Category: Case Studies

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Case Study: Repair of Leaking Stainless Steel Pipe Inside Farm Biodigester Tank

A stainless steel pipe in a biodigester tank at a pig farm undergoes repair using a SylWrap Universal Pipe Repair Kit

Rescuing a pig’s ear of a repair – SylWrap seals a leaking pipe in a farm biodigester tank after patch welding failed

A leaking stainless steel heating pipe inside a biodigester tank at a pig farm undergoes repair after an initial attempt to arrest the damage via patch welding was found to have failed.

Case Study Data

Site
Pig farm
Location
United Kingdom
Repair Type
Leak Repair
Defect
Damaged stainless steel pipe in biodigester tank

Products Used

Wrap & Seal Pipe Burst Tape
Repair tape with high pressure and temperature resistance to seal the leak

SylWrap HD Pipe Repair Bandage
Provided an impact-resistant layer to protect against possible future damage

SylWrap Universal Pipe Repair Kit
The products were supplied to the farm in a SylWrap Universal Pipe Repair Kit

Case Study PDF

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Case Study Details

Biodigester systems are installed on farms for the purpose of turning waste into fertiliser and gas. The process involves organic material such as plant matter and animal manure being diluted with water and mixed in an airtight tank. Microorganisms present in the waste ferment the mix, creating a liquid called digestate.

During fermentation, the bacteria responsible for decomposition produce methane. Also known as biogas, this methane is captured and used to help power the farm. Digestate meanwhile is either kept in its liquid form and sprayed back onto the farm as fertiliser, or it can be dried out to a solid material which is used for animal bedding.

The biodigester system at the pig farm consisted of a wide circular tank 20 metres in diameter and around five metres tall. Inside the tank were a number of stainless steel heating pipes which warmed the digestate to aid fermentation. The digestate itself was mixed by a large propeller blade attached to a metal pillar.

The propeller mixer blade and metal pillar had caused damage to a steel pipe behind

Over time, the propeller mixer had pushed the metal pillar backwards to the point where it came into contact with one of the heating pipes. This in turn led to a breach of the steel and a leak developing.

The farm were alerted to the problem through a noticeable drop-off in the efficiency of the biodigester. They accessed the inside of the tank, discovered the damage and attempted to try and seal the pipe via patch welding.

Patch welding failed to seal the leak with numerous pinhole leaks appearing through the weld, after which it was ground down for a SylWrap repair

Not long after the repair and again the biodigester began underperforming. A second inspection revealed that the patch welding had failed, with water sprouting out of numerous pinhole leaks through the weld.

The farm opted for a SylWrap Universal Pipe Repair Kit for their second repair attempt. The pipe was cleaned and the patch weld ground down prior to Wrap & Seal Pipe Burst Tape being applied as the first stage of the SylWrap repair.

Wrap & Seal Pipe Burst Tape used to seal a leaking stainless steel heating pipe in a biodigester tank and a pig farm
Wrap & Seal Pipe Burst Tape applied along a 600mm long repair area

There being multiple leak areas across a 600mm area of pipe made it easier to wrap along the length of the line using Wrap & Seal than trying to encapsulate or plug each individual hole with Superfast Epoxy Putty.

When applied to the pipe, Wrap & Seal amalgamated to form a solid rubber band over every pinhole leak present. The tape was easily capable of withstanding both the pressure and temperature which the heating pipe operated at.

SylWrap HD Pipe Repair Bandage used to seal a leaking stainless steel heating pipe in a biodigester tank and a pig farm
SylWrap HD provided an impact resistant sleeve to protect the pipe from future contact with the pillar

To reinforce and protect the repair should the mixer blade and pillar come into contact with the pipe again in future, a SylWrap HD Pipe Repair Bandage was applied over the top of the Wrap & Seal.

The resin within SylWrap HD was activated with water and the bandage wrapped and smoothed around the pipe. It cured in minutes, encompassing the entire repair with a rock hard sleeve capable of protecting the pipe from impact by the pillar.

Applying Wrap & Seal and SylWrap HD took less than one hour. The biodigester tank was put back into service the following day and with no issues regarding the efficiency or performance of the system noticed, the pipe 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: Reinforced Welded Corners in Chromic Acid Tank Sealed Using SylWrap HD

A chromic acid tank at a factory in Argentina undergoes repair to heavily corroded corners using SylWrap HD Pipe Repair Bandage

Preventing a chromic acid attack – SylWrap HD seals welded corners in a corroded tank repair

After new corners were welded in place during the repair and reinforcement of a badly corroded chromic acid tank at a factory in Argentina, SylWrap HD provided sealing security against any leaks in the welding.

