Category: Case Studies

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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

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Case Study: Leaking Concrete Flood Defence Wall Repair at Major Scotland Dam

Gaps in a concrete flood defence wall repair made using Sylmasta AB Original Epoxy Putty

Dam good repair – Sylmasta AB Original Epoxy Putty seals gaps in a concrete flood defence wall

Gaps left in a relatively new concrete flood defence wall by an ineffective sealing compound washing out are resealed in a Sylmasta AB Original Epoxy Putty repair made by a civil engineering company.

Case Study Data

Site
Flood defence dam
Location
Scotland
Repair Type
Gap repair
Defect
Gaps between concrete slabs in section of flood defence wall

Products Used

Sylmasta AB Original Epoxy Putty Stick
Super-strength epoxy putty effective on wet surfaces which comes with a two-hour work time for complex gap filling

Case Study PDF

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Case Study Details

A valley in Scotland at the confluence of three rivers had been flooding for over a century, affecting homes and business in three towns and the railway line connecting them.

With climate change making flooding a more regular occurrence, a multimillion pound flood defence project was commissioned. This involved the construction of a large earth storage dam and concrete flood defence walls.

The state-of-the-art dam was designed to retain water from the rivers when levels were high, reducing the risk of flooding in the towns downstream whilst leaving flow unaffected at other times.

Alongside the dam, flood defence walls were built to protect the railway line and the residential estates closest to the river which had suffered the most from water damage over the past 25 years.

Not long after the project finished and one section of the defence walls began leaking. It was made up of concrete slabs sealed together by a grout compound. This compound was now being washed out by floodwater, causing large gaps to appear between the slabs.

A civil engineering company were called in to inspect the problem and formulate a repair. After consultation with Sylmasta, it was decided the gaps in the flood defence wall should undergo repair using AB Original Epoxy Putty.

AB Original is a ceramic-filled, high-strength epoxy putty with an extended work time and excellent underwater and wet surface adhesion.

The engineering company were confident in the suitability of AB Original having seen a previous case study where the Environment Agency sealed a large crack in a wall between a river and a trout farm.

Flood defence wall at a UK dam undergoes repair using Sylmasta AB Original Epoxy Putty after gaps appeared
Sylmasta AB Original Epoxy Putty packed into cracks in a flood defence wall, sealing the gaps
The original sealing compound between concrete slabs had washed away, with the subsequent gaps packed with AB Original

45kg of AB Original Epoxy Putty were delivered to site in 200g sticks. Supplying the putty in sticks formatted to the correct mix ratio removed the need to measure out separate components of resin and hardener from tubs, speeding up the repair.

Each stick was mixed by hand until it turned a uniform colour. Whilst still soft, the putty was pushed into the gaps between slabs. The two-hour work time of AB Original meant the engineers making the repair could take their time mixing and carefully applying the putty without the threat of premature curing.

Once cured, AB Original formed a rock-hard material and a watertight seal much more effective than the original grout compound. With its wet surface properties, the putty easily bonded to the saturated concrete.

Gaps in the concrete flooring were also sealed thanks to the underwater curing properties of AB Original

Gaps had also appeared between slabs making up a floor, which was now underwater because of the flooding. AB Original cured below the water line, sealing the floor in the same manner as the wall.

Such a straightforward repair ensured the construction of the flood defence wall being completed with an ineffective sealing compound did not cause long-term issues.

AB Original allowed the problem to be remedied quickly and easily, avoiding a costly rebuild or significant reinforcement of the structure within only a few years of completion of the project.

The putty is now playing a small part in protecting homes, businesses and transport infrastructure in the valley against flooding.

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: Oil Refinery Repair Cooling Pipe System Attacked by Microbially Induced Corrosion

An oil refinery repair welded joints leaking due to microbially induced corrosion in the stainless steel water cooling pipe system

MIC at oil refinery – leaking joints in a water cooling system undergo repair to keep facility online despite microbially induced corrosion

A significant pipe repair programme at an oil refinery seals leaks in a stainless steel water cooling system after microbially induced corrosion caused the failure of welded joints across the site.

Case Study Data

Site
Oil refinery
Location
Middle East
Repair Type
Live leak pipe repair
Defect
Leaking welded joints in stainless steel water cooling system caused by microbially induced corrosion

Products Used

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

SylPad Pressure Resistance Multiplier
Increases the pressure resistance of Wrap & Seal by up to three times when making live leak repairs to pipes over 150mm diameter

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap sets rock hard, reinforcing and protecting the initial Wrap & Seal repair

SylWrap Pipe Repair Contractor Case
Easy-to-store Case containing enough Wrap & Seal and SylWrap to make multiple live leak repairs on pipes of various diameters

Case Study PDF

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Case Study Details

The stainless steel water cooling system at the oil refinery was meant to have a lifespan of up to 50 years, yet numerous welded joints across the site were already starting to fail after less than half that time.

