Category: Case Studies

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Case Study: Pipe Capping of Decommissioned Underground Drainage System at Landfill Site

A pipe stub undergoes encapsulation at a landfill site in Cardiff after capping

Limiting leachate from landfill – a pipe stub undergoes encapsulation to further reinforce it after capping

A landfill site in Wales encapsulates a pipe stub and flange plate after capping to protect it against corrosion and a potential future failure, ensuring a decommissioned drainage system could not release toxic leachate into the environment.

Case Study Data

Site
Landfill site
Location
South Wales
Repair Type
Encapsulation of pipe stub
Defect
Reinforcement of stub and flange plate after pipe capping

Products Used

Liquid Metal Epoxy Coating
Brushable epoxy coated onto pipes and structures to create a metallic surface which protects the original metalwork from corrosion

SylWrap HD Pipe Repair Bandage
Composite repair wrap with a water activated resin which sets in minutes to form a rock hard protective shell

Case Study PDF

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Case Study Details

A series of underground drainage pumps were found to not be working at the landfill site in South Wales. Drainage is vital on landfill as it is important that rainwater does not flood, gather or pool on the site unchecked to mix with other fluids, which will often be toxic.

Rainwater that does mix with landfill to dissolve environmentally harmful substances is known as leachate. Leachate must be collected and managed properly. If it is allowed to escape into soil, groundwater or surface water, it can have an acute and chronic impact on the environment, causing serious pollution.

Rather than carrying out a complicated and expensive repair of the pumps, it was decided to decommission and replace them with an entirely new drainage system. The old system needed all pipes to be capped off at the start of the network as part of the decommissioning process.

To further reinforce after capping, the landfill site wanted to protect and encapsulate the main pipe stub and its flange plate. This would save it from corrosion and a possible failure in the future, which could lead to the release of leachate.

Despite the pipe stub’s location in a difficult to access area, Liquid Metal was successfully applied

The stub was protruding around 300mm from a concrete wall, located towards the bottom of a chamber. There was very little space to manoeuvre within the chamber and various metal structures above the stub made access more difficult still. The flange plate itself had seven bolts and a tap which needed to be tightly sealed around.

Arch Services were appointed by the site to find a solution. Arch are a Sylmasta approved contractor for major projects and after consultation with Sylmasta technicians, a method for reinforcing the pipe stub after capping was formulated.

Liquid Metal Epoxy Coating used to encapsulate a pipe which had undergone capping to prevent the escape of leachate
Liquid Metal created a new corrosion resistant shield for the flange plate and stub

Liquid Metal Epoxy Coating was first used to protect the pipe stub and flange plate. Liquid Metal is a brushable epoxy which cures to form a new metallic surface when painted over pipework and other structures. It offers excellent protection against corrosion and chemicals by acting as an external shield.

Several coatings of Liquid Metal were painted all over the pipe stub and flange plate. Whilst the final coating had gelled but remained a little tacky, the stub was then encapsulated with SylWrap HD Pipe Repair Bandage.

SylWrap applied to a pipe stub for encapsulation after a pipe undergoes capping
The entire stub was encapsulated with SylWrap HD Pipe Repair Bandage to complete the repair

A SYL633HD bandage was used. The resin was activated with water and the bandage wrapped around the stub and smothered over the plate. More water was applied to smooth the wrap, which cured to form a rock-hard, impact resistant covering of the stub.

Arch said after the successful completion of the application: “Given the protruding bolts and cramped application position, this was not a ‘pretty’ repair. But it absolutely did the job!” The site now had full confidence that the capped pipe would not fail in future.

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

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

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Case Study: Repair of Leaking 350mm Effluent Pipe Running out to Sea Underneath Salt Marshes

A leaking effluent pipe under salt marshes undergoes a SylWrap repair in an eight hour window whilst the tide was out

Against the tide – the leaking effluent pipe repair beneath salt marshes that had to be completed in under eight hours

A chemical plant in the UK faced a logistically challenging repair, needing to seal a leaking 350mm effluent pipe running underneath salt marshes and out to sea with only an eight hour timeframe to work whilst the tide was out.

