe was repaired using Wrap & Seal Pipe Burst Tape before overwrapping with SylWrap HD Pipe Repair Bandage

Completing the bilge pipe repair took under 30 minutes at a material cost of a little less than £70. And having discovered how quick and easy a SylWrap repair is, the superyacht now permanently carries a Pipe Repair Contractor Case on board.

The Case contains enough products to make up to six live leak repairs to pipes of different diameters. It is easily stored onboard and means repairs can be made to any boat pipes on the superyacht as soon as leaks develop – even when sailing the high seas.

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

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

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Case Study: Classical Composite Order Column Restoration at Former Cinema Built in 1920s

Concrete classic composite order column repair using Sylmasta AB Original Epoxy Putty

Back to the movies – repair of composite order column tops restores a former cinema facade to its 1920s heyday

Heavily damaged composite order column capitals made from concrete are returned to their highly detailed original state in a Sylmasta AB Original Epoxy Putty repair during the renovation of a neoclassical style former cinema in Portsmouth built during the 1920s.

Case Study Data

Site
1920s neoclassical former cinema
Location
Portsmouth
Repair Type
Concrete restoration
Defect
Heavily damaged classical composite order column capitals

Products Used

Sylmasta AB Original Epoxy Putty Stick
Super-strength epoxy putty which bonds to all materials and can be easily carved and shaped to hold intricate details

Case Study PDF

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Case Study Details

Renowned local Portsmouth architect Arthur Edward Cogswell designed the building in neoclassic style. It opened in 1921 as a cinema and remained in use as a picture house through several names changes for 52 years, until 1973.

It reopened as a snooker hall in 1976 and played host to budding local Stephen Hendrys and Ronnie O’Sullivans until the 2000s. More recent uses included a martial arts centre, a lounge bar, a short-lived return to snooker and darts, and a karaoke bar.

The uncertainty over what to do with the inside of the building over the past 20 years was reflected by a lack of maintenance and care for the outside.

By the time the karaoke bar heard its final song, the facade had become an untidy mess of different coloured paints peeling away, damaged concrete and broken windows.

An ambitious project was launched to renovate the building for community use. This included restoring the dilapidated facade as close to its original 1920s state as possible.

The facade of the building was an untidy mess. The capitals of the classical composite order columns had suffered heavy damage and had large parts missing

The most challenging part of the refurbishment was repairing the tops of four composite order columns – known as capitals – which were in a sorry state. Faded red and blue paint was flaking off. Much of the intricate carved detail had crumbled away and been lost.

With its super strength, long work time and ability to hold shape after being carved, Sylmasta AB Original Epoxy Putty proved the ideal repair material to restore the columns.

Each column was blowtorched as part of the cleaning process

The columns were first thoroughly cleaned, including using a blowtorch to burn off any remains of old paint. AB Original was then mixed by hand, after which the installers had around two hours to carve the putty into the original style of A.E. Cogswell and apply it to the column before it set.

Damaged concrete classic composite order column before undergoing repair with Sylmasta AB Original Epoxy Putty
Sylmasta AB Original Epoxy Putty used to create intricate carvings for the repair of a concrete composite order column
AB Original was carved and sculpted to restore details missing from the columns

Because AB Original sets harder than other epoxy putties, it easily held the highly intricate detail needed to match a classic composite order column. Each sculpted piece of AB Original adhered directly to the concrete, forming a permanent bond.

All four columns were repaired in this way before the entire facade was painted a dignified white. The end result was a seamless restoration of each column. AB Original was so effective, it left no trace that a significant repair and rebuild had taken place.

Classic composite order column repair made using Sylmasta AB Original Epoxy Putty
The columns and entire front facade of the building were painted white to complete the renovation

If A.E. Cogswell came back to life and visited his cinema, even he would have struggled to tell the detailing on the columns was not the original work.

The entire renovation project took around 12 months to complete and included modernising the inside of the building. It now serves the local community, looking almost identical from the outside as it did when first opened as a cinema a century ago.

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: Corroded 30-Metre Section of Sewer Force Main In Underground Vault Repair

A severely corroded sewer force main pipe in Hawaii undergoes repair and refurbishment using the Sylmasta Pipe Refurbishment System

Say aloha to a sewer force main in Hawaii restored from a corroded state by a repair made using the Sylmasta Pipe Refurbishment System

An engineering company in Hawaii refurbish a severely corroded 30-metre section of 450mm ductile iron sewer force main inside an underground vault, rectifying a previous repair attempt which ended up sandblasting a 75mm round hole in the pipe.

