Category: Case Studies

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Case Study: Repair of a Leaking 150mm Steel 90 Degree Elbow Bend at a Quarry Wash Plant

A 150mm steel pipe elbow bend leaking at a quarry wash plant undergoes repair with a SylWrap Standard Pipe Repair Kit

When clamps don’t work – the repair of a 90 degree pipe elbow bend at a quarry wash plant

When a quarry in the UK was unable to repair a leaking 150mm steel pipe in their wash plant using a clamp due to the pinhole being located on a 90 degree elbow bend, they instead turned to Sylmasta for an alternative, versatile solution.

Case Study Data

Site
Quarry wash plant
Location
Hampshire, United Kingdom
Repair Type
No pressure pipe repair
Defect
Pinhole leak in a 150mm steel pipe elbow bend

Products Used

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

SylWrap HD Pipe Repair Bandage
Composite wrap applied over the sealed pinhole leak for reinforcing the repair and further protecting the pipe

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 150mm steel pipe was located in the wash plant of the quarry, passing across a lake. Wear and tear had caused a pinhole leak to appear in the line around 50mm away from a 90 degree elbow bend, leading foul water to escape into the lake below.

Normally when pipework failed on site, the quarry would fit a pipe repair clamp over the problem area. This was not possible in this case because of the location of the leak area being so close to the elbow.

Seeking a more versatile repair method capable of being effective on the bend, the quarry contacted Sylmasta. Once it was established that pressure could be easily shut off, a SylWrap Standard Pipe Repair Kit was delivered to the site.

A leaking elbow bend on a 150mm steel pipe at a quarry wash plant before undergoing repair with a SylWrap Standard Pipe Repair Kit
The steel pipe was leaking close to an elbow bend

The pipe was cleaned as best it could be before the repair began. Superfast Steel Epoxy Putty Stick was used to seal the pinhole. The required amount of putty was cut from the stick and kneaded by hand.

After around two minutes of mixing and whilst still soft, the putty was pushed into the hole in the pipe. Within 10 minutes it had hardened, forming a material as hard as steel which now filled the pinhole.

To further reinforce the repair, a SylWrap HD Pipe Repair Bandage was applied around the leaking section. SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes.

Completed repair of a 150mm steel pipe on an elbow bend
Completed repair finished with a SylWrap HD Pipe Repair Bandage

SylWrap was wrapped and smoothed around the pipe, curing to form an impact resistant sleeve. This would help protect the pipe from future breakages, a common occurrence due to the abrasive nature of operations at the quarry.

The entire application was completed in under 30 minutes by a member of the operations team at the quarry. No training was required; they simply followed the instructions provided with the Kit to make a permanent pipe elbow bend repair.

Since the repair, the quarry group have taken further stock of SylWrap Pipe Kits, knowing them to be capable of making more versatile repairs than heavy, bulky pipe repair clamps.

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: Desalination Plant Partially Buried 3000mm FRP Discharge Return Pipe Repair

A 3 metre diamete FRP desalination plant discharge pipe underoges repair in Saudi Arabia

Pipeline in the sand – how a composite patch repair helped seal a partially buried three metre diameter FRP pipe in Saudi Arabia

Problems during the installation of a three metre diameter FRP discharge pipe at a desalination plant in Saudi Arabia had caused gaps to appear between connecting rings on the line, which had to be sealed in a repair carried out whilst the pipe remained partially buried.

Case Study Data

Site
Desalination plant
Location
Saudi Arabia
Repair Type
Leak repair
Defect
Gaps between rings in a 3000mm FRP discharge return pipe

Products Used

Sylmasta AB Original Epoxy Putty
Epoxy putty used to seal gaps between the ring and the pipe through which water was escaping from a join in the FRP pipe

E190 Brushable Epoxy
Brushable epoxy resin coated onto strips of Fibreglass Tape to create a composite patch repair to reinforce the putty

Fibreglass Tape
Fibreglass Tape soaked with E190, after which it cured to form a rock hard material reinforcing the initial repair

Epoxy Composite Repair Kit
E190 Resin and Fibreglass Tape can be purchased in an Epoxy Composite Repair Kit for making complex patch repairs to pipes and tanks

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Case Study Details

The three metre diameter FRP (fibreglass reinforced plastic) pipe was to play a crucial role at the plant, returning discharge water not turned into fresh water during the desalination process to the Red Sea.

