Category: Case Studies

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Case Study: External Surface Damage Repair to Restore Integrity of 400mm GRP Pipe

A GRP pipe suffering from external surface damage undergoes repair and strengthening with a Superfast Steel Epoxy Putty Stick

Repair damage now, avoid leak later – the oil refinery who reaped the benefits of external pipe surface restoration

When construction work revealed a 400mm GRP pipe suffering from areas of external surface damage, an oil refinery in Saudi Arabia decided to restore the integrity of the line to lessen the chances of a future breach requiring leak repair.

Case Study Data

Site
Oil refinery
Location
Saudi Arabia
Repair Type
Pipe surface profile restoration
Defect
External damage to 400mm GRP pipe

Products Used

Superfast Steel Epoxy Putty
Fast-working epoxy putty smoothed over areas of damage and weakness for restoring pipe strength and integrity

Case Study PDF

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Case Study Details

Ongoing construction work at the oil refinery resulted in the excavation of an underground section of 400mm GRP pipe. The external surface of the line was discovered to be damaged, with two areas suffering from heavy scoring.

Although the pipe was not yet leaking, the refinery were concerned that the weakening of the exterior would lead to a future breach of the line.

The damaged external surface of the GRP pipe

If this happened, they would then be faced with the inconvenient and costly exercise of again excavating the reburied line to fix the problem. Should any future leak prove to be too challenging repair, an even more costly pipe replacement might be required.

Keen to avoid that fate, the refinery decided to seek a method to repair the external damage whilst the pipe remained excavated and accessible. This would strengthen the line and restore its integrity.

Superfast Steel was pushed onto the pipe, filling imperfections in the line

Sylmasta supply several products for damage repair. For this particular application, Superfast Steel Epoxy Putty was deemed the best solution due to the relatively small areas requiring repair, and the speed and ease with which it can be worked.

Superfast Steel comes in pre-formatted 114g stick. Multiple sticks were used for the repair. Chunks of putty were cut from the stick and kneaded by hand. Once the putty had turned to a uniform colour and whilst remaining soft, it was pushed down onto the pipe and smoothed over the scored areas.

A GRP pipe in Saudi Arabia suffering from external surface damage undergoes repair with Superfast Steel Epoxy Putty Stick
The putty cured to a material hard as steel over the weakened parts of the pipe

Within 10 minutes of mixing beginning, the putty began to harden. Once fully cured, it permanently imbedded into imperfections in the line. In effect, the putty created a new waterproof layer hard as steel over the weakened parts of the GRP pipe. The entire repair took less than two hours to complete.

Had the area of damage been larger and deeper, then Industrial Metal Epoxy Paste would have been recommended. Industrial Metal is trowel applied and with a longer work time, allowing more to be mixed and spread over significant sections of weakened pipes requiring rebuild.

Superfast Steel Epoxy Putty Stick used to restore external surface profile of a GRP pipe in Saudi Arabia
The completed repair with all damage filled

The GRP line could have been further reinforced using a SylWrap HD Pipe Repair Bandage. However, the trench dug as part of the construction work was not deep enough to effectively wrap a bandage around the bottom of the pipe.

Not wanting to excavate further down, the refinery decided to rely on Superfast Steel to strengthen the line. Several years later and the underground line had still not been breached. Superfast Steel had done its job.

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: Rapid 5 Minute Epoxy Adhesive Used to Repair Broken Ceramic Teapot Lid

Repair of a broken teapot lid made of ceramic using Sylmasta Rapid Epoxy Adhesive

Tea for two – Rapid 5 Minute Epoxy Adhesive keeps a teapot brewing with the repair of a ceramic lid cracked into two pieces

A ceramic teapot lid cracked into two pieces when it was accidentally dropped on a hard floor undergoes a permanent repair using Sylmasta Rapid 5 Minute Epoxy.