Case Study Data

Site
Sewer force main
Location
Hawaii
Repair Type
Pipe repair and refurbishment
Defect
Severely corroded 450mm ductile iron pipe, including 75mm round hole

Products Used

Industrial Metal Epoxy Paste
Metal-filled epoxy paste used to bridge large holes, rebuild weakened pipes and restore surface profile

Liquid Metal Epoxy Coating
Brush applied coating which cures to a hard wearing, metallic surface for protecting pipes 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

Case Study PDF

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Case Study Details

The 450mm ductile iron pipe inside the vault was the final section of the sewer force main before it discharged into a manhole housing a gravity collection system. Its operating pressure was around 3 bar.

It was installed in the 1970s. Conditions inside the often-flooded vault over a period of nearly 50 years had led to severe exterior corrosion and a significantly weakened pipe.

Water was pumped out of the flooded vault before repair

A recent attempt to add structural strength and protect against further corrosion involved sandblasting the line prior to coating with epoxy. Unfortunately, the contractor failed to realise just how weakened the ductile iron had become.

Sandblasting to clean the pipe subsequently put a 75mm round hole in the top of the sewer between a flange and the concrete wall where the main entered the adjacent manhole. Wastewater could escape through this hole when the line was pressurised.

To seal the leak in the pipe, the contractors ordered a pipe repair clamp specifically fabricated for the line. But because the surface was so badly deformed by corrosion, it was impossible for the clamp to achieve a watertight seal. There were also concerns that tightening the clamp fully would further breach the brittle metalwork.

The pipe surface was severely corroded, leaving it weakened and brittle

The contractors contacted Sylmasta for assistance with the corroded sewer main repair. They needed to improve the surface profile of the pipe to make the clamp effective, before refurbishing the entire 30-metre section inside the vault to keep the line operational and protect against further degrading.

Any repair method had to take into account the weakness of the line and the damage already done by sandblasting. Sylmasta therefore recommended using Stages 2, 3 and 4 of their Pipe Refurbishment System.

The hole was attended to first. Wire mesh was used to bridge the gap. Industrial Metal Epoxy Paste was then applied around the entire diameter of the pipe between the flange and the wall, including over the hole. The wire mesh prevented any epoxy paste entering the pipe.

Sandblasting to clean the pipe during a previous repair attempt left a hole in the pipe, through which water could escape when the sewer main was pressurised

Industrial Metal is a two-part epoxy paste used to rebuild weakened metalwork and improve surface condition of pipes. In this application, 5kg of Industrial Metal filled in all imperfections caused by pitting and increased pipe thickness surrounding the hole.

Once cured, Industrial Metal sealed the hole and rebuilt the pipe, leaving it strong enough to withstand the clamp being fitted and smooth enough to ensure a watertight seal could now be achieved.

Industrial Metal Epoxy Paste used to repair a hole in a corroded sewer main line
Industrial Metal was applied to seal the hole and rebuild the area of pipe around it, enabling a repair clamp to be fitted

Industrial Metal could have held the leak of its own accord. The contractors though decided to take a belt and braces approach by also fitting the clamp, seeing as it had been specifically made for this sewer line.

Attention next turned to refurbishing the rest of the corroded sewer main. Loose material was carefully cleaned off using wire brushes before the sewer main was painted with Liquid Metal Epoxy Coating.

10kg of Liquid Metal was used to apply two coatings across the entire 30-metre pipe, the two flanges at either end and the coupling in the middle. Re-coat time was four hours, meaning the application of Liquid Metal took one day.

Corroded sewer main pipe in Hawaii before undergoing repair and refurbishment with Liquid Metal
Liquid Metal used to repair a heavily corroded sewer main ductile iron pipe
Liquid Metal refurbished the sewer main by creating a metallic external shield around the entire pipe

Liquid Metal cured to create a new, metallic, hard-wearing pipe exterior for the sewer main, providing a shield against corrosion and a waterproof barrier against future leaks.

The final stage of the repair saw the sewer main given further reinforcement using 20 x SYL866HD SylWrap Pipe Repair Bandage. SylWrap Bandage is a composite repair wrap with a water-activated resin.

It was wrapped and smoothed around the whole pipe, curing within minutes to form a rock-hard, impact resistant layer of further protection. Six layers of SylWrap Bandage were used based on the 3 bar operating pressure of the sewer main.