Problems during the installation of the line meant that one section of the pipe was not connected properly. It was only when the system was fully pressurised and water began escaping that the issue was noticed.

The three metre diameter FRP pipe prior to undergoing repair

Even though flow was immediately shut off, the amount of water passing through the pipe meant that the chamber housing the problem section became flooded and had to be drained.

Once drained, a scaffold was erected around the pipe and pressure turned back on with minimal flow rate to properly identify what was causing the leak.

It was discovered that gaps had appeared at both ends of a 310mm wide ring connecting sections of the line together. These gaps had to be sealed before the line could be put into service.

  • Water excaping from a 3 metre FRP pipe in Saudi Arabia before the line underwent a Sylmasta repair
Water escaping between gaps in a join in the pipe

The system was again shut off to enable the repair of the gaps using Sylmasta AB Original Epoxy Putty. After being kneaded by hand, AB Original was pushed into the gaps between the connecting ring and the rest of the pipe and left to harden.

AB Original was chosen as its two hour working time allowed larger quantities of putty to be mixed in one go without the worry of premature curing.

This was a particularly important consideration because of the size of the pipe being repaired and the temperature on-site in Saudi Arabia. Sylmasta recommend AB Original to most clients working in hotter climates.

  • Sylmasta AB Epoxy Putty used to repair and seal gaps in a 3 metre diametre FRP pipe in Saudi Arabia
Sylmasta AB Original was pushed into the gaps to seal the line

The second stage of repair would normally involve reinforcing the AB Original with a SylWrap HD Pipe Repair Bandage to create a rock hard, impact resistant layer of protection.

However, with the bottom of the FRP pipe remaining buried, it was not possible to wrap SylWrap HD around the line in this application. Even if the line had been completely accessible, its size would have made effective wrapping extremely difficult.

Instead, Sylmasta E190 Brushable Epoxy Resin and Fibreglass Tape were used to build a composite patch repair over the ends of the connecting ring which had been earlier sealed with AB Original.

Fibreglass Tape wrapped over the pipe which had been coated with E190 Brushable Epoxy
  • Sylmasta E190 Brushable Epoxy is coated onto Fibreglass Tape to reinforce and repair a 3000mm FRP pipe in Saudi Arabia
Coating the Tape with further E190 created a composite patch repair

E190 was painted onto the pipe and strips of Fibreglass Tape of the required length cut off and placed over the epoxy. The E190 soaked through the Tape, attaching it to the pipe.

Another coating of E190 was painted over the top of the Fibreglass Tape, with the open weave of the Tape allowing significant amounts of epoxy to saturate the fabric.

The resin-soaked Fibreglass Tape now constituted a composite wrap similar to a SylWrap Bandage, the crucial difference being that it could be layered over areas requiring repair rather than wrapped.

Multiple layers of Fibreglass Tape were applied over each other and soaked with E190. The repair continued in this manner until the last layer of Fibreglass Tape was covered with a final coating of E190 and left to cure.

  • A composite patch repair made using Fibreglass and E190 Brushable to an FRP pipe in a desalination plant
The completed repair with all cracks sealed and the problematic section of line reinforced

E190 has a work time of 30 minutes and a full cure of 24 hours. The reinforcement of the pipe was completed within 36 hours, after which the line could be returned to service.

Once it had been established that the FRP pipe was no longer leaking and the repair had therefore been a success, the line was buried. It was now ready to serve the desalination plant after construction of the facility was finished.