Case Study Data

Repair Type
High-strength bonding
Defect
Ceramic teapot lid broken into two pieces

Products Used

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

Case Study PDF

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Case Study Details

The ceramic teapot lid was broken when accidentally dropped onto a hard floor. Fortunately, it cracked into two pieces rather than shattering into many, meaning that it could be repaired relatively easily.

Sylmasta Rapid 5 Minute Epoxy Adhesive was chosen for the job of glueing the teapot lid back together. As an epoxy adhesive, Rapid 5 Minute offered much stronger bonding power than a traditional superglue.

The ceramic teapot lid had cracked into two pieces. Epoxy Adhesive was applied to the entire white break area on the smaller piece

Its longer working time also allowed for careful application of the adhesive along the complex shape of the break, and for the two pieces to then be fitted together more accurately. With superglue came the risk of an instant cure and misalignment, after which it would be too late to rectify the error.

Rapid 5 Minute is supplied with the two epoxy adhesive components – resin and hardener – stored separately. These were extruded onto a flat and stable surface which could be easily disposed of afterwards (an empty cereal box) and mixed together with a stirrer.

After 30 seconds, an even mix had been achieved. The epoxy was then spread using the stirrer over the entire break joint of the smaller piece of the teapot lid. Once the adhesive had been applied, the two parts of the lid were pressed together and carefully adjusted for a seamless fit.

A ceramic teapot lid having undergone repair using Sylmasta Rapid 5 Minute Epoxy Adhesive
Completed repair of the teapot lid

The two parts of the teapot lid continued to be pushed together for five minutes, the functional cure time of the epoxy. Once the adhesive had begun to bond, the lid no longer required pressure to keep the parts together.

It was left undisturbed for 30 minutes for the epoxy adhesive to achieve maximum properties. A full cure was achieved after one hour. The teapot could then be reunited with its lid following the successful repair.

The structurally strong bonds provided by Rapid 5 Minute will last for a very long time – providing nobody drops the teapot lid onto a hard floor to damage the ceramic again.

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

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

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Case Study: Live Leak Pipe Repair of Above and Below Ground Water Supply Pipelines

A cracked water supply pipe in Libya having undergone a completed repair with a SylWrap Universal Pipe Repair Kit

Two for the price of one – Underground and overground live leak repair to a water supply pipe network in Libya

One above-ground water pipe and one below-ground water pipe servicing a town in Libya as part of a supply network required live leak repair to seal cracks through which significant levels of water were escaping.

Case Study Data

Site
Water supply network
Location
Brega, Libya
Repair Type
Live leak pipe repair
Defect
Cracks in two sections of 100mm steel pipe operating at 5 bar pressure

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape used to seal high pressure leaks on both sections of pipe

SylWrap HD Pipe Repair Bandage
Composite wrap applied to reinforce the repaired areas with a rock hard, impact resistant sleeve

SylWrap Universal Pipe Repair Kit
Kit containing Wrap & Seal and SylWrap HD for making fast, live leak pipe repairs

SylWrap Pipe Repair Contractor Case
Case with enough products to make multiple pipe repairs, which could have been used here if available rather than 2 x Universal Kits

Case Study PDF

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Case Study Details

Around 80 percent of the population of Libya live along or near the northern Mediterranean coast. With freshwater scarce, they rely on supplies being pumped via pipelines from aquifers in the south – known as the Great Man Made River of Libya.

The town of Brega in the north east is serviced by a network of 100mm steel water pipes running both above and below ground, connecting to the Great Man Made River. At least one underground leak was known about through visible signs in the earth surrounding the pipe.

Attending to the problem had never been a priority because of the complexity and cost involved in excavating the pipe, shutting down the line and then either repairing or replacing the leaking section.

The leak was not visible and so it could be ignored. This school of thought was changed when a section of above ground pipe developed a longitudinal split, through which significant amounts of water were escaping at around 5 bar pressure.