Application of SylWrap Pipe Repair Bandage to a heavily corroded sewer main pipe in Hawaii
SylWrap Pipe Repair Bandage forms a rock hard, impact resistant layer of protection for a sewer main ductile iron pipe in Hawaii
The repair was completed by wrapping the entire 30-metre pipe with SylWrap Bandage for a rock-hard, reinforced final layer of protection

From sealing the hole to reinforcement with SylWrap Bandage, the repair was completed over the course of one week. The contractors were impressed with how easy all three Sylmasta products were to apply given the cramped, wet and dirty conditions inside the vault.

They had originally planned to encase the sewer main in concrete after refurbishment as an additional means of protection. This was no longer deemed necessary once they saw the strength and effectiveness of the repair.

At a total cost of just under $5000 including delivery to Hawaii, refurbishing the corroded sewer force main provided a significant financial saving compared to ripping out the pipe and replacing it.

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: Emergency Live Leak Pipe Repair Keeps Heating on at Nursing Home

SylWrap Universal Pipe Repair Kit seals a leaking heating pipe at a nursing home

Winter is coming – and a SylWrap Universal Pipe Repair Kit keeps the heating on at a nursing home

The maintenance manager of a nursing home drives to Sylmasta HQ, collects a SylWrap Universal Pipe Repair Kit and makes a live leak repair to a 150mm metal pipe to keep the heating system running and residents warm.

Case Study Data

Site
Nursing home
Location
United Kingdom
Repair Type
Live leak pipe repair
Defect
Pinhole leak in 150mm metal heating pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape seals live leaks by fusing together to form a solid rubber band

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap which sets rock hard in minutes to reinforce and protect repairs

SylWrap Universal Pipe Repair Kit
Kit containing products needed to make a single permanent live leak repair in under 30 minutes

Case Study PDF

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Case Study Details

Sylmasta offices received an early morning phone call from a panicked maintenance manager of a nursing home in the south of England. A 150mm metal pipe in the heating system running through loft space had developed a pinhole leak.

A constant, steady drip of water was escaping the pipe and saturating the surrounding loft space. Shutting off the pipe to stop the leak whilst waiting for a plumber or heating engineer to make a repair or replacement would have left the nursing home without heating. This was not an option with winter approaching.

The nursing home therefore needed to make a live leak repair that same day to ensure residents were kept warm and prevent significant water damage in the loft space.

Heating pipe at a UK nursing home leaking through a pinhole before undergoing repair with a SylWrap Universal Kit
A steady drip of water was escaping a pinhole in the metal heating pipe, saturating the surrounding loft space

Immediately after the phone call, the maintenance manager drove 20 miles to Sylmasta HQ in Sussex to collect a SYL-616-UP SylWrap Universal Pipe Repair Kit. A Universal Pipe Repair Kit seals leaking pipes even when pressure cannot be turned off by following a simple two-stage process.

Wrap & Seal Pipe Burst Tape was used to repair the pinhole leak. Wrap & Seal is a self amalgamating waterproof tape which stretches by three times its length. As it is wrapped and applied around a pipe, it fuses to form a solid rubber band containing pressurised live leaks.

One 25mm x 2m Wrap & Seal was applied to the heating pipe, easily withstanding the pressure the pipe was operating at to seal the leak. The second stage of the repair involved overwrapping the tape with a SylWrap HD Pipe Repair Bandage.

SylWrap Pipe Repair Bandage used to seal a leaking heating pipe at a nursing home in England
Wrap & Seal Pipe Burst Tape sealed the pinhole leak with the repair area reinforced with SylWrap HD Bandage

SylWrap HD is a composite wrap with a water activated resin which sets rock hard in minutes. It was wrapped and smoothed around the pipe, curing to form an impact resistant protective shell reinforcing the Wrap & Seal for a permanent repair.

It took the maintenance manager under 30 minutes to repair the leaking pipe once they arrived back at the nursing home, leaving residents none the wiser there was a problem with the heating system.

Not only did a SylWrap Pipe Repair Kit ensure there was no impact to residents, but it cost less than £80 – representing a significant saving compared with an emergency callout for a plumber at a time when many nursing homes in the UK are in deep financial trouble.

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: Christmas Saved With Broken Outdoor Light Projector Repair

Broken fitting from a Christmas laser light projector after repair with Superfast Aluminium Epoxy Putty

Keeping the light on at Christmas – Superfast Aluminium and the outdoor projector repair

Superfast Aluminium Epoxy Putty saves Christmas for one British family by enabling the quick and easy repair of a broken outdoor light projector fitting, ensuring the festive show could go on.