Microbially induced corrosion was found to be the cause, a type of corrosion relatively little is known about compared to other forms. It occurs when microbes fix to a surface, producing a biofilm layer where multiple bacteria combine to accelerate the corrosive process.

This biofilm affects the electrochemical environment in multiple ways, including changing ion concentrations, pH values, oxidation levels and creating hydrogen sulphide.

As more biofilm layers form, the bacteria and microbes are given greater protection from treatment methods such as biocides, chemicals and temperature treatments. It becomes increasingly difficult to slow corrosion or eliminate microbes from the pipe system.

Stainless steel normally has enhanced protection against corrosion thanks to its passivation layer, which prohibits microbes attaching and makes a surface less prone to developing biofilms. But if the passivation layer is damaged, microbially induced corrosion will take place.

Installation of the water cooling system at the oil refinery included welding joints together. Unbeknown to the refinery, this had weakened the internal passivation layer of the stainless steel pipework.

When the water cooling system went live, microbes in the water were able to settle on the uneven surface at each welded joint. Bacteria collected and a corrosive action began between the metal and the microbes, attacking the stainless steel from the inside.

Eventually, a series of leaks appeared at welded joints throughout the water cooling system. This represented a major problem at a relatively new and expensively built facility. Replacing the stainless steel pipework was not an option due to the cost and disruption it would cause.

With every welded pipe joint now a potential point of failure, the oil refinery contacted Sylmasta to find a repair solution. Sylmasta recommended the refinery stock a range of different sized Wrap & Seal Pipe Burst Tape and SylWrap HD Pipe Repair Bandages, which permanently seal live leaks when used in conjunction.

Online pipe repair capability was essential to the oil refinery as draining the system would result in at least five days loss of production, along with vast costs for diversion of water.

Over 500 SylWrap HD Bandages and 1,700 Wrap & Seal Tapes were sent to the refinery. Sylmasta also flew to the Middle East and spent a week training, testing and certifying refinery installers and supervisors on using the products.

Workers were shown how to apply Wrap & Seal for high-pressure live leak repair. Wrap & Seal stretches by three times its length and amalgamates together, fusing to form a solid rubber band containing pipe content.

Wrap & Seal Pipe Burst Tape used to repair leaking welded joints in a water cooling pipe system
Multiple Wrap & Seal Tapes applied to leaking welded joints in the water cooling system built repairs with pressure resistance up to 10 bar

Multiple Wrap & Seal Tapes applied on top of each other amalgamate in the same way, building pressure resistance up to 30 bar. This was more than suitable for the cooling system, operating at a maximum 10 bar pressure.

For pipework 150mm diameter or above, workers were also trained in using SylPad Pressure Resistance Multiplier. SylPad is applied alongside Wrap & Seal when making live leak repairs to pipes 150mm diameter and above.

It better concentrates the pressure resistance of Wrap & Seal directly over the leak by directing more of the Tape’s elastic force downwards. Depending on pipe size, nature of the leak and repair quality, SylPad can increase the pressure resistance of Wrap & Seal by up to three times.

The final stage of repair involves overwrapping with SylWrap Bandage. SylWrap is a composite repair wrap with a water-activated resin which sets rock hard in minutes. It provides an impact resistant protective sleeve, reinforcing the repair.

SylWrap Pipe Repair Bandage applied to leaking welded joints on a stainless steel water cooling system at an oil refinery
SylWrap HD provided a rock hard, impact resistant protective sleeve around repairs – which could be made to difficult sections of pipes, including where the water cooling system ran overhead

Since Sylmasta visited, the refinery have used their extensive supply of SylWrap products to repair numerous leaks in the water cooling system – including to sections of overhead and difficult-to-access pipework where the system passes through constrained spaces.

With eliminating microbially induced corrosion from the system impossible, instant live leak repair has proven the best solution for the refinery.

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: 6 Bar Live Leak Repair to 300mm Steel Pipe at Malaysia Water Treatment Plant

A live leak in a 300mm steel pipe at a wastewater treatment plant in Malaysia live leak repair

6 bar sealed – water company in Malaysia seal online leak on 300mm pipe after two weeks of leaking

Just one week after Sylmasta carried out a series of demonstrations and site visits in Malaysia, a water company make their first repair using a SylWrap Contractor Case to seal a 6 bar live leak on a 300mm steel pipe at a water treatment plant.