Case Study Data

Site
Chroming factory
Location
Argentina
Repair Type
Tank repair
Defect
Reinforcement and sealing of corroded tank corners

Products Used

SylWrap HD Pipe Repair Bandage
Composite wrap used to encompass parts and structures which sets rock-hard for ultimate protection

Case Study PDF

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Case Study Details

The iron tank was at a chroming factory in Argentina. It held chromic acid and was used during the re-chroming process of piston parts for oil extraction pumps. It was 10 metres long, 1.5 deep and 1.5 metres wide.

After a long time in service, the tank was suffering from corrosion. The damage was particularly heavy in the corners. The factory decided to repair the chromic acid tank, which involved installing welded reinforcements to each inside corner.

Not wanting to risk the possibility of there being leaks in the welding which could cause a future escape of chromic acid, the factory used SylWrap HD Pipe Repair Bandage to provide additional sealing security to the corners of the tank.

New metal corners were welded to reinforce the corners of the tank. These were then covered in SylWrap HD

The normal method of application for SylWrap HD is to activate the resin, then wrap around the pipe or structure requiring repair whilst the bandage cures to form a rock hard material.

Wrapping was obviously not possible to the inside of the tank. Instead, the factory unwound their SylWrap HD and cut it into patches, making sure not to contaminate the bandage with dirt or grime.

These patches of SylWrap HD were then activated and smoothed as tightly as possible up the entire 1.5 metre length of the welded reinforcement, creating a watertight seal between the weld and the existing frame of the tank.

The corner of a chromic acid tank having undergone repair and reinforcement using SylWrap HD Pipe Repair Bandage
Complete repair with patches of SylWrap HD encompassing the welded corner, sealing any potential holes or cracks

SylWrap HD was applied to all four corners of the tank in this way. Within 10 minutes of application, it had completely set to encompass each welded corner and cover any gaps or holes which may have otherwise been left exposed.

The final stage of the tank repair saw an acid-resistant PVC covering added. Whilst SylWrap HD offers good resistance against chemicals including sulphuric acid (which is a stronger concentration than chromic acid), this additional step was taken with the aim of further protecting the entire tank from future corrosion and attack.

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: Boat Owner Repairs Pinhole Leak in Rubber Hose Connected to Engine

A rubber hose connecting to a boat engine undergoes repair using a SylWrap Standard Pipe Repair Kit

Plain sailing – a rubber hose connected to a boat engine undergoes repair after developing a pinhole leak

A boat owner keeps their vessel afloat by making a repair to a pinhole leak on a difficult to access section of hardened rubber hose which played an important role in the cooling of the engine.

Case Study Data

Site
Boat
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Pinhole leak in rubber hose connected to boat engine

Products Used

Superfast Steel Epoxy Putty Stick
Fast working steel epoxy putty used to seal the pinhole leak in the hose

SylWrap HD Pipe Repair Bandage
Composite wrap applied over the sealed pinhole leak for reinforcing the 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

The hose was connected to the engine, carrying water as part of the cooling process. Once the pinhole leak had developed, water was able to spray out at high pressure whenever the engine was in service. This was dangerous and unsustainable.

Repairing the leak was made challenging by the pinhole being located on a bend in the rubber hose. The hose itself was in a confined space below deck, surrounded by other pipes and engine components. A pipe repair clamp could not be fitted because of the constraints.

The hose was in a confined space making a repair difficult

The boat owner contacted Sylmasta seeking a versatile repair method capable of sealing the leak despite the difficulties in accessing the hose. A SylWrap Standard Pipe Repair Kit containing all the products needed to repair a pipe when pressure can be turned off was recommended for the application.

First, the pinhole was sealed using Superfast Steel Epoxy Putty. The putty was kneaded by hand and whilst soft, applied over the pinhole leak. It easily adhered to the rubber. After 5 minutes when the putty had started to harden, it was overwrapped using a SylWrap HD Pipe Repair Bandage.

SylWrap HD is a composite wrap with a water-activated resin, which sets rock hard in five minutes. As the Bandage was wrapped and smoothed around the hose, it forced the Superfast Steel as it cured further into the pinhole, completely sealing the leak. Once SylWrap HD had set, it formed an impact resistant sleeve to increase the repair’s effectiveness.

Superfast Steel Epoxy Putty used to repair a rubber hose in a boat engine system suffering with a pinhole leak
A rubber hose connecting to a boat engine wrapped with SylWrap HD Pipe Repair Bandage
Superfast Steel was used to seal the pinhole. The repair was reinforced with SylWrap HD Pipe Repair Bandage

When used together, Superfast Steel and SylWrap HD create a repair with pressure resistance up to 30 bar and temperature resistance to 200ºC. When the boat engine was started, no water was escaping from the hose. The vessel could return to the sea.

Completing the boat pipe repair took under 30 minutes and cost less than £25, including delivering of the SylWrap Kit. This represented a significant cost saving compared to quotes offered by specialist marine engineering contractors to fix or replace the hose.