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: CAE1500 With a Miracle Decoration Repair to Save a Family’s Christmas

A Christmas decoration repair made using CAE1500 High Viscosity Superglue

All I want for Christmas… is Sylmasta to repair a priceless decoration passed through generations of a family

When a decoration which had been in a family for generations was accidentally snapped in two, it was down to Sylmasta CAE1500 High Viscosity Superglue to provide a repair to save Christmas.

Case Study Data

Repair Type
Christmas decoration repair
Defect
Wise man from nativity scene snapped in two

Products Used

CAE1500 High Viscosity Superglue
High viscosity superglue with a bond time of between 10 and 45 seconds to non-absorbent materials

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Case Study Details

It is not all fixing major pipelines and other infrastructure at Sylmasta. Sometimes an application of real importance comes along, like the repair of a priceless Christmas decoration passed through generations of a family which had been accidentally snapped in two.

The ornament in question was one of the Three Wise Men from a nativity scene. In the annual tradition of getting the Christmas decorations out of the loft, he had become broken and meaning he was no longer able to join Mary, Joseph, Baby Jesus, the wee donkey and the rest on display.

A broken Christmas decoration before undergoing repair with Sylmasta CAE1500 High Viscosity Superglue
The Christmas decoration had been snapped cleanly in two

Christmas would not be Christmas without the full nativity set, and so the family desperately sought a means of repairing the wise man. Sylmasta CAE1500 High Viscosity Superglue was chosen for the application on account of its slightly longer cure time and versatility.

CAE1500 is a cyanoacrylate superglue which offers strong bonding between materials including ceramic, porcelain, plastic, metal, wood, paper and some fabrics. Its thickness means that when used on non-absorbent surfaces, it has a bond time of between 10 and 45 seconds.

CAE1500 High Viscosity Superglue applied to a wise man ornament in a Christmas decoration repair
CAE1500 High Viscosity Superglue was applied to the bottom piece of the wise man

This allows a small window for parts being glued together to be adjusted to ensure that they are correctly fitted; something which becomes more difficult or even impossible with superglue which bonds instantly.

CAE1500 Superglue was carefully applied directly to the break on the bottom half of the wise man. Once this had been done, the two pieces were pushed back together and held in place for around 20 seconds whilst CAE1500 worked its magic.

Completed repair of a wise man Christmas decoration
The completed repair with no visible glue or crack line

Excess superglue which had been squeezed out of the joints during bonding was wiped away before it had the opportunity to fully cure, leaving a wise man who had been perfectly healed with no visible glue or crack line.

The decoration repair had been a complete success and the wise man could be returned to the nativity scene, ready to play his part in celebrating Christmas for many years to come.

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: Refurbishment & Repair of Power Plant Condenser Unit Deformed by Corrosion

A cast iron face deformed by corrosion in a power station condenser unit undergoes repair and refurbishment using Sylmasta Ceramic Supergrade Abrasion Resistant Epoxy Paste

Putting a new face on it – the cast iron face of a turbine cooler condenser unit deformed by corrosion undergoes repair and refurbishment

Replacing a turbine cooler condenser unit because of a cast iron face deformed by heavy corrosion was not a cost-effective solution for a power plant in Puerto Rico, so they instead turned to Sylmasta for a repair and refurbishment method.

Case Study Data

Site
Electrical Power Plant
Location
Puerto Rico
Repair Type
Metal repair & corrosion resistance
Defect
Turbine cooler condenser unit deformed by corrosion

Products Used

Ceramic Supergrade
Epoxy paste used to rebuild the deformed cast iron face via the creation of a new corrosion and abrasion resistant surface

Case Study PDF

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Case Study Details

The condenser was part of the turbine cooler at the electrical power plant operated by the Puerto Rico Power Authority. It was used to condense steam back into water and had been in operation for approximately 20 years.

There were two components of the condenser. The tubes were made from bronze and the face was made from cast iron. Having been exposed to steam and water for over two decades, the cast iron face had become heavily corroded and deformed.

