Category: Case Studies

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Case Study: Alcohol Line Live Leak Pipe Repair at Sugar Mill in Costa Rica

Live leak pipe repair made to an alcohol line at a sugar mill in Costa Rica

The alcohol line repair which had a sugar mill in Costa Rica raising a glass of guaro to the SylWrap Pipe Repair Contractor Case

Having a SylWrap Pipe Repair Contractor Case on site enabled a sugar mill in Costa Rica to make an instant live leak pipe repair when a pinhole was discovered in an alcohol line running vertically up a tower.

Case Study Data

Site
Sugar mill
Location
Costa Rica
Repair Type
Live leak pipe repair
Defect
Pinhole leak in 70mm alcohol line

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 to reinforce and protect repairs

SylWrap Pipe Repair Contractor Case
Products were part of a Contractor Case kept on-site, capable of making up to six live leak repairs

Case Study PDF

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Case Study Details

A SylWrap Pipe Repair Contractor Case contains enough products to seal up to six live leaks, making it the ideal kit to keep on-site for rapid response to emergences.

The sugar mill had approved its use several years earlier. Because the milling season in Costa Rica lasts only around four months, efficiency is paramount. Any downtime, disruption or delays to production are costly.

Numerous repairs had since been made by the sugar mill using their stock of Contractor Cases. These included 90 degree elbow bends in elevated pipelines and a particularly challenging Y-joint leaking from the exact point where three separate pipes connected. Most of these pipes carried hot water.

Previous repairs made by the mill using Contractor Cases

The leaking alcohol line was 70mm in diameter and transported alcohol juice extracted from sugar cane during fermentation, which would eventually be used in the production of spirits including rum and guaro, the official liquor of Costa Rica.

It ran vertically up the tower, with the leak developing in a weakened section as the line passed through a circular hole in one of the upper floors. Alcohol juice was left spraying through the pinhole at around two bar pressure.

Alcohol juice extracted from sugar cane escaping through a pinhole leak in a 70mm steel pipe before repair
Alcohol juice spraying out of the pinhole leak in the pipe

As the pipe could not be isolated, Wrap & Seal Pipe Burst Tape was used as the leak sealant. Wrap & Seal is made from self-amalgamating silicone. When stretched by up to three times its length as it is wrapped around a pipe, the Tape fuses to form a solid rubber band capable of sealing live leaks .

Despite the space constraints around the pipe where it passed through the hole in the floor, the engineer making the repair managed to stretch the Tape to a suitable length so that it amalgamated successfully.

Wrap & Seal Pipe Burst Tape seals a live leak in an alcohol line at a sugar mill in Costa Rica
Wrap & Seal Pipe Burst Tape sealed the live leak

Once the engineer was satisfied the leak had been fully arrested and alcohol was no longer escaping, a SylWrap HD Pipe Repair Bandage was applied over the top to reinforce the Wrap & Seal.

SylWrap HD is a composite repair wrap containing a water activated resin. As it was wrapped and smoothed around the Wrap & Seal, it cured to form a rock-hard protective sleeve over the pipe.

SylWrap HD Pipe Repair Bandage applied during the live leak repair of an alcohol line at a sugar mill
SylWrap HD reinforced the repair with an impact resistant layer of protection

Both Wrap & Seal and SylWrap HD have WRAS approval, meaning they are safe to use with drinking water. The sugar mill were therefore reassured that neither product would affect the alcohol juice inside the pipe.

Because the sugar mill already had all the products required to repair the pipe on-site in their Contractor Case, it took less than 20 minutes to seal the alcohol line from the moment the pinhole was discovered.

Only a minimal amount of alcohol juice escaped thanks to the speed and ease of the repair. All systems remained fully operational, meaning there was no disruption whilst the application took place.

Had a Contractor Case not been available, a much greater quantity of juice would have been lost. The mill may have even been forced to shut down the leaking section until such time as it could be repaired at significant cost both financially and to production.

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 & Corroded Shared Water Supplying Eight Cottages

Liquid Metal Epoxy Coating used in the repair of a corroded shared water supply pipe

Cottages counter corrosion – the Sylmasta Pipe Refurbishment System is used to repair and reinforce a water supply line shared by eight properties

Four cottages in a terrace of eight in London use the Sylmasta Pipe Refurbishment System to repair and reinforce their respective sections of a 48 metre long shared water supply pipe weakened and breached by corrosion.

Case Study Data

Site
Terraced cottages
Location
London, UK
Repair Type
Leak repair and pipe reinforcement
Defect
Heavily corroded 48 metre long steel shared water supply pipe breached in places

Products Used

Superfast Aqua PW Epoxy Putty Stick
Fast working, WRAS approved epoxy putty with excellent wet surface adhesion used to seal leaks in pipework

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

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

Case Study PDF

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Case Study Details

The row of eight terraced cottages were built in the middle of the 19th century. They were connected to the public water network at a later date, which led to a somewhat unusual setup involving an above-ground shared supply pipe.