Case Study Data

Site
Water treatment plant
Location
Malaysia
Repair Type
Live leak pipe repair
Defect
4mm hole in 300mm steel pipe

Products Used

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

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap which sets rock hard, reinforcing and protecting the initial repair

SylWrap Pipe Repair Contractor Case
Easy-to-store Case containing enough products to make multiple live leak repairs on pipes of various diameters

Case Study PDF

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Case Study Details

The pipe had been leaking for around two weeks through a 4mm hole. It could not be shutdown because of its importance to operations at the treatment plant, leaving a steady 6 bar jet of water escaping and saturating the floor.

Such a leak would normally be sealed by the water company using a pipe repair clamp. The hole though was located on a section of pipe with a saddle joint welded on, sitting approximately 15mm above the original line. A clamp would therefore be ineffective.

6 bar live leak at a wastewater treatment plant in Malaysia before repair using a SylWrap Pipe Repair Contractor Case
Water was escaping the pipe through a 4mm hole at 6 bar pressure, saturating the surrounding floor

After a visit and presentation from Sylmasta a week earlier, the water company operating the treatment plant had taken a supply of SYL-PRO-866 SylWrap Pipe Repair Contractor Cases for sealing multiple leaks on pipework between 300mm and 600mm diameter.

One of the water company’s maintenance teams who Sylmasta had worked with whilst in Malaysia were tasked with using a Contractor Case to make a live leak repair to the pipe at the water treatment plant.

The leak was sealed with Wrap & Seal Pipe Burst Tape. Wrap & Seal stretches by three times its length and fuses together as it is wrapped around a pipe, forming a solid rubber band which seals the leak.

Applying multiple Wrap & Seals on top of each other builds pressure resistance. In high pressure repairs, tapes continue to be added until no water is seeping through and the user is satisfied the leak has been fully arrested.

Three 50mm x 11m Wrap & Seals were used by the maintenance team until the repair could withstand the 6 bar pressure. A SYL866HD SylWrap HD Pipe Repair Bandage was then applied to reinforce and protect the Wrap & Seal.

SylWrap Pipe Repair Bandage applied to a live leak in 300mm steel pipe at a wastewater treatment plant in Malaysia
Wrap & Seal was used to build a repair pressure resistant to 6 bar before overwrapping with a SYL866HD SylWrap HD Bandage

SylWrap HD has a fast-working, water activated resin. It was wrapped directly over the repair area, where it set rock hard within minutes to form an impact resistant outer shell.

Completing the repair took one hour. Having seen how quickly and easily it is to make a live leak repair when maintenance teams are equipped with a Contractor Case, the water company is already planning to expand their use – including onto the public supply network.

All the products in the Case have WRAS approval, meaning they are certified to British standards as safe to use with drinking water.

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: Underground 600mm Concrete Water Pipe Break Repair in Canada

A break in a 60mm underground concrete water pipe in Canda is repaired using Sylmasta products

BC pipe break repair – reducing water loss from an indefinable leak for a city in western Canada

A city authority in Canada repair an underground 600mm diameter concrete pipe with a difficult break at the point it passed through a wall, reducing a 2 bar leak losing significant amounts of water down to a slow and steady drip.

Case Study Data

Site
Public Water Network
Location
British Columbia, Canada
Repair Type
Leak Repair
Defect
Crack in a 600mm diameter concrete water supply pipe

Products Used

Sylmasta AB Original Epoxy Putty Stick
Epoxy putty offering excellent wet surface adhesion for sealing pipework which cannot be made dry before repair

SylWrap HD Pipe Repair Bandage
Composite wrap with water activated resin which sets rock hard to reinforce repairs by forming an impact resistant outer sleeve

Case Study PDF

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Case Study Details

The 600mm diameter pipe ran beneath a road in a city in British Columbia. A break was detected and with other concrete pipe bursts making headline news across Canada, the city authority carried out an immediate excavation to assess the problem and repair the leak.

A steady, hard spray of water was discovered jetting out of the pipe through a joint at the exact point the line passed into a solid concrete wall. This made identifying the exact source of the leak impossible.

The city authority contacted Sylmasta for help with what was a very challenging application. Not only was the precise leak point unknown, but the pipe was unable to be fully shutdown.

An underground water pipe in Canada with a break through which water was leaking at 2 bar pressure
The pipe was leaking from a break somewhere beneath a joint at the point it passed into a solid concrete wall

A further complication came with the break being so close to the wall, meaning the normal live leak repair method of applying Wrap & Seal Pipe Burst Tape would be ineffective.