The corroded, deformed face of the cast iron condenser prior to repair

Replacing the condenser would have been an extremely costly exercise compared to the value of the turbine cooler as a whole, which itself would need replacing within the next 5 to 10 years.

Parts were no longer made for this particular type of condenser because of its age, and so a replacement face would have had to be specially fabricated and then shipped to Puerto Rico.

Rather than install an expensive new condenser with a lifespan of 20 years for a turbine that would have to be condemned long before that, the Power Authority instead sought a way of keeping the condenser in operation until such time as the whole turbine needed replacing.

Sylmasta recommended the use of Ceramic Supergrade Abrasion Resistant Epoxy Paste for the repair and refurbishment of the condenser, to rebuild the deformed face and offer protection from future corrosion and wear.

Ceramic Supergrade is filled with silicone carbide for ultimate surface hardness and an extremely smooth finish. It is applied to worn or damaged surfaces to rebuild, or to new equipment to protect parts from abrasion, corrosion and chemical attack.

Before the application began, the condenser was cleaned as best it could be, with traces of rust and grime removed. Rods were inserted into every tube hole in the face, covering them so that they did not become inadvertently filled with epoxy paste.

Ceramic Supergrade Epoxy Paste used to rebuild the cast iron face of a condenser unit damaged by heavy corrosion in a repair and refurbishment application
Ceramic Supergrade built a new, ultra-smooth layer with high corrosion and abrasion resistance over the original deformed cast iron face

Ceramic Supergrade was then applied to the face around these rods. The epoxy paste filled in imperfections in the cast iron as it was built up to create a new, waterproof, surface on top of the original deformed face with high resistance to abrasion and corrosion.

The 60 minute work time of Ceramic Supergrade allowed large quantities of the paste to be mixed and applied carefully without the threat of premature curing.

A full cure was achieved in 24 hours, after which the condenser could be returned to the turbine and the system put back into operation following a successful epoxy paste rebuild. The high-wear resistance of Ceramic Supergrade would keep the condenser in service for many more 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: Steel District Heating System Pipe Suspended in Ceiling Live Pinhole Leak Repair

A steel pipe in a district heating system leaking from a pinhole undergoes a live leak repair using a SylWrap Pipe Repair Contractor Case

Saved from substantial district heating damage – the energy company rewarded for equipping all their vans with a SylWrap Pipe Repair Contractor Case

A pinhole leak in a 50mm steel pipe suspended in the ceiling as part of a building’s district heating system required an urgent live leak repair when escaping, pressurised water began causing substantial damage to surrounding surfaces.

Case Study Data

Site
Public building
Location
United Kingdom
Repair Type
Live leak pipe repair
Defect
Pinhole in a 50mm steel district heating system pipe

Products Used

SylWrap Pipe Repair Contractor Case
The energy company responsible for the district heating system equip every van with a Contractor Case

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape used to seal the leak on the pipe despite the difficulty in gaining access to the ceiling

SylWrap HD Pipe Repair Bandage
Composite wrap applied to encapsulate the repaired section with an impact-resistant, protective sleeve

Case Study PDF

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Case Study Details

The district heating system was operated by a United Kingdom based company who specialise in installing and maintaining sustainable energy generation systems in public buildings, residential developments, factories and manufacturing sites.

Because of the importance of pipes to these systems, Sylmasta already had an established relationship with the company prior to the repair. Each of the company’s vans are equipped with a SylWrap Pipe Repair Contractor Case in case of emergencies, enabling contractors to make up to four live leak repairs as soon as problems are identified.

A pinhole leak in a 50mm steel pipe in a district heating system prior to being repaired with a SylWrap Pipe Repair Contractor Case
Water jetting from the pipe was causing substantial damage to surfaces and surrounding pipework, both above and below

The repair in question was to a large pinhole leak in a section of 50mm pipe suspended in the ceiling of the building. Pressurised water was jetting out in numerous directions, causing substantial damage to surfaces and surrounding pipework both above and below the leaking pipe.