Case Study Data

Site
Chemical plant
Location
United Kingdom
Repair Type
No pressure leak repair
Defect
Corroded steel pipe leaking in numerous areas from a defective clamp

Products Used

Sylmasta AB Original Epoxy Putty
Super-strength, waterproof epoxy putty capable of sealing leaks underwater and in aggressive environments

SylWrap HD Pipe Repair Bandage
Composite repair wrap which sets rock hard in minutes to reinforce leak repairs and strengthen and protect pipelines

Case Study PDF

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Case Study Details

The 350mm steel pipe carried effluent from the chemical plant underneath salt marshes and out to sea. It had undergone a repair just one year earlier, which was now discovered to have failed.

When originally installed in the 1960s, the steel had been coated in cement for reinforcement. The previous repair had consisted of removing part of the cement and covering the heavily corroded and perforated section of steel pipe with a clamp.

The pipe could only be accessed when the tide left the salt marshes, via digging by hand

The line’s location under the salt marshes made any repair logistically challenging. The pipe could only be accessed when the tide went out, after pumping away seawater and then digging by hand through sludge. No heavy tools or machinery could be transported onto the marshes to help dig as it would simply sink.

When nature ran its course and the tide then came back in, the pipe was flooded again and so the process had to begin from scratch. This left only an eight hour window in which the pipe was under dry conditions and could be worked on.

350mm steel effluent pipe located underneath salt marshes prior to undergoing leak repair
Excavation revealed the pipe to be leaking from both ends of a clamp

The chemical plant appointed a specialist marine engineering contractor to formulate a repair method. First, the pipe was excavated for inspection. This revealed it to be leaking from both ends of the pipe repair clamp.

To complicate matters further, the steel had now deteriorated significantly. The wall of the pipe was so thin beneath the clamp that the contractor was concerned removing the original repair could have led to the collapse of the line.

Water was pumped out of the hole to access the pipe for the repair
A wooden framework created a safe working area around the line

The contractor consulted Sylmasta, who recommended encapsulating the clamp with a waterproof material to seal it. Further protection could then be provided with a composite wrap. All products used in the repair had to be applied and functional quickly because of the short timeframe in which the pipe was accessible.

As soon as the tide went out, the process of excavating the pipe began again. Sludge was removed from the hole and water pumped away. A temporary wooden framework was built around the pipe to create a safe working area. Sylmasta AB Original Epoxy Putty was then applied around the entire clamp for the purpose of sealing the leak areas.

The clamp in the centre of the pipe was to be encapsulated with Sylmasta AB Original
Sylmasta AB Original Epoxy Putty is applied to a leaking effluent pipe to seal and repair the line
AB Original was applied around the clamp, creating a watertight seal

AB Original is a waterproof, super-strength epoxy putty with a two hour work time. Once cured, it would easily withstand the harsh environment of the salt marshes. The putty was mixed by hand and pushed onto the clamp, filling all holes and cracks through which effluent had previously escaped.

Two inspection hatches were then cut into the steel pipe either side of where the putty had been applied, so the inside of the line could be accessed. Reaching through these hatches, the contractors were able to coat the interior of the pipe with a liquid metal epoxy coating.

Inspection hatches were cut into the pipe, through which an epoxy coating could be applied to re-line the weakened interior
This left the pipe with two sealed inspection hatches and the entire clamp encapsulated with AB Original

Liquid metal cured inside the pipe to provide a new metallic lining, increasing the sealing security of the repair and restoring wall thickness. The two inspection hatches were then fitted with cover plates and firmly sealed.

A concrete coating was next reapplied over the pipe, and the entire excavated section wrapped with several layers of SylWrap HD Pipe Repair Bandage. SylWrap HD is a water-activated composite wrap which sets rock hard in minutes.

SylWrap HD Pipe Repair Bandage is applied to a 350mm effluent pipe in a complex leak repair application
The line was covered in rapid concrete and wrapped with SylWrap HD across its entire length
SylWrap HD restored integrity to the entire pipe, protecting it from the sludge and seawater which would return with the tide

Numerous bandages were smoothed and wrapped around the pipe, curing to form a reinforced protective sleeve. This restored the integrity of the line, uniting and strengthening both the weak and solid areas of the repair.