There was insufficient space to stretch the tape by the required 300 percent to ensure it successfully amalgamated to form a solid rubber band.

Sylmasta suggested reducing the pressure as much as possible from the 2 bar the pipe operated at, followed by using AB Original Epoxy Putty to seal around the entire joint.

AB Original was recommended because it has excellent underwater adhesion, meaning it could bond to the pipe even if wet from the ongoing leak. Its two-hour work time also offers longer to work the putty without worrying about premature curing during application.

The importance of the pipe to the city network meant pressure could only be reduced between midnight and 5am, giving the two maintenance workers making the repair a five-hour window in which to work.

Sylmasta AB Original Epoxy Putty Stick used in the repair of a concrete water main pipe break in Canada
Two maintenance workers mixed AB Original Epoxy Putty by hand inside the hole dug to access the pipe before applying it to the leak area

Just under 8kg of AB Original was used in the repair, supplied in 200g sticks. Each stick was mixed by hand until it turned a uniform colour. It was then packed around the leaking joint, building a repair which encompassed the entire break area.

Despite water pouring out the top of the pipe during the repair, AB Original bonded successfully. After two hours, the putty had set to form a watertight material which reduced the amount of water being lost down to a slow drip.

The pipe was then wrapped with SylWrap HD Pipe Repair Bandage for added reinforcement. Two SYL866HD were used, creating a rock-hard outer shell to further protect the pipe and help increase the effectiveness of the repair.

SylWrap Pipe Repair Bandage used to reinforce a break in a concrete water main pipe in Canada
AB Original was packed around the break in the pipe, encompassing the leak area. The repair was then overwrapped with SylWrap HD Bandage.

Completing the application took around three hours. The city authority were particularly impressed with Symasta’s efficiency. It took under five days from initial contact for a repair method to be devised, the goods shipped from the UK to British Columbia and the leak reduced to an acceptable level until the section of pipe can be replaced.

The need for speed in addressing the leak before it could escalate into a major problem was particularly important at a time when Canada’s pipe network is under scrutiny following high-profile bursts in Calgary and Montreal which led to flooding and the rationing of public water supplies.

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 1.05-Metre Long Crack in Cast Iron Downpipe at UK Hospital

Repair of a crack in a cast iron downpipe at a UK hospital through which rainwater had previously been leaking

Emergency operation at UK Hospital… to repair a crack in a cast iron downpipe

A 1.05-metre long crack through which rainwater leaked from a cast iron downpipe located in a constrained wall cavity is sealed in under 30 minutes, with the ease and speed of repair limiting disruption to patients and staff at a busy UK hospital.

Case Study Data

Site
Hospital
Location
United Kingdom
Repair Type
Leak Repair
Defect
1.05-metre longitudinal crack in cast iron downpipe

Products Used

CrackSeal Pipe Sealant
Sealant extruded directly into cracks in cast iron pipework, setting almost instantly for rapid sealing and repairs

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin which sets rock hard to encompass pipes with an impact resistant outer sleeve

SylWrap Drain & Waste Pipe Repair Kit
Specialist Kit containing products for repairing low-pressure cast iron and plastic waste, sewer and drain pipes

Case Study PDF

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Case Study Details

The hospital contained an internal 150mm diameter cast iron pipe system for taking away rainwater. The system was reaching the end of its lifespan, but budget restraints and the possibility of new facilities being built in the future meant replacing the ageing pipework was not considered viable.

Instead, the hospital was told to find cost-effective repair methods in the event of the system failing. Which is what happened when a 1.05-metre longitudinal crack developed in one section of pipework.

The leak was located in a constrained wall cavity where the pipe passed downwards through plasterboard on its way to the ground floor. The length of the crack meant it extended far enough on the pipe to also pass through the plasterboard.

Longitudinal crack in a cast iron downpipe before undergoing repair using a SylWrap Cracked Pipe Repair Kit
A 1.05-metre longitudinal crack had developed in the cast iron downpipe

When it rained, water escaped the pipe and saturated the plasterboard. This eventually led to rainwater dripping into a ward full of patients, at which point the hospital became aware of the problem. To ignore it would risk a significant leak developing into the ward, and damaging consequences for the ceiling and wall structure.

A specialist drainage engineer was called in. After accessing the wall cavity, removing some of the plasterboard and inspecting the crack, they decided to use the products in the SylWrap Drain & Waste Pipe Repair Kit to permanently seal the leak.