Flow could not be turned off, as this would have involved shutting down heating across the entire building. A live leak repair to the district heating system was therefore necessary, using lightweight materials which could be easily carried and applied from the top of a ladder used to reach the ceiling.

From the Contractor Case, Wrap & Seal Pipe Burst Tape was used to successfully seal the leak. Despite the difficulty in accessing the pipe caused by the minimal space to work in the ceiling cavity and the surrounding pipes, Wrap & Seal was still stretched by 300 percent, amalgamating to form a solid silicone band over the steel pipe.

Wrap & Seal successfully applied to seal the pinhole

The entire section was then encapsulated with a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets rock hard in minutes. Once cured, it reinforced the pipe from any future breakages.

After seeing the extent of the damage that escaping water managed to cause in the short space of time between the leak being identified and the Contractor Case arriving on site, the company were appreciative of their partnership with Sylmasta.

Had a Contractor Case not been so readily available, then this could easily have turned into a major incident for the district heating system and the building. Instead, the company’s reputation was enhanced for the swift manner in which they reacted to and repaired the problem.

Completed repair of a steel pipe in a district heating system suspended in the ceiling of a building
The repair was completed by encapsulating the entire section with SylWrap HD

The company have since used their Contractor Cases to make live leak repairs to pipes in various systems they operate made from aquatherm, a semi-rigid polypropylene material.

Aquatherm pipe is popular because it does not react with water, preventing leaching, corrosion, scaling and erosion – major causes of water contamination and long-term pipeline failure.

Once thought to be foolproof, it is now known that failures can happen in aquatherm. Reasons for this include excessive clamping, elevated temperatures, extreme vibrations, flow velocity, water pressure and chemistry, or the presence of copper ions.

There is also the danger posed when a section of aquatherm pipeline has been repaired by inserting copper or iron pipe, leading to different coefficients of thermal expansion and severe cracks.

In the event of any failures in aquatherm piping, the presence of Contractor Cases across the company’s fleet of vehicles means that leaks and bursts can be attended to instantly, instead of suffering delays waiting for materials or parts to be delivered.

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

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

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Case Study: Repair of a Cracked 90-year-old 70mm Malleable Iron Water Supply Pipe

A SylWrap Pipe Repair Kit is used to seal a crack on a 90-year-old malleable iron water supply pipe

Helping towards a century – the malleable iron pipe repair that kept a 90-year-old water supply line in operation

With replacement fittings of the required size and type no longer manufactured because of the age of a 90-year-old malleable iron water supply pipe, when the pipe became cracked a repair solution was needed to avoid digging out and replacing the entire line.

Case Study Data

Site
Domestic property
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Cracked 90-year-old malleable iron water supply pipe

Products Used

Superfast Steel Epoxy Putty Stick
Fast working epoxy putty used to seal all holes in the pipe

SylWrap HD Pipe Repair Bandage
Repair area was overwrapped with a SylWrap HD Bandage for reinforcement and protection

SylWrap Standard Pipe Repair Kit
Superfast Steel and SylWrap HD were provided together in the Standard Pipe Repair Kit

Case Study PDF

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Case Study Details

The 70mm malleable iron pipe connected a property with the public supply network. When the property owner was alerted to a potential leak, excavation revealed that an awkward-shaped large crack and several smaller holes had developed, through which water was now escaping.

Because the pipe was 90 years old, replacement fittings of the correct size and type were no longer manufactured. The crack and holes therefore had to either be repaired, or the entire section would need to be dug out and replaced with a new line at considerable expense.

Sylmasta recommended a SylWrap Standard Pipe Repair Kit for the application. All products in the Standard Kit have WRAS approval, meaning they are certified as safe to use for the repair and maintenance of pipes carrying drinking water.

Pressure was turned off and the malleable iron pipe cleaned and dried as best it could be prior to the two-stage repair.