The speed and ease with which AB Original and SylWrap HD could be applied enabled the application to be completed within the eight hour window. By the time the tide returned to the salt marshes, the pipe had been successfully sealed ahead of being covered with mud and seawater again.

Following the completion of the effluent pipe repair, the contractors told Sylmasta that they were very impressed with the products and the technical assistance provided. They are intending to use AB Original again on a similarly complex application for another client in the near-future.

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

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

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

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

Rebuild after rust – a heavily corroded steel pipe undergoes repair and reinforcement before the line was breached

An industrial site in Saudi Arabia use two stages of the Sylmasta Pipe Refurbishment System to reinforce a 2 metre long section of heavily corroded steel pipe before the line was breached and required a complex leak repair.

Case Study Data

Site
Industrial site
Location
Saudi Arabia
Repair Type
Pipeline reinforcement and protection
Defect
Heavy corrosion to a 600mm patch causing a serious weakening of the line

Products Used

Sylmasta AB Original Epoxy Putty
Two part epoxy putty offering excellent protection against corrosion and chemical attack used to rebuild the weakened area

SylWrap CR Pipe Repair Bandage
Composite repair wrap specially formulated to prevent corrosion and strengthen pipes in aggressive environments

Case Study PDF

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Case Study Details

The steel pipe was suffering from a 600mm patch of very heavy corrosion to its external surface. It was only a matter of time until the pipe was breached, at which point the site would have been forced to shut off the line whilst either the leak was sealed or a new section was installed.

To avoid this, it was decided to rebuild and strengthen the line before corrosion could eat all the way through the metalwork. The first stage of repair involved rebuilding the area weakened by corrosion, bringing it back up to full specification.

Heavily corroded section of pipe before undergoing repair using the Sylmasta Pipe Refurbishment System
Heavy corrosion to the pipe looked like to breach the line in the near future

Because the corrosion was impacting only a relatively small area of pipe, it was decided to use Sylmasta AB Original Epoxy Putty to fill in the damage and restore the integrity of the line. Had the damage been on a much larger scale, an epoxy paste like Industrial Metal would have been applied using a hand tool.

Sylmasta AB is a super strength putty filled with ceramic to make it harder wearing. A two hour work time means it is more suitable for warmer climates like Saudi Arabia, where the cure is often accelerated by the natural temperature.

AB Original offers excellent protection against corrosion and chemical attack. In chemically aggressive environments, it can be used as a sacrificial layer to protect pipes and metalwork.

Heavily corroded section of steel pipe having undergone repair with Sylmasta AB Original Epoxy Putty
Sylmasta AB was applied across the entire corroded section, restoring the integrity of the line

The two parts of the putty were mixed by hand in equal measures. It was then pushed down onto the pipe, where it cured to strengthen the heavily corroded areas by increasing the thickness of the pipe back towards its original specification.

Once the putty had cured, SylWrap CR Corrosion Protection Wrap was applied over the top to further protect the repair. SylWrap CR is a black-coloured composite repair bandage incorporated with highly effective corrosion inhibitors.

It has been specially formulated to protect pipes, metalwork and other structures in harsh and aggressive environments against corrosion. SylWrap CR was activated with water and then wrapped and smoothed along a 2 metre section of the pipeline.

The pipe was reinforced with SylWrap CR to complete the repair

Within minutes, it began to cure rock hard. Once set, SylWrap CR formed an impact resistant shell around the pipe to further strengthen it from future attack and remove the prospect of a breach in the line.

Completing the repair from the first kneading of Sylmasta AB to the finished application of SylWrap CR took half a day. The line remained in operation throughout, meaning there was no disruption to the site and the reinforcement cost a fraction of a future leak repair or replacement of an entire section of the line.

The site were therefore very pleased that they opted for strengthening the steel pipe before their corrosion problem could develop into a much bigger issue.

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

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

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

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

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

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

Case Study Data

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

Products Used

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Case Study: Permanent Anti Slip Solution to Protect Workers When Standing on Helicopter Skids

The Puerto Rico Power Authority uses Liquid Metal Epoxy Coating to help create ant slip surfaces on helicopter skids

Helicopter health and safety – Keeping workers in Puerto Rico safe by providing anti slip surfaces on helicopter skids

With workers regularly carrying out jobs whilst standing on the legs of helicopters belonging to the Puerto Rico Power Authority, the company decided to seek a permanent solution for creating an anti slip surface for helicopter skids to prevent accidents happening.