This steel pipe connected with a water main underground at one end of the terrace. It rose up the side of the first cottage and was then fixed at a height of around three metres to the back wall of all eight properties, along which it ran for 48 metres.

The height of the line meant it was surrounded by extensions built onto the cottages, downpipes, guttering and other installations and improvements added to the buildings over time. Access to certain sections was therefore severely restricted.

Lagging being removed from the section of pipe climbing up the side wall. The line then ran for 48 metres along the back of the cottages.

Each cottage was responsible for the section of pipe outside their property, giving them around six metres to maintain and upkeep. Lagging had been added around all 48 metres of the line to protect it during winter.

Unfortunately, low-quality insulation material was used which soaked up moisture like a sponge, causing water and condensation to become trapped against the steel. Over time, this led to heavy corrosion and a weakening of the pipe.

When temperatures in London dropped as low as -8°C in an unusually cold spell and water inside the pipe froze, the brittle metalwork was unable to cope. Several cracks appeared outside one cottage, requiring repair.

The lagging was removed from the leaking section to access the pipe, at which point the extent of the corrosion problem became clear. The other seven cottages were inevitably going to suffer from bursts on their sections in future if something were not done.

Corrosion covered the pipe where it ran along the back wall of the cottages

Initially, the cottages contacted their water company for help. Because the pipe was a shared supply line and not part of the public network, the water company said they had no responsibility for it. It was therefore down to the eight property owners to find a solution themselves.

The cottages were quoted £22,000 to replace the entire line. Some of the property owners did not wish to contribute £2,750 towards the cost, preferring instead to take a chance their section would not burst.

It next became clear that replacing individual sections of pipe for those cottages wanting to avoid future leaks would not be practical either. New fittings would struggle to connect with old, brittle pipes not being replaced.

Installation would also be disruptive to those cottages not undertaking work, with shared electrical boxes and satellite dishes having to be taken out of service whilst new sections of pipe were fitted.

With no common route forward found, the cottage with the leaking section contacted Sylmasta for advice on sealing the holes on their part of the line. At this point, the owner also explained the complications caused by the shared water supply pipe and the concern about how it might deteriorate further.

Sylmasta suggested that in addition to sealing the cracked section of pipe outside one cottage, their Pipe Refurbishment System be used to reinforce individual sections along the line for those property owners wanting protection against future leaks.

Two cottages requested their sections be attended to, and so Sylmasta sent an approved contractor to London to carry out the repair and strengthening of the shared water supply pipe.

Superfast Aqua PW Epoxy Putty used to repair a crack in a heavily corroded shared water supply line
Superfast Aqua PW Epoxy Putty sealed the holes in the section of pipe which had burst

Once the lagging had been removed, the first stage of the Pipe Refurbishment System involved application of the leak sealant – in this case, Superfast Aqua PW Epoxy Putty.

Superfast Aqua PW was chosen for its excellent wet surface adhesion to alleviate concerns the pipe may have been weeping water. It has WRAS approval, meaning it is certified as safe to come into contact with potable water.

Aqua PW is supplied in a pre-measured 114g stick. The required amount of putty was cut from the stick, kneaded by hand and then pushed into the cracks and damage in the pipe whilst soft. Within 20 minutes, it cured to form a rock-hard sealing material.

Liquid Metal could be easily painted onto difficult-to-access areas of the pipe

The second stage of the Pipe Refurbishment System saw Liquid Metal Epoxy Coating applied to strengthen the line and protect it from corrosion. Liquid Metal was painted on by brush to sections of the pipe outside every cottage who wanted their part of the line reinforced.

Repair of a shared water supply pipe made using Liquid Metal Epoxy Coating
Liquid Metal coated around a bend in the repair of a shared water supply line
Liquid Metal applied during the repair of a section of shared water supply running awkwardly behind a gutter down section
Liquid Metal coated onto the pipe to form a new metallic outer surface

Once cured, Liquid Metal formed a smooth, metallic, hard-wearing outer surface around the pipe to act as a shield against external corrosion. Should the brittle steel be breached from the inside by freezing temperatures in future, the Liquid Metal shell will contain the contents of the pipe.

Liquid Metal Epoxy Coating brush applied during the repair of a corroded shard water supply line
The cottages who did not wish for their sections of pipe to be reinforced were left with the original lagging and corroded pipe, contrasting with the refurbishment provided by Liquid Metal

SylWrap HD Pipe Repair Bandage was added as the final stage of the Pipe Refurbishment System, to provide the shared water supply pipe with another layer of protection. SylWrap HD is a composite repair wrap with a water-activated resin which sets rock-hard in minutes when wrapped and smoothed around pipework.

SylWrap HD Pipe Repair Bandage reinforces a shared water supply pipe during a repair
The pipe was given further protection using SylWrap HD Pipe Repair Bandage

Nine SylWrap Bandages were applied per cottage to build up thickness to four layers, with the application taking place whilst the Liquid Metal remained tacky to improve adhesion to the pipe. Once cured, SylWrap HD formed an impact resistant shell encompassing the pipe.