Case Study Data

Site
Domestic home
Location
UK
Repair Type
Plastic repair
Defect
Broken fitting for outdoor Christmas light projector

Products Used

Superfast Aluminium Epoxy Putty
Fast working epoxy putty which permanently bonds broken parts back together in under 10 minutes

Case Study PDF

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Case Study Details

The Christmas light projector projected festive scenes of joy and happiness onto the outside wall of a house in the United Kingdom via a relatively simple setup.

A spike was stuck into the ground where the projector was to be positioned. The projector then slid into the spike and was fixed in place by a fitting.

One day, the family returned home to find the projector detached from the spike and the fitting had snapped into two pieces. The family believed there were two possible causes; either accidental damage or one of the neighbouring allotment holders channelling their inner Ebenezer Scrooge.

The Christmas light projector fitting had been broken into two pieces

Whether accident or deliberate sabotage, no decorative light show meant Christmas would have to be cancelled with much wailing and gnashing of teeth – unless the fitting could be repaired.

Thankfully, no wise men nor Christmas miracle were needed. Just Superfast Aluminium Epoxy Putty Stick to permanently bond the fitting back to together.

Broken Christmas projection light bonded back together in a repair made with Superfast Aluminium Epoxy Putty
Superfast Aluminium Epoxy Putty bonded the pieces of the broken fitting back together

Superfast Aluminium is a fast-working epoxy putty. Although it is formulated for the repair of aluminium, other alloys and metals, it can also bond to many plastics. It was shaped in this application to hold the parts together mechanically.

Enough putty was cut from the stick and kneaded by hand until it turned a uniform silver colour. Whilst soft, it was used to reassemble the pieces of the fitting.

A ring of Superfast Aluminium was applied around the break area after reassembley for added reinforcement

Within 10 minutes, Superfast Aluminium had hardened to form a cohesive bond holding the fitting back together. More epoxy putty was then mixed and applied as a ring around the entire break area, reinforcing the repair and giving it added strength. Just in case Scrooge returned.

Outside Christmas laser projection light repair made using Superfast Aluminium Epoxy Putty
The repaired fitting enabled the Christmas light show to resume

The outer ring was left for one hour to reach a full cure before the fitting was placed back in the spike in the ground. The projector light was then turned back on, leaving the repair to be hailed a success and Christmas saved for the family.

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: Narrowboat Engine Heat Exchanger Manifold Hole Repair With Superfast Titanium

A hole in a narrowboat engine heat exhchanger manifold undergoes repair with Superfast Titanium Epoxy Putty Stick

Cool engine heat exchange repair keeps a narrowboat sailing

A narrowboat owner uses Superfast Titanium Epoxy Putty Stick to make a high temperature repair to a 15mm x 15mm hole which appeared in the engine heat exchanger manifold of the vessel.

Case Study Data

Site
Narrowboat
Location
United Kingdom
Repair Type
Heat exchanger manifold repair
Defect
15mm x 15mm hole

Products Used

Superfast Titanium Epoxy Putty
Epoxy putty resistant to 280°C for making repairs to high temperature systems, equipment and parts

Case Study PDF

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Case Study Details

The narrowboat had a raw water system for cooling the engine, including a manifold mounted heat exchanger. It worked by pumping canal water into a tank containing a series of pipes on the exhaust manifold.

Inside these pipes ran engine coolant, circulated around the engine block by another pump. The canal water in the tank passed over the pipes, cooling the engine coolant in the same way a fan does in a car. The water was then expelled through the exhaust.

The narrowboat was moored on a canal in Hertfordshire, around 30 miles north of London, when the owner discovered a 15mm x 15mm hole had appeared in the heat exchanger manifold.

A 15mm x 15mm appeared in the engine heat exchanger manifold

They decided to repair the manifold using Superfast Titanium Epoxy Putty Stick. Superfast Titanium was selected because of its high temperature resistance, enabling it to withstand up to 280°C.

Within 24 hours of the narrowboat owner contacting Sylmasta, Superfast Titanium had been delivered to a collection point close to where the vessel was moored.

Before the repair, the narrowboat owner cleaned and rubbed down the heat exchanger manifold to improve adhesion with the epoxy putty. Aluminium mesh was placed over the hole as a precautionary measure to prevent any epoxy putty entering the manifold exchanger.