Case Study Data

Site
Puerto Rico Power Authority
Location
Puerto Rico
Repair Type
Creation of anti slip surfaces on helicopter skids

Products Used

Liquid Metal Epoxy Coating
Brush applied to bond silicon carbide grit to helicopter legs, creating an anti slip surface

Case Study

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Case Study Details

The Puerto Rico Power Authority operates a fleet of helicopters. The helicopters help workers reach remote areas of Puerto Rico which are difficult to access by road and smaller islands off the mainland.

They are also used to help repair and maintain equipment operated by the company. Some of these jobs required workers to stand on the metal legs of the helicopter. To protect their workers from the very real risk of slipping from the helicopter legs and having a serious accident, the Power Authority applied anti slip tape to the skids.

A helicopter belonging to the Puerto Rico Power Authority

With their helicopters often operating in harsh environments and the anti slip tape not being the most robust of materials, in some instances the Power Authority were having to spend time and money on re-taping skids once a month.

They also had concerns about the safety of the tape. The frequency with which it became worn, damaged and lost adhesion therefore left the Power Authority seeking a long term, trustworthy alternative.

Sylmasta suggested coating each of the helicopter skids with Liquid Metal Epoxy Coating and then applying silicon carbide grit to the wet surface, creating a permanent anti slip surface to better protect workers.

Liquid Metal is a metal-filled, brushable epoxy which is painted onto surfaces to create a new layer. Whilst sticky, it offers high strength adhesion to all materials. Its 90 minute gel time allows careful application without the threat of premature curing.

The epoxy was mixed and then applied via brush across the top of each helicopter skid. Silicon carbide grit was then deposited over the coating of Liquid Metal, completely covering the skid. Once cured, the grit was permanently bonded.

Helicopter skids are provided with a permanent anti slip surface to protect workers standing on the legs of the helicopter
Silicon carbide grit bonded to the helicopter skid with Liquid Metal created a permanent anti slip surface

Within three days, the Power Authority had successfully carried out the procedure to every helicopter in their fleet. Since the application was first carried out 15 years ago, the skids have been re-coated with Liquid Metal and silicone carbide grit once every five years.

A repair every half a decade is a far cry from the laborious task of regularly applying anti skid tape. Workers standing on helicopter legs to keep the power running in Puerto Rico are now much better protected thanks to Liquid Metal.

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 of a Leaking Underground GRP Seawater Return Pipe

An underground seawater cooling system return line undergoes repair using epoxy putty

Sealing in seawater – the rapid repair of a cooling system return pipe that had an oil refinery back online in no time

A rapid epoxy putty repair made to an underground 3000mm FRP return pipe in a seawater cooling system cut downtime at an oil refinery to just two days of reduced production, compared to several weeks for a replacement section to be fitted.

Case Study Data

Site
Oil refinery
Location
Saudi Arabia
Repair Type
No pressure leak repair
Defect
Cracks in an underground 3000mm GRP seawater cooling system return pipe

Products Used

Superfast Copper Epoxy Putty
Fast-working epoxy putty with a cure time of under five minutes used to permanently seal small holes and cracks on pipes of all diameters

Sylmasta AB Original Epoxy Putty
Epoxy putty with a longer work time, allowing more to be mixed and applied to larger cracks without the threat of premature curing

Case Study PDF

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Case Study Details

The oil refinery was one of the biggest in the Middle East, processing approximately 400,000 barrels per day. Various processes at the site relied upon the seawater cooling system, which extracted water from the Red Sea and transported to and from the refinery.

This was done via a network of underground 3000mm GRP (glass reinforced plastic) lines. Whilst such large pipes enabled vast quantities of seawater to be moved around, any failure would have a hugely detrimental impact on the efficiency of the system and cause massive water loss unless attended to as a matter of urgency.

A potential problem with the return line was first flagged when the ground above a section of buried pipe was noticed to be wet. The line was taken out of service and excavation organised, leading to a hole being dug to access the top 50 percent of the vast pipe.