In addition to the two planned repairs, a third cottage owner asked for their section to be reinforced, having seen how straightforward and cost-effective the process was. Their part of the shared water supply pipe had not been as badly weakened by corrosion and therefore required only Liquid Metal for suitable strengthening.

All three cottages were completed in a single day, with the approved contractor also installing new lagging to replace the original insulation which had to be removed. A fourth cottage then requested the approved contractor return and attend to their part of the pipe, meaning half the 48 metres had been reinforced.

Lagging installed for insulation during the repair of a shared water supply pipe
Lagging added to complete the repair

Around one year after the original repair and a fifth cottage contacted Sylmasta. 12 months of further corrosion had left their section of the pipe on the verge of collapse.

Refurbishment of this section was now far more challenging and costly than the repair the other four cottages had opted for – highlighting the benefits of strengthening and protecting systems before more serious problems develop.

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: Luxury Portable Toilet Trailer Leaking Wastewater Holding Tank Repair

The wastewater holding tank of a luxury toilet trailer undergoes repair and refurbishment

Repair and refurbishment helps a portable toilet company avoid flushing two working luxury trailer units down the drain

Holding tanks with the capacity to store 3000 litres of wastewater underneath two luxury portable toilet trailers undergo repair and strengthening after the metalwork became weakened by corrosion, causing numerous holes to appear.

Case Study Data

Site
Luxury Portable Toilet Trailer
Location
United Kingdom
Repair Type
Tank repair and refurbishment
Defect
Heavy corrosion to two wastewater storage tanks

Products Used

Sylmasta AB Original Epoxy Putty
Epoxy putty pushed into holes and cracks in tanks and pipes, where it will cure to a rock-hard material which permanently seals leaks

Liquid Metal Epoxy Coating
Brush applied coating which strengthens and protects metalwork by forming a new metallic, hard-wearing surface

Case Study PDF

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Case Study Details

Luxury portable toilet trailers are mobile restroom facilities used for large outdoor occasions, such as music festivals and sporting events. They include flushing toilets, urinals, sinks with running water, mirrors and lighting, offering a much more comfortable experience than standard portable toilets.

Toilet trailers require no connection to permanent plumbing. Instead, the wastewater they produce is stored in holding tanks between the floor of the restroom and the undercarriage of the trailer. When the event has finished, the tanks are drained and the wastewater taken to a treatment site before the trailer is moved onto its next destination.

Constructing a portable toilet trailer is expensive, and so when one of the United Kingdom’s leading suppliers discovered holes starting to appear in the wastewater holding tanks of two of their units, they contacted Sylmasta for advice on whether a repair was feasible.

Damage to the underneath of the first portable toilet trailer
The second trailer was suffering from more extensive corrosion and surface damage

The plumbing, fixtures and fittings in each of the trailers were otherwise in perfect working order. The company therefore wanted to avoid decommissioning the two trailers if the holes in the wastewater tanks could be plugged and the weakened metalwork strengthened against future damage.

Sylmasta recommended a two-stage repair, starting with Sylmasta AB Original Epoxy Putty and finished with Liquid Metal Epoxy Coating. The first trailer was jacked up, enabling access underneath the wastewater holding tank. The metalwork was then ground down to remove rust, dirt and grime.

AB Original Black was supplied in stick format for the plugging of the holes. An AB Original Stick combines the resin and hardener pre-measured rather than in a tub of Part A and a tub of Part B, eliminating the need for weighing out and mixing separate components. This makes a repair quicker and easier.

AB Original Epoxy Putty used to seal leaks in a portable toilet trailer wastewater tank repair
Wastewater tank underneath a portable toilet trailer undergoes repair and sealing using Sylmasta AB Original Epoxy Putty
A significant number of holes underneath trailer one sealed with AB Original Black Epoxy Putty.
Holes underneath trailer two sealed with AB Original Black

The required amount of putty to fill a hole was cut from the stick and kneaded by hand. Once the putty had turned a uniform black colour but was still soft, it was pushed into the hole. After two hours, AB Original cured to form a rock-hard sealing material. Every hole in the tank was permanently filled in this way.

Once all the holes had been attended to, the entire bottom of the trailer – an area 1.3 metres by 2.5 metres – was painted with Liquid Metal Epoxy Coating. Also painted were the metallic box and pipe fitted to the bottom of the holding tank, through which wastewater was removed. Two coatings of Liquid Metal were brush applied, curing to form a smooth, metallic, hard-wearing surface.

This new surface repaired and strengthened the weakened metalwork to increase structural integrity. It acted as a protective shield against further external corrosion and encased the wastewater tank in a new outer shell, capable of containing the wastewater if the original metalwork became fully breached in future.

Trailer one coated with Liquid Metal to complete the repair
Liquid Metal coated onto the wastewater storage tank of a portable toilet trailer to complete a corrosion protection repair
Liquid Metal Epoxy Coating used to protect a portable toilet trailer from corrosion during a repair and refurbishment
Trailer two having been reinforced and refurbished with Liquid Metal

After the repair of the first toilet trailer was completed, the second was jacked up and fixed by following the exact same process. Each trailer could go back into service 24 hours after the second coating of Liquid Metal had been applied.