Water pouring from the split in the above ground pipe

A blind eye could not be turned to such a substantial leak causing flooding to the area underneath the pipe. The importance of the line meant it could not be isolated whilst the line was fixed or replacement took place.

It was decided to use a SylWrap Universal Pipe Repair Kit to make a live leak repair. All the products contained within the Kit are WRAS approved, meaning they are safe to use with drinking water.

First, Wrap & Seal Pipe Burst Tape was applied to seal the pipe. Made from self-amalgamating silicone, Wrap & Seal stretches by 300 percent and fuses to form a solid rubber band capable of sealing high pressure leaks.

The tape was anchored to the side of the split and then wrapped towards and over it. Once the split had been covered, layers of Wrap & Seal were built up until no more water was detected leaking from the pipe. This indicated a successful repair.

A SylWrap HD Pipe Repair Bandage applied to an above ground water supply line as part of a live leak repair
The above ground pipe successfully repaired with SylWrap HD

To reinforce the line, a SylWrap HD Pipe Repair Bandage was then applied. SylWrap is a composite wrap with a water activated resin which sets rock hard in minutes. It was wrapped and smoothed across the entire repair area, creating an impact resistant protective shell around the pipe.

Completing the repair took less than 30 minutes. Having seen how quick and easy the SylWrap Universal Kit was to use, the decision was taken to proceed with the repair of the leaking underground section of water supply pipe.

An underground water supply pipe is excavated and leak sealed using a SylWrap Pipe Repair Kit
The below ground pipe having been excavated and repaired

A trench was dug to reach the line with enough clearance underneath so that both Wrap & Seal and SylWrap HD could be applied. The defect in this pipe was a smaller crack easily arrested using the same repair method as with the above ground pipe.

Two leaking sections of water supply pipe had now been successfully repaired without disruption to homes and businesses in Brega. More importantly, there was now an awareness of how quick and easy pipe repair can be.

Future leaks are now set to be tackled with SylWrap Pipe Repair Kits as soon as they are identified, something which can help make a huge difference in an arid country like Libya.

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: Dairy Delivery Truck 466 International Engine Cracked Timing Cover Repair

The repair of a crack in a 466 International engine timing cover made using Industrial Metal Epoxy Paste

The delivery truck timing cover repair which meant no crying over spilt milk for a dairy in Puerto Rico

Replacing a delivery truck’s 466 International engine timing cover after it developed a hairline crack was set to cost a milk company in Puerto Rico $1000 until Sylmasta formulated a faster, more cost-effective repair method.

Case Study Data

Repair Type
Timing cover repair
Defect
Crack in 466 International engine timing cover

Products Used

Industrial Metal Epoxy Paste
Epoxy paste used to fill the crack, permanently sealing it to prevent any further oil escaping

Case Study PDF

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Case Study Details

The delivery truck belonged to a milk company in Puerto Rico. Oil was discovered to be leaking from the timing cover of the vehicle’s 466 International engine. Once opened, a hairline crack was discovered in the casing.

A replacement cover would have cost $1000. Delivery of the part was estimated to take up to a week. The company needed the truck to be back in service as soon as possible and so they sought a faster, more cost-effective repair.

The opened timing cover during inspection
A crack developed in a 466 International Engine timing cover which then underwent repair with Industrial Metal Epoxy Paste
A hairline crack discovered in the centre of the metalwork

Sylmasta technicians were able to formulate a repair method for the timing cover, involving a degree of preparation followed by the use of Industrial Metal Epoxy Paste. Instructions were sent to the engineer, who had been asked to find a solution by the company.

Before the application of the paste began, Sylmasta recommended that the ends of the crack were drilled. This was to relieve stress concentration and prevent the crack from spreading further.

Repair instructions, showing the V-shaped grooves to be cut along the top and bottom of the crack and the overlap of epoxy paste

A coarse 3-square file was used to cut a V-shaped groove along the length of the crack, widening the gap in both the top of the metalwork and underneath. This increased the available surface area to which Industrial Metal could bond. The V-grooves were then degreased to remove contamination.