Aluminium mesh was placed over the hole as a precautionary measure to prevent any Superfast Titanium entering the manifold exchanger

Enough Superfast Titanium to cover the hole was then cut from the stick and kneaded by hand until it turned a uniform, golden brown colour to indicate successful mixing.

The putty was applied over the mesh and surrounding area. It was pushed firmly onto the manifold to ensure maximum contact before being smoothed off with a little water.

Superfast Titanium Epoxy Putty used to seal a hole as part of a narrowboat engine heat exchanger manifold
The hole was sealed by encompassment with Superfast Titanium

Superfast Titanium has a work time of 90 minutes. It reached working strength in eight hours and achieved a full cure after 72 hours.

The narrowboat engine could have gone back into service after eight hours, but the owner was in no rush to set sail again and so remained moored for the full cure time.

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: Copper Mine Repair Pump Housing Heavily Damaged By River Water Extraction

A copper mine in Bulgaria repair pump housing left heavily damaged after years of extracting water from a nearby river

Copper mine wear repair – refurbishing and protecting pump housing after river water damage

Pump housing at a copper mine left heavily damaged by many years of extracting river water containing sand, silt and other debris, undergoes repair and refurbishment after the cost of replacement was deemed too expensive.

Case Study Data

Site
Copper mine
Location
Bulgaria
Repair Type
Pump housing repair
Defect
Heavily damaged metalwork

Products Used

Ceramic Brushable Epoxy Coating
Epoxy coating reinforced with silicon carbide which sets to an ultra-smooth finish for sealing and protecting parts and surfaces

WearShield Epoxy Paste
Epoxy paste heavily filled with alumina beads used to create an impact resistant shell to protect metalwork in abrasive environments

Case Study PDF

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Case Study Details

The pump housing was part of a system which extracted water from a nearby river and transported it around the copper mine, where it was then used in a number of different processes.

Sand, silt, dirt, stones and other debris were all present in the water as it passed through the pump housing. Following years of exposure to the river water, the housing was now suffering from severe corrosion, abrasion and wear damage.

As it appeared the pump housing was beyond repair, the mine sought quotes for fabrication and installation of a replacement part from several companies. When these were deemed too expensive, it was decided to attempt refurbishment.

The pumping house was heavily damaged after years of extracting water from a river

The mine contacted Sylmasta’s approved supplier in Bulgaria. The supplier had recently spent several days completing a comprehensive product training programme at Sylmasta HQ in the United Kingdom, including a module on restoring damaged metalwork.

They recommended using Ceramic Brushable Epoxy Coating and WearShield Epoxy Paste in conjunction to both repair the existing damage and protect the pump housing from further deterioration.

Ceramic Brushable is a ceramic-filled epoxy coating reinforced with silicon carbide. It seals and protects parts, machinery and surfaces by forming an ultra-smooth, hardened layer of protection.

WearShield is an epoxy paste heavily filled with alumina beads and a high resin content. The dense alumina structure of the cured material enables it to offer the ultimate resistance against all types of impact in the most abrasive environments.

The pump housing was thoroughly cleaned before the repair took place

The pump housing was taken apart and thoroughly cleaned to remove as much rust, dirt and grime as possible. An initial coating of Ceramic Brushable Blue was painted all over the metalwork using a brush, sealing the original surface.

Ceramic Brushable Blue and WearShield use in conjunction to repair heavily damaged pump housing metalwork
WearShield Epoxy Paste applied during the repair of pump housing at a copper mine to created an alumina-reinforced layer of protection
Ceramic Brushable Blue was applied to the pump housing followed by a thick layer of WearShield. The alumina beads are visible in the material

Once Ceramic Brushable had cured, WearShield was applied on top with a spreader. The composition of WearShield makes it easy to build significant, dense layers of protection quickly. In this case, WearShield cured to form a 30mm thick alumina-reinforced shell over the pump housing.

Ceramic Brushable Epoxy Coating provides an ultra-smooth, low-friction finish during pump housing repair in Bulgaria
A top coating of Ceramic Brushable left an ultra-smooth, low-friction finish to complete the repair

Because the alumina beads make cured WearShield a slightly rough material, it was decided to topcoat with more Ceramic Brushable. The ultra-smooth, low-friction finish provided by Ceramic Brushable would improve flow through the pump housing, making it more efficient once it went back into service.

Completing the repair took just two days and saved the mine a substantial amount of money, The pump housing will remain in service for many more years thanks to the significant protection provided by WearShield and Ceramic Brushable.

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