In total, 10kg of AB Original and 10kg of Liquid Metal were used to repair the two portable toilet trailers at a cost of under £800, representing a huge saving on replacing the units. The company are now planning to use the repair method on other units when they become weakened by corrosion, potentially extending the lifespan of their entire fleet by up to 10 years.

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: Reassembly & Repair of Composite Stone Water Fountain Cracked into Pieces

A composite stone water fountained cracked into multiple pieces undergoes repair and reassembly

Water fountain repair cracked – putting the pieces of a favourite garden ornament back together

A tiered composite stone water fountain in a Welsh garden undergoes a DIY repair after winter temperatures caused water left inside the upper bowl of the ornament to freeze, cracking it into multiple pieces.

Case Study Data

Site
Garden
Location
Wales
Repair Type
High-strength bonding and stone repair
Defect
Composite stone water fountain cracked into multiple pieces

Products Used

Sylmasta Rapid 5 Minute Epoxy Adhesive
Epoxy adhesive with a five-minute work time which creates high-strength, permanent bonds between all materials

Sylmasta AB Original Epoxy Putty
Hard-wearing epoxy putty used to fill gaps and replace missing sections of damaged stonework

Case Study PDF

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Case Study Details

The water fountain consisted of two tiers and was made from composite stone. When winter temperatures in Wales plummeted below -10°C, the upper bowl cracked into several pieces due to water inside it freezing.

When Spring arrived, the owner of the water fountain decided to try and repair and restore their favourite ornament. Not only did the upper bowl need to be bonded back together, but there were numerous other cracks and missing sections requiring attention.

A badly cracked bowl from a composite stone water fountain before undergoing a Sylmasta repair
Crack lines show the significant damage across the entire upper bowl of the fountain

Sylmasta advised that Rapid 5 Minute Epoxy Adhesive be used first to reassemble the fountain. Rapid 5 Minute creates high-strength, permanent bonds between many materials, including composite stone.

The five-minute cure meanwhile is long enough for parts to be carefully assembled and rearranged if necessary before the adhesive sets, at the same time as requiring minimal holding or clamping.

Rapid 5 Minute comes with the two components that make up an epoxy adhesive – resin and hardener – kept separate. The 25ml cartridge extrudes the parts in equal measures, after which they are mixed together for around 30 seconds with a spatula.

The fountain owner extruded the epoxy onto a piece of cardboard for mixing. The mixed adhesive was then applied using the spatula to one of the surfaces to be bonded, and the pieces pushed together and held in place.

A bowl from a composite stone water fountain cracked into two pieces underwent repair with Sylmasta Rapid 5 Minute Epoxy Adhesive
The two largest pieces of upper bowl after the cracks caused it to completely come apart

Any overspill of epoxy was thoroughly cleaned off the stonework. Rapid 5 Minute exposed to sunlight can yellow with age, which would have looked unsightly against the pale coloured fountain.

After five minutes, the stonework no longer needed to be held together as Rapid 5 Minute had begun to set. The fountain was left undisturbed for a further 30 minutes, allowing the epoxy adhesive to reach maximum properties.

Once the upper bowl had been reassembled, any remaining cracks and missing sections were filled in using Sylmasta AB Original Epoxy Putty. AB Original is a hard wearing, waterproof, ceramic-filled putty which bonds to all materials.

It offers a two-hour work time, enabling the putty to be mixed, moulded into shape and applied without any worry about premature curing. It is suitable for use in interior or exterior settings and achieves a full cure in 24 hours.

Cracks in a stone water fountain are barely visible after repair using Sylmasta AB Epoxy Putty
Cracks and missing chunks were filled with AB Original, which can just about be identified as the off-white colour down the centre of the stonework

The putty was kneaded by hand until it turned a uniform colour. It was then shaped and formed to replace missing areas of stonework and pushed into cracks. For shallow cracks, the surface of the curing putty was wetted whilst still pliable to create a type of slurry which could be worked further in.

To help disguise larger sections of AB Original, powdered dust from the stonework was pressed into the putty. This took it from its standard off-white and towards the colour of the fountain, helping the repaired areas blend in.

Once the repair was completed, the water fountain retuned to full working order

The owner even discovered that painting yoghurt onto the fountain helped further disguise the repair by encouraging lichen and moss to grow. The distressed touch this added was in keeping with the original stone.

Once the repair and restoration had been completed, the end result was a robust and fully watertight upper bowl. The fountain could go back into use for the summer with any visitors to the garden none the wiser that just a few months earlier, it had been cracked into multiple pieces.

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 Hairline Crack Around Diameter of Porcelain Toilet Soil Pipe

Wrap & Seal Pipe Burst Tape seals a hairline crack in a porcelain toilet waste pipe repair

Soil pipe sealing – Wrap & Seal forms a rubber ring to repair a porcelain toilet

A homeowner carries out a DIY pipe repair to a porcelain soil pipe which developed a hairline crack around its entire diameter after an unstable bathroom floor caused the toilet to shift away from the wall it was connected to.