Part A and part B of Industrial Metal were mixed in the instructed ratio. A spatula was used to force the paste into the crack, completely filling both V-grooves. The paste was also overlapped by 20mm either side of the crack to ensure full adhesion.

Crack in 466 International timing cover undergoes repair using Industrial Metal Epoxy Paste
The crack seamlessly filled in and repaired once Industrial Metal had cured

Industrial Metal has a work time of 60 minutes, allowing it to be carefully applied to the crack without needing to worry about premature curing. A full cure was achieved in 24 hours, after which the paste set to form a solid metallic material which seamlessly filled and repaired the crack.

One day after the application had been completed, the delivery truck was back on the road with the timing cover no longer leaking. The company were very pleased with the technical advice offered by Sylmasta, and the speed and ease with which they had been able to complete the 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: Leaking Hydrogen Line Pipe Repair at Power Station in Puerto Rico

A hydrogen line at a power station in Puerto Rico undergoes leak repair and reinforcement after it was discovered to be leaking

Helping hand with hydrogen – The leaking hydrogen pipe repair that put a power station cooling system into service

When a hydrogen line newly installed as part of upgrades to a power station cooling system in Puerto Rico was discovered to be leaking from two joints, repair and reinforcement was needed before the pipe went into full service.

Case Study Data

Site
Power station
Location
Puerto Rico
Repair Type
Leak repair and pipe reinforcement
Defect
Two leaking joints on a 600mm section of hydrogen line

Products Used

Superfast Steel Epoxy Putty Stick
Fast working epoxy putty applied around and over pipe joints where it forms a steel-like material for sealing leaks

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

SylWrap Standard Pipe Repair Kit
Superfast Steel and SylWrap HD can be purchased together as part of the Standard Pipe Repair Kit

Case Study PDF

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Case Study Details

The power plant had previously stored hydrogen used for cooling in an off-site tank. Procuring hydrogen, refilling the tank and then keeping vast amounts of gas was an expensive process.

It was also inefficient. It could take up to four days to deliver refills to the tank, sometimes causing interruptions to power output as turbines at the plant had to be shut down when hydrogen supply ran out.

To overcome this, the plant took the decision to install a new cooling system, including an on-site hydrogen generator capable of supplying gas as and when it was needed.

Pipes would carry hydrogen from the generator to the areas of the plant it was required for cooling purposes, eliminating the need for the plant to buy and then store gas away from the site.

Because gaseous hydrogen consists of such a small molecule, very small leaks are common. These tend not to be dangerous as the tiny amounts of hydrogen being released are not enough to cause a flammable mixture in the air. Problems arise only when the gas can accumulate in a confined area.

Human senses cannot detect small hydrogen leaks as the gas is colourless, odourless and tasteless. To ensure that the newly installed cooling system was in good working order before it was put into full service, the plant therefore used portable hydrogen detectors to analyse the pipes.

It was discovered that a section of the line was leaking, suspected to be from two joints between two valves around 600mm apart. Although the hydrogen leaks posed little threat, the plant decided to repair and reinforce the pipe for efficiency reasons as well as their own peace of mind.

The line was isolated and Superfast Steel Epoxy Putty Stick applied to the joints at either end of the pipe. The required amount of Superfast Steel was cut from the stick and kneaded by hand.

Whilst soft, it was pushed tightly onto the pipe around both joints. Within 10 minutes, the putty hardened to form a steel-like material to plug any gaps in the pipe through which hydrogen could be leaking.

The line was then further reinforced with a SylWrap HD Pipe Repair Bandage applied along the entire 600mm section. SylWrap HD is a composite repair wrap with a water-activated resin which sets in minutes, curing to form an impact resistant sleeve around pipes and structures.