The earth surrounding the pipe was thoroughly saturated, indicating a significant leak. When pressure was then turned back on, so much water escaped from several areas that the hole was instantly flooded. This water had to be pumped out to regain access to the line.

So much water escaped the line when pressure was restored that the hole dug to access the pipe became heavily flooded

Clearly, the pipe could not go back into service leaking so much water until it had been sealed. This was problematic for the refinery, who needed the line in operation for oil to be produced at full capacity. For this reason, replacement of the damaged section was not considered an option as it would have left the line out of action for up to three weeks.

With a rapid repair required, it was decided to use two epoxy putties to seal the seawater cooling system return pipe. For the smaller cracks on the line, Superfast Copper Epoxy Putty Stick was chosen. Although designed for copper pipe repair, it adheres to all materials and comes with a fast work time.

Epoxy putty applied to repair a seawater cooling system return line at an oil refinery in Saudi Arabia
Superfast Copper applied to seal the smaller cracks in the pipe

Superfast Copper is supplied in a 114g stick containing pre-measured resin and hardener. The required amount of putty was cut from the stick, kneaded by hand, and then pushed into the cracks on the GRP line whilst soft.

The heat of Saudi Arabia accelerated the five minute cure time of Superfast Copper so that within a couple of minutes, the putty began to set to a material as hard as steel, permanently fillin the cracks and starting to seal the line.

Sylmasta AB Original was used for the larger cracks because of its extended cure time

For the bigger cracks, a putty with a longer work time was needed so that greater quantities could be mixed and then applied over larger areas without the threat of premature curing. Sylmasta AB Original Epoxy Putty was used for both its two-hour cure and its availability in bulk sizes far beyond the 114g per stick offered by Superfast Copper.

Both Sylmasta AB and Superfast Copper achieved maximum properties after 24 hours. Applying the epoxy putties to all leak areas took less than four hours. A day later and the system was turned back on.

Completed repair of a leaking 3000mm FRP seawater cooling system return pipe using epoxy putty at an oil refinery in Saudi Arabia
The line was successfully sealed using epoxy putty

Once it had been established that no water was now leaking from the pipe, the line was reburied. Whilst the repair was carried out, the refinery had to operate below full capacity for only two days with all the required materials costing under £100 – a far cry from the disruption and expense which would have come with replacing the damaged 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

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Case Study: Protection of Wooden Entrance Gates at an Estate in Scotland Against Rotting

An entrance gate at an estate in Scotland where wood slats were protected from rot using Sylmasta AB Original Epoxy Putty

Stopping the rot – the ingenious solution an estate in Scotland found for the protection of wood slats on an entrance gate

When upgrades to an entrance gate at an estate in Scotland left an area where rainwater could pool and potentially rot wooden slats, protection was provided for the wood through a clever piece of engineering involving epoxy putty.

Case Study Data

Site
Country estate
Location
Scotland
Repair Type
Rot protection
Defect
Wooden slats on an entrance gate with the potential to be damaged by static water

Products Used

Sylmasta AB Original Epoxy Putty
Versatile epoxy putty with a longer work time which cures to create an ultra-smooth, waterproof material

Case Study PDF

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Case Study Details

The estate was located in beautiful open countryside. When Storm Arwen brought wind gusts in excess of 90mph to Scotland in November 2021, the wooden gates were an easy victim to the violent weather and subsequently became damaged.

In response, the estate decided that more robust gates would need to be installed to withstand future storms. A heavy steel frame was constructed for each gate with wooden slats attached to the frame via stainless steel self-tapping screws, providing a much stronger structure.

A new, robust steel frame constructed for the gates

One problem was identified during the construction of the new gates – the potential for rainwater to gather in a groove at the base of the frame. Static water left here would have no means of escape other than evaporation. Where this water came into contact with the wooden slats, it would eventually lead to rotting of the bottom of the slats.

To overcome this, the estate had the ingenious idea of creating a bevelled edge using a waterproof epoxy putty between the base and the frame behind it. Water would be diverted onto the ground instead of pooling at the bottom of the frame.