Case Study Data

Site
Bathroom
Location
United Kingdom
Repair Type
Leak repair
Defect
Hairline crack in porcelain soil pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape which formed a watertight rubber ring to encompass and seal the pipe

Case Study PDF

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Case Study Details

The porcelain soil pipe connected the bowl of the toilet with the sewer pipe behind. The increasingly unstable bathroom floor meant that whenever anyone sat on the toilet, it tilted forward and pulled the pipe away from its fixed connection to the back wall.

Eventually, the stress being put on the pipe by the frequent movement of the toilet caused a hairline crack to appear around the entire diameter, through which water dripped whenever the toilet was flushed. This had the potential to make the floor even more unstable.

A hairline crack in a porcelain toilet waste pipe caused by an unstable floor
The crack caused by movement of the toilet pulling the porcelain soil pipe away from its connection to the bathroom wall

The homeowner was planning a full bathroom renovation to address the floor issue, which would include replacing the toilet. They therefore wanted a quick, easy and cost-effective DIY method to repair the porcelain soil pipe until said renovation took place.

There were several challenges with the repair. The crack was too thin to force epoxy putty into and was located on a bend in a difficult position, close to the back wall and with minimal space between the pipe and floor.

The continued movement of the toilet also had to be taken into account. Any repair needed to offer a degree of flexibility, as rigidly fixing the pipe back in place would leave the potential for cracks to develop elsewhere.

Sylmasta recommended encompassing as much of the pipe as possible with Wrap & Seal Pipe Burst Tape to create a watertight rubber ring bonded to the porcelain. This would seal the leak, allow the pipe an element of movement to reduce stress, and prevent water escaping from any other cracks which developed elsewhere in the porcelain.

A hairline crack in a porcelain toilet soil pipe having undergone repair with Wrap & Seal Pipe Burst Tape
Wrap & Seal Pipe Burst Tape created a rubber ring around the entire leak area, sealing the crack

Wrap & Seal is made from self-amalgamating silicone which fuses to itself to form a solid rubber band as it is wrapped around a pipe. One 50mm x 4m tape was enough to cover the leak and the surrounding area susceptible to future cracks.

Despite the space constraints between the back wall, the floor and the toilet bowl, the homeowner was able to stretch the tape to three times its length whist wrapping, creating maximum tension.

The tape easily fused, fully sealing the leak and preventing any more water escaping when the toilet was flushed. Completing the porcelain soil pipe repair took less than 15 minutes and cost under £30, including delivery of the Wrap & Seal Pipe Burst Tape.

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: 3 Metre Section of Corroded Steel Gas Pipe in CHP System Repair & Refurbishment

A heavily corroded steel pipe in a CHP system carrying natural gas undergoes repair with the Sylmasta Pipe Refurbishment System

Combined Liquid Metal and SylWrap HD repair combined heat and power system natural gas pipe

An industrial plant repair and refurbish a three-metre section of steel pipe carrying natural gas in a combined heat and power system after water trapped between the line and an incorrectly installed PVC tape caused heavy corrosion.

Case Study Data

Site
Industrial Plant
Location
Puerto Rico
Repair Type
Pipe refurbishment
Defect
Three metre section of corroded 100mm steel pipe in CHP system

Products Used

Liquid Metal Epoxy Coating
Brush applied coating which cures to form an ultra-smooth, hard wearing, metallic surface over pipes and structures

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

Case Study PDF

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Case Study Details

The pipeline was 100mm in diameter and ran for 365 metres through the plant, carrying natural gas produced by a combined heat and power system. It was hung on a series of U-shaped supports welded to I-beams suspended from the roof of the building.

When originally installed, the pipe had been wrapped with a protective PVC tape. Unfortunately, incorrect application of the tape had left a three-metre section where it was possible for water and condensation to become trapped between the tape and the line.

Removal of the yellow PVC tape revealed very heavy corrosion to the steel pipe

This had led to heavy corrosion, which was particularly prevalent at the bottom of the pipe and the area where the section in question rested on its U-shaped support. The weakened three metres of the natural gas pipe now required strengthening and repair before the steel became breached.

The pipe was cleaned of paint and grime before repair of the corroded surface

The plant decided to use the Sylmasta Pipe Refurbishment System to bring the damaged section of the line back up to specification, by reinforcing the metalwork and giving the pipe greater protection against future corrosion.

First, the U-Shaped support was cut away from the I-beam to enable better access to the corroded area. The PVC tape was removed and rust, grime and paint ground off. Alcoholic cloths were then used to remove any remaining residue from the grinding process.

Liquid Metal applied to repair a natural gas pipe suffering from heavy exterior corrosion
Liquid Metal was brush applied across the three metres of the pipe suffering from corrosion

To repair the damage and restore the pipe exterior, the three-metre section was coated in Liquid Metal Epoxy Coating. Liquid Metal is brush applied and cures to form a smooth, metallic, hard-wearing outer surface which acts as a shield against external corrosion and chemical attack.