Despite the pipe being positioned close to a wall, the maintenance team at the plant were able to wrap the pipe effectively with a 50 percent overlay.

The Bandage was smoothed with water as the application continued. Once set, it provided a rock-hard, chemically inert outer shell over the leaking joints strong enough to prevent further hydrogen molecules escaping.

24 hours after the repair and the hydrogen pipe was repressurised. With the hydrogen detector now finding no gas in the air, the application had been a success and the new cooling system could be put into full service.

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: Filler Repair of 50mm Crack Between Toilet Waste Pipe & Bathroom Floor

Cracks left during the installation of a toilet waste pipe undergo repair using Sylmasta AB Epoxy Putty as a filler material

No falling through the cracks – Sylmasta AB Repair Epoxy Putty connects a toilet waste pipe during bathroom renovation work

A hole cut into a bathroom floor during renovation work was made too big for the toilet waste pipe it was to house, meaning a waterproof repair material was needed to permanently fill gaps of up to 50mm width between the pipe and the floor.

Case Study Data

Site
Bathroom
Location
United Kingdom
Repair Type
Filler repair
Defect
50mm wide crack between toilet waste pipe and bathroom floor

Products Used

Sylmasta AB Original Epoxy Putty
Waterproof, hard-wearing epoxy putty with a longer work time used to permanently fill all gaps between the pipe and the floor

Case Study PDF

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Case Study Details

Renovations at a property in the United Kingdom involved the toilet being moved to a new location within an improved bathroom. To prepare for the move, the contractors carrying out the work cut a hole out of the floor where the toilet waste pipe was to connect with the sewer pipe.

When the toilet waste pipe was fitted in place, it was discovered that the hole which had been cut was too big. This left gapping all the way around between the base of the pipe and the floor. At its largest, the gapping extended to 50mm wide.

Large gapping between the pipe and the floor needed to be filled

The contractors wanted a straightforward method to fill the cracks so that the plumbing in of the toilet waste pipe could be completed. Sylmasta recommended the use of Sylmasta AB Original Epoxy Putty.

AB Original is a ceramic-filled, general purpose, waterproof epoxy putty which is the hardest wearing available. It comes with a two-hour work time for use in larger and more complex repairs.

It was calculated that around 1kg of AB Original would be needed to repair the toilet waste pipe. This was delivered to the property, where the resin and the hardener were mixed in equal measures and kneaded by hand.

Epoxy putty used to full in cracks between a toilet waste pipe and a bathroom floor in a repair required during renovation work
AB Original was worked and pushed into the crack
The putty was smoothed off using water

Once the putty had turned an off-white colour to indicate successful mixing, it was pushed into the gapping between the waste pipe and the floor whilst it remained soft enough to shape and manipulate.

The longer cure time of Sylmasta AB meant that more of the putty could be mixed in one go without the threat of premature curing. As the putty was applied, it was smoothed off with a little water and a filling knife and then left to harden.

Completed epoxy putty filler repair of cracks between a toilet waste pipe and the floor
The completed repair with all gapping successfully sealed

A full cure was achieved in 24 hours, leaving the cracks permanently filled with a waterproof material sharing similar properties to the floor. The renovation of the bathroom was able to continue with virtually no disruption to timeframe.

When it came to the installation of a new bathroom floor surface further along the renovation process, AB Original would withstand being tapped, drilled, screwed, sawed, ground, filed, painted and any other treatment needed to complete the improvements.

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: Superfast Steel Epoxy Putty Used to Fix Rust Holes on a Classic Car

Superfast Steel Epoxy Putty used to fix rust holes in the metal frame of a steel car

How to fix rust holes on a classic car in a repair time (nearly) as quick as a lap of Silverstone

When rust holes developed on a classic car, the owner turned to Superfast Steel Epoxy Putty as a cost-effective, quick and easy way to permanently fix the problem.