Sylmasta AB Original Epoxy Putty was chosen for the application because of its waterproof qualities and two-hour work time, enabling the putty to be shaped and formed without the threat of premature curing.

Sylmasta AB Original Epoxy Putty used as a means of protection against rot for wood slats on an entrance gate at a Scottish estate
AB Original formed into a bevelled edge to prevent water pooling at the bottom of the frame
Epoxy putty used to create a bevelled edge, diverting rainwater away from wood slats as a means of rot protection
Putty was applied along the entire length of the base of the frame

AB Original was mixed by hand. The putty was pushed onto the frame, easily adhering to the steel before being moulded into the required bevel. The bottom of each slat had been similarly bevelled, leaving a 5mm gap separating the wood and the putty.

Once set, AB Original provided an ultra-smooth run off. Rainwater would now drip down this run off, through the gap between putty and slats and onto the driveway below.

The bevel created with putty hidden behind the bottom of each slat
The gates were painted a uniform colour before being installed

The steel frame, wooden slats and epoxy putty were then coated in a protective paint. The paint was a beige colour, disguising the steel frame and the epoxy putty to make the entire structure appear uniformly made of wood.

Since being installed, the new gates have proven to be far more robust against the extreme Scottish weather. The application constituted a fine piece of engineering involving some out-of-the-box thinking which should last a very long 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: Repair & Refurbishment of Corroded 20 Metre Long Porth Pipe Bridge

The repair and refurbishment of a pipe bridge crossing the Rhonda River made using the Sylmasta Pipe Refurbishment System

Troubled bridge over water – the repair and refurbishment of a dilapidated steel pipe bridge crossing the Rhonda River

Sylmasta and Arch Services repair and refurbish a dilapidated 20-metre long pipe bridge crossing the Rhonda River in Porth, South Wales, helping to save Dwr Cymru Welsh Water from an expensive replacement of the heavily corroded structure.

Case Study Data

Site
Pipe bridge
Location
Porth, South Wales
Repair Type
300mm steel pipe bridge repair
Defect
Significant cracking and weakening of line caused by corrosion

Products Used

Liquid Metal Epoxy Coating
Brush applied to coat pipes and structures with an ultra-smooth, hard wearing, metallic surface

SylWrap CR Pipe Repair Bandage
Composite repair wrap specially formulated to prevent corrosion and strengthen pipes in aggressive environments

Case Study

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Case Study Details

Sylmasta were contacted by Dwr Cymru Welsh Water for advice on repairing and extending the lifespan of a dilapidated pipe bridge crossing the Rhonda River in Porth, South Wales. The bridge was gravity fed and made up of a 300mm diameter, 20 metre long steel pipe rested inside an angle-iron structure for support and protection.

For such a complex project, it was recommended that the four-stage Sylmasta Pipe Refurbishment System be used as a starting point. A final decision on the repair elements required would be decided once the pipe had been fully inspected.

Dwr Cymru official contractors appointed Arch Services of Porth to carry out the work, and it was agreed that Sylmasta would keep in close communication throughout the project to deal with any questions that might arise.

A heavily corroded pipe bridge prior to undergoing repair by Sylmasta
The steel pipe was covered in corrosion, which had eaten through in places

On inspection, the pipe was discovered to be totally covered in corrosion. This had eaten completely through the steel in several places along the top of the pipe, leaving large holes in the brittle surface.

As these holes were too large or delicate to be repaired with epoxy putty, Arch decided to use fibreglass patches layered over the cracked sections of pipe to seal the leaks. The entire pipe was then coated with Liquid Metal Epoxy Coating.

Liquid Metal is a metal-filled, brushable epoxy. After being coated onto the pipe, it cured to form a smooth, metallic, hard-wearing surface. Several layers of Liquid Metal were used to create an impermeable skin around the original pipe, preventing any further corrosion to the steel and ensuring fluids could no longer escape.

Liquid Metal Epoxy Coating applied to pipe bridge in South Wales to rebuild the corroded outer layer of the pipe
Liquid Metal created an ultra-smooth, hard-wearing metallic surface around the pipe

The 90 minute gel time of Liquid Metal allowed significant amounts of epoxy to be mixed without the threat of premature curing. Arch Services used a roller to apply each coating to a 1mm – 2mm thickness, also painting with Liquid Metal the corroded steel hoops and beams which held the pipe in place.