The 90-minute gel time of Liquid Metal allowed significant amounts of epoxy to be mixed and painted on without the threat of premature curing. A SylWrap HD Pipe Repair Bandage was then wrapped around the area of the line which had contact with the U-shaped support.

SylWrap HD Pipe Repair Bandage applied to a heavily corroded steel natural gas pipe
SylWrap HD was wrapped around the area of the pipe which came into contact with the U-shaped support, which was to be welded back in place to the I-beam above

SylWrap HD is a composite repair wrap with a water-activated resin. It was applied whilst the Liquid Metal remained tacky and cured within minutes to form a rock-hard, impact resistant outer shell around the pipe. This further increased the thickness of the weakened section and provided an additional layer of protection.

A second layer of Liquid Metal was applied across the three-metre section, including over the SylWrap HD. Although an additional coating on top of the composite bandage is not a required step of the Sylmasta Pipe Refurbishment System, the plant wanted to make the line look aesthetically pleasing with a final metallic finish.

A second Liquid Metal coating was applied over the SylWrap, the U-support welded back in place and the pipe fixed to it via a support clamp

Once the pipe had been refurbished, the removed U-shaped support was welded back to the I-beam. The line was then fixed to the U-shape via a new pipe support clamp fitted to prevent movement caused by vibration. The clamp was also coated in Liquid Metal.

Refurbishing the pipe was carried out with no impact to operations at the plant. It prevented an expensive and disruptive future repair or replacement being needed when corrosion eventually ate through the line.

The ultra smooth finish provided by Liquid Metal compared to the pitting caused by corrosion

The plant were very happy with the outcome and how easy their maintenance team found the application. They are now intending to use Liquid Metal to extend the lifespan of other pipes and structures at both this facility and across other sites.

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 Welded Saddle Joint Repair on 150mm Steel Pipe at Pumping House

A leaking saddle joint welded on a 150mm steel pipe undergoes repair after being found to be leaking from both ends

Saddle up for a complex repair – sealing a leaking welded saddle joint with a 20mm step using Wrap & Seal Pipe Burst Tape

A 150mm steel pipe connected to a pumping house in Malaysia which was leaking from both ends of a welded saddle joint is sealed in a successful repair built up and over a 20mm step between the line and the joint.

Case Study Data

Site
Pumping house
Location
Malaysia
Repair Type
Live leak repair
Defect
Leaking saddle joint on a 150mm steel pipe with a 20mm step

Products Used

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

Case Study PDF

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Case Study Details

The 150mm steel pipe ran water out of the pumping house. The saddle joint had been welded in place to reinforce a capped tee and sat approximately 20mm higher than the original line. One end of the joint was suffering from heavy corrosion.

Water had been found seeping from both ends of the joint, leaving the pipe surface noticeably wet and the ground beneath the pipe sodden. The pipe could not be isolated or replaced because this would involve shutting down the pumping station.

Several repair attempts had failed, including a clamp
A 150mm steel pipe with a heavily corroded saddle joint prior to undergoing leak repair
One end of the saddle joint was suffering from heavy corrosion whilst water was seeping from both

Several repair attempts had been made using different methods by the water company operating the facility, including the use of a clamp and epoxy putty, but none had been successful. The pipe had therefore been left to leak.

Whilst on a visit to Malaysia, a technician from Sylmasta was asked to accompany a engineering team to inspect the pipe and see if a solution could be formulated. They recommended using Wrap & Seal Pipe Burst Tape to start a repair on the original steel pipe and build it up and over the weld, encompassing and sealing either end of the saddle joint.

The pipe was cleaned and prepared before repair

First, an angle grinder was used to sand down the pipe, clean it of loose material and remove corrosion. A first Wrap & Seal Tape was then applied directly next to the step. Wrap & Seal is self-amalgamating and stretches by three times its length, fusing together to form a solid rubber band.

Diagram explaining how to repair a leaking saddle joint weld with a step using Wrap & Seal Pipe Burst Tape
Wrap & Seal application started on the pipe next to the saddle, was built up until level with the step and then continued across onto the joint

With each rotation, the Tape moved closer to being level with the top of the saddle joint. The application continued until enough Wrap & Seal had been applied to bridge the 20mm step between the pipe and the saddle.

Once this had been achieved, Wrap & Seal was applied 50mm across the saddle to achieve a good connection. It was then returned to directly over the edge of the joint.

Once Tape had been built up and over the saddle, wrapping continued immediately over the leak area
Wrap & Seal Pipe Burst Tape applied to a leaking saddle joint in a successful repair despite a 50mm step being present
The finished repair with both ends of the saddle joint sealed

Here, a ridge was created directly over the leak area to increase the pressure resistance of the repair. It was estimated that three Wrap & Seal Tapes needed to be used to seal one end, after which the process was repeated at the other end of the saddle joint.

Because the welded saddle joint had been seeping water slowly, the only way to check whether the application had been effective was to inspect several days later. When the pipe surface was found to be dry, the repair was deemed a success.