Case Study Data

Repair Type
Metal filler repair
Defect
Rust holes in classic car

Products Used

Superfast Steel Epoxy Putty Stick
Metal repair putty used to permanently fill rust holes and help prevent further corrosion

Case Study PDF

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Case Study Details

The classic car had developed a rust hole. Corrosion had eaten away at a section of the inside car door where the window mechanism was anchored, causing it to fail.

As a DIY enthusiast, the car owner wanted to find a quick, cost-effective and easy method to permanently fix the rust hole. The owner required a lightweight, metal filler material which would offer resistance to water, temperature extremes and future corrosion.

Heavy corrosion had caused significant rusting to the inside door of the car

They decided to use Superfast Steel Epoxy Putty Stick for the application. Superfast Steel sets in under 10 minutes and makes permanent repairs to damage in steel, iron and other ferrous metals.

Before the repair began, the metalwork was cleaned and prepared as best as it could be. Dirt, grime, and rust were removed. Moisture repellant spray was used to drive moisture and grease out from the crack and leave a fine lubricating film to protect against corrosion.

The area was cleaned prior to repair

Once preparation was completed, the required amount of Superfast Steel Epoxy Putty was cut from the 114g stick and kneaded by hand. Whilst soft, the putty was pushed into the hole in the metalwork, where it was shaped and moulded around the screw.

Within 10 minutes, the putty had begun to harden into a material sharing the look and feel of steel. Maximum properties were reached after an hour, leaving the hole filled and the damage caused by corrosion repaired.

Superfast Steel Epoxy Putty used as a metal filler in the fix of rust holes on a classic car
Superfast Steel filled the hole. Once fully cured, it was painted red to match the car

Once cured, the putty was filed and painted red to appear uniform with the rest of the metal frame. The total cost of the rust hole repair was less than £20, including delivery of the Superfast Steel Stick.

The Superfast and Sylmasta AB ranges of epoxy putties are used frequently across various sections of the motoring industry, including classic car repairs such as this one and in Formula One.

Lightweight yet robust repair materials which are straightforward to use and effective quickly provide the sort of speedy repairs required when it comes to fixing damage on cars.

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: Leak Repair of a Bathroom Sink PVC Plastic Drain Pipe

Superfast Plastic Epoxy Putty Stick used to repair a leak in a PVC plastic pipe connected to a bathroom sink

Stopping that sinking feeling – Superfast Plastic plugs a leak in a DIY bathroom plastic pipe repair

A homeowner used Superfast Plastic Epoxy Putty Stick to make a quick and easy DIY leak repair to cracks in a PVC plastic drain pipe located in a cupboard underneath their bathroom sink.

Case Study Data

Site
Domestic bathroom
Location
United Kingdom
Repair Type
Leak repair
Defect
Cracks in a PVC plastic sink drain pipe

Products Used

Superfast Plastic Epoxy Putty Stick
Specially formulated epoxy putty used to permanently seal holes and cracks in all types of plastic pipe

Case Study PDF

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Case Study Details

The homeowner was alerted to the problem when they noticed that the bathroom floor next to the cupboard below the sink was wet. After inspecting inside the cupboard, it was discovered that several small cracks had developed in the PVC plastic drain pipe at the point where it connected with the sink.

The homeowner did not want to go to the expense of hiring a plumber to fix what they considered a minor problem. They instead purchased a Superfast Plastic Epoxy Putty Stick from Sylmasta to carry out a DIY repair of their own.

Cracks in a PVC plastic bathroom sink pipe before undergoing repair with a Superfast Plastic Epoxy Putty Stick
Several cracks had appeared in the pipe where it met the sink fitting

Superfast Plastic is a semi-flexible epoxy repair putty in an easy-to-use 114g stick format. It sets white and has been specifically formulated for the repair and bonding of all major plastic types, including PVC.