To further reinforce the pipe and reinstate its integral strength, it was wrapped with four layers of SylWrap CR Corrosion Protection Wrap. SylWrap CR is a composite repair bandage incorporated with highly effective corrosion inhibitors.

SylWrap CR was carefully applied along the length of the pipe, further reinforcing the repair

It has been specially formulated for the prevention of corrosion and the protection and strengthening of pipes, metalwork, and other structures in harsh and aggressive environments.

SylWrap CR was applied to the pipe whilst the final coating of Liquid Metal remained tacky. The resin in SylWrap CR was activated with water and the bandage tightly wrapped and smoothed around the pipe.

SylWrap CR Corrosion Protection Wrap used to reinforce and repair a pipe bridge in Porth, South Wales
The completed repair along the 20 metre length of the pipe

Within minutes, SylWrap CR cured to form a rock-hard, impact resistant shell around the pipe. Arch Services were particularly careful in ensuring that no area of the pipe was left without SylWrap CR. This required precision application close to the steel hoops.

The final result was a very smart pipe bridge now well protected from future corrosion and reinforced against breaches by Liquid Metal and SylWrap CR. Arch Services have subsequently become Sylmasta’s approved contractor for similar projects after their excellent documentation of the process and attention to detail.

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

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

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

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

Pump it up – the repair which allowed a water treatment plant to keep pumping water from their below ground well

Sylmasta provide a long-term repair solution for a water treatment plant in Puerto Rico, whose pump extracting from a below ground well had become heavily worn due to minerals and sediment in the water.

Case Study Data

Site
Water treatment plant
Location
Puerto Rico
Repair Type
Damage repair
Defect
Heavily worn pump extracting water from a well

Products Used

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

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Case Study Details

The large water pump was used by the water treatment plant to extract water from a well. The water was then distributed around the entire site for various purposes, making the pump central to operations.

This natural groundwater contained minerals, sediments and impurities which caused deterioration to the pump. Over time, the pump became so worn and degraded that there was a substantial risk of bursting.

A burst would have been a disaster for the plant. Operations would have needed to be shut down and a replacement pump fitted. This would have been a costly and time-consuming exercise, potentially involving the fabrication of a new pump and its shipping to Puerto Rico.

Before the water well pump reached the stage whereby it needed to be replaced, the treatment plant decided to repair and reinforce the system using a hard-wearing, abrasion resistant coating.

Ceramic Brushable Green Epoxy Coating was used for the application. Ceramic Brushable is reinforced with silicone carbide, giving it a toughened, ultra-smooth finish.

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

Ceramic Brushable Green Epoxy Coating used to repair a well water pump which had become extremely worn at a treatment plant in Puerto Rico
The well pump repaired and strengthened with Ceramic Brushable Green

The two parts of the epoxy coating were mixed in the prescribed ratios and then brushed onto the pump. The 90 minute gel time of Ceramic Brushable enabled more epoxy to be mixed and applied without the threat of premature curing.

Four coatings were used, each between 1mm and 2mm thick. This built up a substantial, reinforced shell around the worn pump to restore the weakened metalwork to its original thickness.

With a recoat time of around four hours, it took two days to complete the repair. The application took place over night whilst the site was shut down to limit disruption and the cost was insignificant compared to fitting a new pump.

The treatment plant now monitor the pump on a regular basis for future wear caused by corrosion and erosion. When there are concerns that it is becoming too weak, further coatings of Ceramic Brushable are added to restore integrity.

Speaking about the process, the maintenance manager at the plant said: “The pump deteriorates very soon but coating it in Ceramic Brushable helps a lot.” In this way, Sylmasta have provided a cost-effective and long-term solution.

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

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

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

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

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

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

Case Study Data

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

Products Used

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


Case Study Details

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

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

The shaft on the mill wheel had been damaged by abrasion

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

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

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

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

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

The shaft underwent an extreme mechanical clean prior to repair

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

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

Titanium Supergrade Epoxy Paste was mixed and applied to the shaft

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

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

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

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

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

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

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

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