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: Burst Copper Pipe Repair in Portable Horse & Dog Shower Unit

A copper pipe burst during freezing winter weather undergoes repair with a SylWrap Standard Pipe Repair Kit

Replacement? Hold your horses – the repair of a burst copper pipe which had a horse shower running again in no time

When freezing winter weather led a copper pipe in a portable horse and dog shower to burst, it required a quick and simple repair method capable of being effective inside the cramped space of the unit.

Case Study Data

Site
Portable horse and dog shower
Location
United Kingdom
Repair Type
Leak repair
Defect
Split in copper pipe caused by freezing temperatures

Products Used

Superfast Copper Epoxy Putty Stick
Fast-working epoxy putty pushed into the crack in the copper pipe to seal it

SylWrap HD Pipe Repair Bandage
Composite repair wrap applied over Superfast Copper to reinforce the initial repair

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

Case Study PDF

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Case Study Details

Showerking are a Sussex-based supplier of portable hot shower units designed for horses and dogs. Units are typically stored in unheated outbuildings. Although designed to handle winter weather, copper pipe in the unit which has not been fully drained becomes prone to bursting during periods of exceptionally cold weather.

When temperatures in the United Kingdom dropped as low as -15°C, several Showerking owners reported burst pipes which rendered their units unusable. If they turned the shower on, water would spray out of the large crack created in the copper pipe.

Freezing temperatures had created a split in the copper pipe

Fortunately, Showerking had already contacted Sylmasta about the possibilities of pipe repair for horse showers. The SylWrap Standard Pipe Repair Kit provided the most suitable method as units would be turned off in the event of leaks or bursts, meaning no pressure to the pipe.

It had been established that the smallest Standard Pipe Repair Kit (SYL-106-NP) was ideal for application because of both the cramped space inside the unit and the difficult shape of the pipework. There were many bends which were unrepairable with a clamp.

Through the relationship between Showerking and Sylmasta, users whose horse showers had suffered burst pipes were directed to the exact product they needed to fix the problem, and had the straightforward repair process explained to them.

Superfast Copper Epoxy Putty used to repair a burst in a horse shower copper pipe caused by freezing temperatures
Superfast Copper Epoxy Putty was used to cover the split

Loose material was removed from the burst copper pipe before repair. Superfast Copper Epoxy Putty Stick was then used to seal the crack. Enough putty to cover the crack was cut from the stick and kneaded by hand until it turned a uniform colour.

Whilst soft, the putty was pushed onto the pipe, encompassing the entire crack. This completed the first stage of the repair. The second stage involved applying a SylWrap HD Pipe Repair Bandage over the Superfast Copper.

A burst copper pipe in a portable horse shower unit repaired and reinforced with SylWrap HD Pipe Repair Bandage
The repair was finished with reinforcement via a SylWrap HD Pipe Repair Bandage

SylWrap HD is a composite repair wrap with a water-activated resin which sets rock hard. The bandage was wrapped and smoothed around the pipe as the Superfast Copper began to harden, forcing the putty into the crack to create a permanent, watertight seal.

Within five minutes of SylWrap HD being applied, the bandage had cured to form a rock hard shell reinforcing the pipe, and which also offered protection from expansion in the future. The completed repair was resistant to 30bar, making it more than capable of holding the pressure the horse shower unit operated at.

The repair took less than 30 minutes from start to finish and the SYL-106-NP Standard Pipe Repair Kit cost under £25 including delivery, returning the £180 Showerking unit to service the same day.

For more information about portable horse and dog showers, please see the Showerking website.

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: Seawater Storage Tank Floor Repair at Gas Processing Plant in Saudi Arabia

Sylmasta AB Original Epoxy Putty used to repair cracks in the floor of a seawater storage tank

Corrosion could have floored this seawater storage tank – until a repair involving Sylmasta AB Original Epoxy Putty

The floor of a seawater storage tank at a gas processing plant in Saudi Arabia undergoes repair after gaps appeared between rubber sheeting, leaving the concrete which coated the bottom of the tank unprotected and exposed.

Case Study Data

Site
Gas processing plant
Location
Saudi Arabia
Repair Type
Floor repair
Defect
Gaps between rubber sheeting leaving concrete tank floor exposed

Products Used

Sylmasta AB Original Epoxy Putty
Waterproof, hard-wearing epoxy putty with a longer work time used to permanently fill gaps and cracks

Case Study PDF

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Case Study Details

The plant collected gasses produced during the extraction of crude oil – such as propane, butane, methane and ethane – and converted them into a number of different chemicals exported worldwide for industrial and agricultural use.

Seawater was extracted from the Persian Gulf and stored in vast metal tanks for use in cooling and other processes on site. The interior of each tank was concrete coated and then lined with rubber matting for protection against corrosion.

Problems with one tank led to it being drained for inspection. This revealed sections of the rubber matting on the floor of the tank had become loosened, lifted and completely broken apart in some places, leaving the concrete lining exposed.

The rubber matting of the tank floor had become damaged, exposing the concrete coating below

There was a risk that this exposure could lead to seawater finding a way through the concrete and coming into contact with the metal frame beneath. This would put the tank in danger of serious and irreparable damaged caused by corrosion. All gaps in the rubber sheeting therefore had to be sealed before the tank could go back into service.