Before the repair began, the pipe was dried and cleaned. The required amount of putty was cut from the stick and kneaded by hand. Superfast Plastic starts out blue before the dye within the putty turns white to indicate successful mixing, after which it can be applied.

Superfast Plastic formed into a sausage shape and pushed into the cracks

Once the putty had become white, it was formed into a sausage shape and pushed against the cracks in the PVC pipe. After 25 minutes, it began to harden. Within 45 minutes, the putty had cured to provide a watertight seal, filling all cracks in the pipe.

Superfast Plastic achieves full properties in two hours, at which point the homeowner ran the tap on their sink. With no water escaping from the pipe into the bathroom cupboard as the sink drained, the leak repair had been a success.

Completed leak repair of a plastic PVC pipe suffering from cracks where it connected to a bathroom sink
The completed repair with the pipe successfully sealed

Carrying out a DIY PVC pipe repair using Superfast Plastic cost less than £20, including shipping. The repair was permanent and the putty blended in unnoticed with the PVC plastic – just in case a future homeowner was a perfectionist and wanted a pipe in a darkened cupboard under the bathroom sink to look aesthetically pleasing.

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 6 Metres of Corroded Steel Pipe in a Fire Station Pumping House

A steel water pipe suffering from heavy corrosion undergoes repair and refubishment in a protection application carried out using SylWrap HD Pipe Repair Bandage

Pump it up – the SylWrap reinforcement of a corroded steel water pipe which kept a fire station pumping water

A six metre long section of steel pipe – which included two 90 degree elbow bends – operating in a water pumping house at a fire station in Saudi Arabia required urgent reinforcement before the heavy corrosion the pipe was suffering from breached the line.

Case Study Data

Site
Fire station pump house
Location
Saudi Arabia
Repair Type
Pipe reinforcement
Defect
Six metre long section of steel pipe suffering from heavy corrosion

Products Used

SylWrap HD Pipe Repair Bandage
Composite repair wrap which was wrapped and moulded around the pipe, forming an impact resistant protective sleeve

Case Study PDF

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Case Study Details

The 150mm steel pipe brought water from a reservoir on the lower levels of the pumping house up to the top levels, where it was required for different operations at the fire station.

After many years of service, the pipe was suffering from heavy corrosion. The damage was particularly bad on the section of pipe beneath the surface of the reservoir, where it was exposed to constant contact with water.

The pipe was suffering from heavy corrosion, particularly towards the bottom of the line

Although the pipe had not yet been breached, the metalwork had been weakened to the point where it was only a matter of time before corrosion caused cracks and holes to appear. Replacing the six metre section after this happened would have been difficult because of the shape of the pipe.

There were two 90 degree elbow bends in the pipe. The first changed the pipe direction from running vertically up and out of the reservoir to horizontally at the point where the line reached the upper levels of the building. The second was some 50cm further along, taking the pipe off to the right to connect with valves and equipment.

A steel pipe suffering from corrosion prior to undergoing reinforcement using SylWrap HD Pipe Repair Bandage
Two 90 degree bends in the pipe meant replacing the damaged section would be difficult

The complex shape meant that replacing the line would require specially fabricated parts at considerable expense. Not only was the cost prohibitive, but there was the possibility the station might be decomissioned in several years time.

With resources stretched, spending money on the expensive installation of a replacement pipe only for the pump house to be taken out of service within a decade would not have been a good use of funds.

The station therefore sought to carry out pipe reinforcement of the existing steel line instead, strengthening it and protecting it against further corrosion. This would extend the lifespan of the line until a decision was made about the future of the pump house and the station.

SylWrap HD is applied to a steel pipe at a fire station as part of a reinforcement application
SylWrap HD could be easily moulded around the complex shape of the pipe

It was decided to wrap the entire six metre section in SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets in minutes to provide an impact resistant protective sleeve around pipes and structures.

Starting from the upper level of the pump house, SylWrap HD was applied to the pipe with a 50 percent overlay. More water was used to smooth the bandage as it was wrapped, moulding it tightly to the line and around both of the bends.