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: Underwater Wall Between River & Trout Farm Crack Repair

A crack in an underwater wall between a river and a trout farm undergoes repair with Sylmasta AB Original Epoxy Putty

River repair runs smooth – a crack in an underwater wall between a river and a trout farm is permanently sealed

The Environment Agency repair an underwater wall discovered to be cracked when a system monitoring how much water was being taken from a Yorkshire river by a local trout farm began returning inaccurate readings.

Case Study Data

Site
Sluice between river and trout farm
Location
Yorkshire, United Kingdom
Repair Type
Crack repair
Defect
700mm long crack in underwater wall

Products Used

Sylmasta AB Original Epoxy Putty
Super-strength epoxy putty effective underwater used to permanently seal holes and cracks

Case Study PDF

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Case Study Details

Trout farms in North Yorkshire are allowed to draw a limited amount of water from local rivers and streams. Extraction is normally controlled by a sluice connecting a farm to a river, which also enables the Environment Agency to monitor water levels to ensure no more than the permitted amount is taken.

Anomalies with data from one farm alerted the Environment Agency to a potential issue, initially believed to be with the sluice or the monitoring equipment. An inspection revealed that the problem was actually a 700mm long crack in a wall next to the sluice. The crack widened into a sizable hole as it reached the riverbed.

The sluice controlling the extraction of water from the river to the trout farm

Water from the river was now escaping through the crack and into the trout farm, making readings of the flow through the sluice completely inaccurate. The wall needed to be sealed to prevent water loss and ensure that the true level of water being taken by the farm could be recorded.

Sylmasta AB Original Epoxy Putty provided the ideal solution. AB Original is a ceramic-filled, high strength epoxy putty which cures underwater. It comes with a two hour work time, meaning that significant amounts of putty could be mixed to fill the crack without the threat of premature curing.

A 700mm long crack in an underwater wall prior to undergoing repair with Sylmasta AB Original Epoxy Putty
Significant levels of water were escaping from the river through the crack in the wall, seen here both above and below the waterline

An engineer from the Environment Agency attended the site with a large quantity of AB Original. Part A and Part B were kneaded in dry conditions. Once the putty had turned a uniform white colour and whilst it still remained soft, it was pushed into the crack.

The application began above the waterline, proceeding below it and then right the way down to where the crack met the waterbed. High-strength adhesion was achieved between the putty and the wall. Once cured, AB Original formed a rock-hard material to permanently fill the crack.

Sylmasta AB Original Epoxy Putty used to repair a crack in an underwater wall located alongside a river
AB Original was pushed into crack, curing to permanently seal the gap in the wall

After the repair was completed, water levels were carefully monitored. A very small leak remained, identified as being at the crack’s widest point near the riverbed. During the initial repair, it had been impossible to tell if all underwater areas in the wall had been sealed.

Further AB Original was applied at the base of the wall on a return visit. This brought the amount of water being drawn by the farm from the river back to expected levels, indicating that the crack had been successfully repaired.

Given the challenging nature of underwater repairs, the Environment Agency were delighted to have discovered such a versatile material capable of being effective underwater. They have since begun using AB Original for other applications and projects.

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: Fence Spurs Suffering from Concrete Cancer Filler Repair Using Epoxy Putty

Fence spur badly damaged by concrete cancer undergoes filler repair using Sylmasta AB Original Epoxy Putty

On the fence – installing replacement trellis provides the spur for a homeowner to repair posts suffering from concrete cancer

A homeowner installing a replacement trellis fence uses Sylmasta AB Original Epoxy Putty to repair damage to the original fence posts caused by concrete cancer, rather than having to undertake the mammoth task of replacing every spur.

Case Study Data

Site
Domestic property
Location
United Kingdom
Repair Type
Concrete filler repair
Defect
Fence spurs badly damaged by concrete cancer

Products Used

Sylmasta AB Original Epoxy Putty
Hard-wearing epoxy putty which offers excellent corrosion protection and can be used as a permanent repair filler

Case Study PDF

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Case Study Details

Concrete cancer occurs where steel reinforcements inside of concrete begins to corrode. This causes the steel to expand and as a result, the surrounding concrete to fall away and disintegrate.

Having been in place for 30 years, the fence posts were already badly damaged. When disturbed during the replacement of the trellis, they shed several more large chunks of material.

Concrete cancer had caused a fence spur to disintegrate, requiring a filler repair made with Sylmasta AB Original Epoxy Putty
Concrete cancer had caused parts of the fence spur to disintegrate, leaving the inner steel exposed and susceptible to further damage

Replacing every spur would have been a mammoth task and so the homeowner instead sought a means to repair the existing posts. They needed a material which would act as a concrete filler to repair the damage whilst at the same time offering greater protection against corrosion to lessen the impact of concrete cancer in future.