A large crack and several holes in a 70mm malleable iron water supply pipe prior to being repaired with a SylWrap Pipe Repair Kit
Holes in the pipe included a large, awkward shaped crack

First, Superfast Steel Epoxy Putty Stick was used to seal the pipe. Superfast Steel is a fast working putty in an easy-to-use stick format which makes permanent repairs to steel, iron and other ferrous metals.

For the smaller holes, the required amount of epoxy was cut from the stick and kneaded by hand. It was pushed into all visible holes in the pipe, where it hardened within five minutes to plug all leaks.

To seal the large crack, Superfast Steel was formed into a disc bigger than the area of the pipe the crack covered. This guaranteed that no part would be missed when sealing.

This disc was then stretched over the entire crack area. Once in position, the edges of the disc were pushed tightly down onto the pipe, forming a good seal with the surface.

Repair of a 90-year-old cracked malleable iron water supply pipe made using a SylWrap Standard Pipe Repair Kit
The completed repair prior to the pipe being re-burried

Once the putty had become firmer but not completely cured, the entire repaired section was tightly wrapped with a SylWrap HD Pipe Repair Bandage to compress the putty into any remaining gaps.

SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes, providing an impact resistant protective layer around the pipe.

Once the application was completed, pressure was turned back on. The pipe had ceased leaking and could therefore be re-buried. The repair had cost less than £25 to complete, including delivery of the SylWrap Kit and the property owner described it as going “fantastically well.”

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

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

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Case Study: Corroded Tank Repair at a Puerto Rico Pharmaceutical Plant

A heavily corroded tank at a pharmaceutical plant in Puerto Rico undergoes repair using Ceramic Brushable Green Epoxy Coating

Putting a lid on corrosion – the roof of a heavily corroded tank undergoes repair using Ceramic Brushable Green

When rust finally breached the top of an industrial tank at a pharmaceutical plant in Puerto Rico, a repair method was needed to keep the corroded tank operational for several more years before a planned replacement.

Case Study Data

Site
Pharmaceutical plant
Location
Puerto Rico
Repair Type
Corrosion protection
Defect
Heavy corrosion to the top of an industrial sized tank

Products Used

E190 Brushable Epoxy
Brushable epoxy resin coated onto strips of Fibreglass Tape to make composite patch repairs to holes in the tank

Fibreglass Tape
Fibreglass Tape soaked with E190, after which it cured to form a rock hard material covering holes in the tank

Epoxy Composite Repair Kit
E190 Resin and Fibreglass Tape can be purchased in an Epoxy Composite Repair Kit for making complex patch repairs to pipes and tanks

Ceramic Brushable Green
Brushable epoxy coating repaired the top of the tank by creating a hard-wearing surface resistant to corrosion

Case Study PDF

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Case Study Details

The tank was suffering from heavy corrosion, especially at the top. The pharmaceutical company responsible for the plant had been determined to try and keep the system operational until the scheduled replacement of the tank.

Unfortunately, the corrosion became so bad that a repair had to be made. The primary consideration was cost; the company did not want to spend thousands of dollars refurbishing a tank, only for it to be condemned within a few years.

A badly corroded tank top at a pharmaceutical plant in Puerto Rico prior to undergoing repair using a Sylmasta brushable epoxy
The top of the tank was suffering from heavy corrosion

It was decided to use Ceramic Brushable Green Epoxy Coating as a cost-effective and convenient means of both repairing the damaged tank roof and protecting it from further corrosion.

Ceramic Brushable Green is reinforced with silicone carbide and painted onto surfaces, structures and machinery to create an ultra-smooth, hard wearing protective layer.

It can be applied to old or new parts made from all metals and most plastics. It seals surfaces and protects against chemical attack, cavitation, erosion and pitting, as well as corrosion.

Large holes appeared in the tank during the surface preparation process

Before the application of Ceramic Brushable Green, the roof of the tank had to be cleaned to remove paint, rust and grime. During this process, several holes appeared in the tank owing to how brittle the metalwork had become.