The engineering team carrying out the seawater tank repair decided to use Sylmasta AB Original Epoxy Putty for the application. AB Original is ceramic-filled, making it stronger and harder wearing than other epoxy putties. It is fully waterproof, adheres to wet surfaces and its high chemical and corrosion resistance mean it is often used as a sacrificial layer.

Sylmasta AB Original Epoxy Putty is pushed into cracks to repair a seawater storage tank floor
Sylmasta AB Original Epoxy Putty applied to cracks in the floor of a seawater storage tank to make a repair
Cracks in the coating of a seawater storage tank after repair with Sylmasta AB Original Epoxy Putty
AB Original was used to fill all gaps for the protection of the exposed concrete

AB Original was mixed by hand. Whilst soft enough to shape and manipulate, it was forced into the gaps and cracks between the rubber sheeting and smoothed off with water and a hand tool.

The two hour work time of AB Original allowed large amounts of putty to be mixed and applied without the threat of premature curing. Once hardened, the putty permanently filled every gap with a waterproof material, protecting the concrete lining from seawater exposure.

The repair was completed by coating fibreglass sheets with an epoxy to form a new protective surface over the damaged rubber matting

After the application of AB Original, fibreglass sheets were layered over the rubber matting and coated with an epoxy resin. This created a new reinforced floor surface over the damaged rubber, offering yet another layer between seawater and the metal frame of the tank.

The plant could then put the tank back into operation safe in the knowledge that the metalwork was now far better protected by a combination of concrete, AB Original, rubber matting and an epoxy composite repair.

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: Live Leak Repair of 150mm Cement Coated Steel Pipe on Water Network in Mexico

An underground cement coated steel pipe leaking through an 80mm long split is repaired using a SylWrap Pipe Repair Contractor Case

Contractor Case calling – the cement coated steel pipe repair carried out by engineers in Mexico equipped for every leak

An underground cement coated steel pipe on a water network in Mexico undergoes a live leak repair after excavation followed by the removal of the outer coating revealed a 80mm long split in the line.

Case Study Data

Site
Underground water network
Location
Mexico
Repair Type
Live leak pipe repair
Defect
80mm split in a cement coated steel pipe carrying potable water

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, providing an effective replacement for the removed cement coating

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

Case Study PDF

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Case Study Details

A potential leak was identified on a section of the water supply network running beneath a street. Excavation took place and revealed a cement coated steel pipe suffering from a crack around 15mm wide across the diameter of its outer coating.

There was no sign that any water had escaped through this crack. To inspect the condition of the pipe inside, engineers removed the cement using a hammer and chisel. As the coating was chipped away, water began spraying out from a 80mm long split in the steel pipe.

A cement coated steel pipe suffering from a 15mm crack before undergoing repair with a SylWrap Pipe Repair Contractor Case
A 15mm wide crack had appeared in the cement coating around the steel pipe
As the coating was removed, water began spraying out from a split in the steel pipe

By the time the cement coating had been fully removed from around the leak area, enough water had escaped into the excavation hole to half-submerge the pipe. There was no means of isolating this section of the network and so the only option was to make a live leak repair.

The specialist company involved in the identification of the leak and excavation of the pipe equip all their engineering teams with SylWrap Pipe Repair Contractor Cases, meaning everything needed to seal the pipe was already on-site.

Contractor Cases contain enough WRAS approved products to make up to six permanent live leak repairs to pipes of all diameters and materials. WRAS approval was necessary for this application because the pipe carried potable water.

A split discovered in cement coated steel pipe before undergoing repair with a SylWrap Pipe Repair Contractor Case
Engineers were equipped with a SylWrap Pipe Repair Contractor Case which they used to seal the split once the cement coating had been fully removed

A bucket was used to remove enough water from the hole to enable the repair to take place. Wrap & Seal Pipe Burst Tape was used to seal the leak in the line, with several Tapes applied to cover the entire length of the split in the steel.

When stretched and wrapped around a pipe, Wrap & Seal fuses to itself to form a solid rubber band. Multiple Tapes can be applied over each other to build pressure resistance up to 30bar. For this repair, the requirement was around 3bar.

Enough Wrap & Seal Tapes were applied until the leak had been fully arrested. A SylWrap HD Pipe Repair Bandage was then wrapped over the top for the purpose of reinforcing and protecting the initial repair.

The completed repair of a leaking cement coated steel pipe in Mexico using a SylWrap Pipe Repair Contractor Case
The pipe was successfully sealed in under an hour

SylWrap HD is a composite wrap with a water-activated resin. After being wrapped and smoothed around the pipe, the bandage set rock hard in minutes. The impact resistant sleeve formed by SylWrap provided an effective replacement for the removed cement coating.

The application was completed in under an hour. Having all the products required to repair the cement coated pipe ready and available via the Contractor Case made a significant difference to response time and how quickly the leak could be sealed, reducing the amount of water lost and disruption to 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