The Drain & Waste Pipe Repair Kit has been designed for repairing cracks and splits in low-pressure cast iron and plastic waste, soil and drain pipes. It comes in a robust red case which is easily kept on-site or on the van by facilities management teams, drain companies and others regularly required to repair such pipework.

Whenever a problem is identified, the user simply retrieves their Kit where everything needed to make multiple repairs quickly and easily is stored.

For this application, CrackSeal Pipe Sealant was used to fill the crack in the pipe. CrackSeal is a high-performance moisture curing sealant specially formulated to fill longitudinal cracks and splits in cast iron pipework.

Crack in a cast iron downpipe filled as part of a repair involving CrackSeal Sealant
CrackSeal Sealant was extruded directly into the crack

Sufficient CrackSeal was extruded directly from its cartridge into the crack until it was totally filled. Although CrackSeal hardens almost instantly, it was left for 10 minutes to form a skin before the repair was reinforced with SylWrap HD Pipe Repair Bandage.

Two SYL616HD Bandages were wrapped along the entire length of the 1.05-metre crack, creating a two-layer repair. The water-activated resin set rock-hard in minutes, providing an impact resistant sleeve protecting both the CrackSeal and the rest of the downpipe.

SylWrap Pipe Repair Bandage applied during the repair of a crack in a cast iron downpipe
Two SYL616HD Bandages were applied around the pipe to create a two-layer repair, completing the application

Sylmasta normally recommend 10 layers of SylWrap HD Bandage be used for full reinforcement. Only two were needed for this application because the pipe took rainwater away at such low pressure.

The cast iron crack repair was completed in under 30 minutes with no disruption to patients or staff in the ward impacted by the leak. Numerous other repairs have now been using the Drain & Waste Pipe Repair Kit made to pipework across the hospital which has since failed.

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: Rotted Wooden Beam Repair in Home Renovation Project

Rotten wooden beam repair made using Sylmasta AB Original Epoxy Putty during a home renovation in Wales

Home facade is made ready for rendering thanks to a rotten wooden beam repair made with Sylmasta AB Original Epoxy Putty

Sylmasta AB Original Epoxy Putty is used to repair a rotted wooden beam, filling in large voids to help create a flat surface which enabled the outside of a home to be rendered as part of a renovation project.

Case Study Data

Site
Residential home
Location
Wales
Repair Type
Wood repair
Defect
Oak beam heavily rotted

Products Used

Sylmasta AB Original Epoxy Putty Stick
Epoxy putty with a two-hour work time applied to wood for repairing damage and filling in voids caused by rotting

Case Study PDF

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Case Study Details

A property owner in Wales was renovating a house they had inherited, including improving its exterior appearance. The facade consisted of an untidy mix of concrete breeze blocks, painted brick and a large oak beam.

The intention was to render the entire wall with cement. Doing so required a flat, sound surface for the cement to be applied to. Unfortunately, the ancient oak was badly rotted in places with large voids which made it impossible to render successfully.

To overcome the problem, the property owner decided to repair the rotted wooden beam using Sylmasta AB Original Epoxy Putty. AB Original was chosen for its super strength, ease of application and two-hour work time, meaning more of the putty could be mixed in one go and carefully applied without needing to rush through fear of premature curing.

Sylmasta AB Original used as a filler repair material for a rotten oak wooden beam
AB Original was used to fill the damage left where the oak beam had rotted

30kg of AB Original were delivered to the site. The putty was supplied in 200g sticks, whereby the resin and hardener are pre-measured. This eliminated the need to measure out separate components of Part A and Part B, making application quicker and more straightforward.

Each stick was kneaded by hand until it turned a uniform white colour. Whilst soft, AB Original was pushed into the voids left where the oak had rotted away, easily bonding to the damaged wood. The homeowner was particularly attracted to AB Original because no tools or equipment were needed for the repair.

Sylmasta AB Original Epoxy Putty used to bond hardwood to a rotten wooden beam as part of a house renovation
Hardwood inserts were bonded to AB Original in areas of the beam with significant damage

Where the gaps left by rot were particularly big, the homeowner added hardwood inserts on top of the putty to reduce the amount of AB Original required.

These inserts were pressed directly into the putty whilst it remained soft. A permanent bond was created between the putty and the hardwood once AB Original had cured to its final rock-hard, watertight material.

Home successfully rendered after rotten wooden beam underwent repair with Sylmasta AB Original Epoxy Putty
The repair helped create a smooth exterior facade which was then rendered

For the AB Original which remained exposed, a little water was used to create an ultra-smooth finish as the putty set. The cured material itself could be rendered onto directly, helping to make adding the cement coating a straightforward task.

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