Sylmasta recommended the use of Sylmasta AB Original Epoxy Putty for the application. AB Original is a hard wearing, ceramic-filled putty with high corrosion and chemical resistance. It is suitable for indoor and outdoor use and comes with a two-hour cure for complex repairs.

The longer work time was particularly important for this application. Over 10kg of epoxy putty was needed to repair every concrete spur. Large quantities of putty could be mixed in one go and applied to significant areas of damage without the threat of premature curing.

Sylmasta AB is available in three colours as standard – white, grey and black. Grey was chosen for this repair because of its resemblance to concrete. Part A and Part B were mixed in equal measures. Whilst soft, the putty was pushed into the spur, filling cracks and replacing chunks of concrete which had been destroyed.

Sylmasta AB Original Epoxy Putty used as a filler to repair damage to a concrete fence spur caused by concrete cancer
AB Original Grey was applied to repair all damage and fill the missing concrete

AB Original adhered easily to the existing concrete. Once cured, it formed a rock-hard material to permanently repair the damage caused by concrete cancer. Had the homeowner wanted the putty to blend in more with the existing spurs, then they could have pushed concrete dust into the soft Sylmasta AB before it fully hardened.

This technique is found in the Sylmasta Brick Repair Kit, containing AB Original and brick dust. It is used for the seamless repair of bricks, filling in defects caused during construction work or by processes such as lime blow.

The repair of every concrete fence spur was completed in the homeowner’s spare time over several weekends. They were very pleased with the result. AB Original successfully repaired the damage caused by concrete cancer and improved the appearance of the fence posts, without taking the considerable amount of time replacing every spur would have.

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: Wastewater Treatment Plant Seal Pipe Flange Against Tree Root Ingress

A pipe flange which had suffered tree root ingress is protected using SylWrap HD Pipe Repair Bandage

Putting down roots – preventing tree ingress from blocking an important pipe in the process of wastewater treatment

When a tree penetrated an underground 1800mm pipe between flange plates connecting to a chlorine contact tank, a wastewater treatment plant needed to seal the line and protect it against future root ingress.

Case Study Data

Site
Wastewater treatment plant
Location
South East England
Repair Type
Flange repair and reinforcement
Defect
Tree root ingress between flange plates on 1800mm underground pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape which fuses to form a solid rubber band for the sealing of live leaks

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

The 1800mm underground steel pipe brought wastewater to the chlorine contact tank for the final stage of the treatment process. Known as tertiary treatment, it involves introducing chlorine to remove harmful pathogens which can cause diseases including cholera, polio, and typhoid.

After a significant reduction in performance was noticed, the ground around the pipe was excavated to identify the problem. It was discovered that a tree root had penetrated between two flange plates. This had caused a blockage of the pipe and potential recontamination of water which had undergone the majority of the wastewater treatment process.

A small amount of water was seeping through the gap caused by the tree ingress. Once the root was removed from the pipe, the plant needed a method to seal the leak and protect the flange against ingress occurring again.

The water company operating the plant sought technical advice from Sylmasta. Because the flange was 100mm thick, there was enough surface area for it to be repaired and reinforced using the normal SylWrap method for a live leak repair.

Wrap & Seal Pipe Burst Tape was wrapped over the point where the two flange plates connected. Wrap & Seal is a self-amalgamating repair tape which stretches by 300 percent, fusing to form a solid rubber band over leak areas.

Several Wrap & Seal Tapes were applied on top of each other, bonding together to build pressure resistance. The application of tapes continued until no more water was seeping from the pipe. Once the flange had been successfully sealed, attention turned to preventing future tree root ingress of the pipe.

A pipe flange suffering from tree root ingress is protected using SylWrap HD Pipe Repair Bandage
SylWrap HD was applied over the 100mm thickness of the flange which had been sealed with Wrap & Seal

The flange was next wrapped in SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water-activated resin. It sets in minutes, curing to form an impact resistant sleeve around pipes and structures.

A SYL412HD Bandage was used as its 100mm width meant it fitted perfectly over the flange plates. With SylWrap HD providing a rock hard shell around the flange, future tree roots growing in the direction of the pipe once it was reburied would be unable to penetrate the weak spot between the plates.

SylWrap HD Pipe Repair Bandage applied over the top of a flange to protect as steel pipe at a wastewater treatment plant from tree root ingress
A SYL412HD Bandage was used as its 100mm width perfectly covered the width of the flange

Wrapping the flange with both Wrap & Seal and SylWrap HD took less than an hour. The water company were delighted with the speed of the application and the lack of disruption carrying out the repair caused.

The plant remained fully operational throughout the repair, compared to the significant downtime it would have faced in isolating both the pipe and the chlorine contact tank had the flange needed replacing.

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: 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 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 section 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