The reinforcement of a steel pipe at a Saudi Arabia fire station made using SylWrap HD Repair Bandage
Completed reinforcement of the top level of the pipe
Completed reinforcement of the bottom level, including the underwater section

The repair continued in this manner as the line headed down to the lower levels of the pump house, including when the pipe went beneath the surface of the reservoir.

SylWrap can be applied and sets underwater, enabling every part of the pipe to be refurbished. Once fully cured, the bandage formed a rock hard shell encompassing the entire line and offering new strength to the pipe.

Within two hours, the repair had been completed and the entire line reinforced. The SylWrap sleeve surrounding the pipe prevented further external corrosion attacking the exterior and weakening the line, reducing the chances of future failure.

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: Using Epoxy Putty for Cracked & Damaged Brick Repair & Restoration

Brick repair carried out using epoxy putty to damaged brickwork suffering from lime blow

Another brick in the wall – How epoxy putty can be used to seamlessly repair cracked and damaged brickwork

When lime blow left numerous bricks at a housing estate in the south of England with cracks, holes and missing chunks, a building company in the UK hit upon the idea of using epoxy putty as a brick repair material.

Case Study Data

Site
Housing estate
Location
South of England
Repair Type
Brick face repair
Defect
Chunks of brick missing due to lime blow

Products Used

Sylmasta AB Original Epoxy Putty
Epoxy putty mixed with brick dust seamlessly filled and repaired holes, cracks and areas of damage

Case Study PDF

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Case Study Details

Lime blow occurs when clay bricks contain small amounts of lime. When the bricks are fired, this lime is converted to calcium oxide, also known as quicklime or burnt lime.

When calcium oxide mixes with water, it begins to slake in a highly vigorous process. Bricks which contain quicklime are therefore at risk or suffering from an eruption at their face when they become wet, causing chunks of brick to break away.

In a country like the United Kingdom where it rains a lot, lime blow is a frequent occurrence. Fortunately, it does not impact on the structural integrity of the brick. Some people even like the weathered, old fashioned look of bricks which have exploded.

The effect of lime blow however was not appreciated when the problem began happening frequently on a fairly new housing estate in the south of England. A building company were asked to find a cost effective and straightforward method of brick restoration, involving filling in the damaged areas.

Chuck of brick missing through lime blow prior to repair using epoxy putty
Chunk of brick missing due to lime blow

After consulting Sylmasta, it was decided to use an epoxy putty. Magic Sculp Sculpting Putty was used for a trial repair, after which the company approved Sylmasta AB Original Epoxy Putty for all future brick repair applications.

The putty was mixed by hand and then pushed into the holes and cracks in the brick face, filling in areas of damage. To ensure that the putty seamlessly matched the colour of the brick rather than the standard off-white it cured to, the putty was wetted once it had been applied to the wall and whilst still soft.

Dust was then taken from the brick undergoing repair and pushed into the putty, creating a material the exact same colour as the brick being repaired. To give the putty an identical texture to the existing brickwork, it was then spittled with a wire brush.

A section of brick missing a chunk because of lime blow undergoes a seamless repair and restoration using epoxy putty
Damaged section of brick repaired using epoxy putty mixed with brick dust

AB Original has a work time of two hours, after which it cures to form a solid material. So effective was the application that it is virtually impossible to tell where the area is on each brick that has undergone repair.

Using epoxy putty for brick repair is a practice that is growing in popularity across numerous sectors involved in construction. As well as builders and specialist brick restorers, Sylmasta also supply epoxy putty to facilities management companies, cable installers, DIY enthusiasts, gardeners and many more.

Any tradesperson or individual who may be required to fix a damaged brick – be it through lime blow, accidental damage or having to drill into brickwork – can easily fix holes, cracks and missing pieces using Sylmasta AB.

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