The holes were bridged using Fibreglass Tape coated with Sylmasta E190 Brushable Epoxy Resin, available to purchase together as part of the Sylmasta Epoxy Composite Repair Kit.

Strips of Fibreglass Tape were cut off, soaked with E190 resin and then layered over each hole to build a composite patch repair. E190 has a work time of 30 minutes, after which the resin-soaked strips cured to form a rock-hard material sealing all holes.

  • A corroded tank top undergoing repair using a brushable epoxy
  • Ceramic Brushable Green used to repair a corroded tank top by creating a new hard wearing surface
E190 Epoxy Resin and Fibreglass Tape patch repaired holes. The tank was then coated with Ceramic Brushable Green Epoxy Coating

Once the holes had been path repaired, the entire tank was painted with Ceramic Brushable Green. The 90 minute gel time meant that large quantities of epoxy coating could be mixed without the threat of premature curing.

Three coatings of Ceramic Brushable Green were applied. The re-coat time between layers was around four hours. A full functional cure was achieved 24 hours after the last coating, with the entire application taking a little under two days to complete.

Although only set to be a temporary repair, complications down the line meant that the planned replacement of the tank had to be suspended. Five years later and the tank was still in service, fully functional thanks to Ceramic Brushable Green with no signs of further corrosion.

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: Liquid Metal Lays Anti Slip Flooring Surfaces at PepsiCo Plant in Chile

An anti slip flooring surface created using Liquid Metal Epoxy Coating and silicone carbide grit at an industrial plant in Chile

Getting a grip in Chile – Liquid Metal combined with silicon carbide grit lay new anti slip flooring at PepsiCo Plant

An industrial plant operated by PepsiCo in Chile required a cost effective method for laying new and replacement anti slip flooring across the site – a problem solved by combining Liquid Metal Epoxy Coating and silicon carbide grit.

Case Study Data

Site
PepsiCo industrial plant
Location
Chile
Repair Type
Creation of anti slip surfaces

Products Used

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

Case Study PDF

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Case Study Details

PepsiCo needed to lay anti slip flooring at various points in their industrial plant in Chile, both to replace existing surfaces which had lost their effectiveness and create new ones across the site.

12 different sections needed laying. These included the gritting of stainless steel ladders and staircases; the tiled floor of a warehouse; concrete corridors; a metal ramp; and the surface of an open lift used to transport goods between floors.

  • Exisiting anti slip flooring at the PepsiCo industrial plant had become worn and in effective prior to being repaired using Liquid Metal and silicone carbide grit
Existing anti slip surfaces had become worn and needed replacing

Because of the scale of the application, the maintenance team carrying out the job wanted to find as cost effective and convenient method for laying anti slip surfaces as possible.

One of the ways they intended on doing this was by finding an epoxy coating capable of bonding to the variety of surfaces upon which the anti slip flooring was required.

  • A stainless steel floor prior to having a new anti slip flooring surface applied using an epoxy coating
Stainless steel floor with worn anti slip surface

Sylmasta therefore recommended the use of Liquid Metal Epoxy Coating combined with silicon carbide grit. Liquid Metal is a metal-filled, brushable epoxy which is painted onto surfaces.

Whilst sticky, it offers high strength adhesion. It cures on all materials, forming an ultra-smooth metallic layer. A gel time of 90 minutes allows for the coating to be mixed and carefully applied without the threat of premature curing, an important consideration for larger, more complex tasks.

Masking tape was used to mark out where the anti slip strips were required. The surface was then painted with Liquid Metal, silicon carbide was sprinkled over the epoxy coating, and the masking tape removed.

Liquid Metal and silicone carbide grit are used to create anti slip flooring at the PepsiCo industrial plant in Chile
Completed refurbishment of the anti slip surface on the stainless steel floor using Liquid Metal and silicone carbide grit

Once the Liquid Metal had cured, the grit was permanently bonded to the floor, creating a new anti slip surface. This method was used successfully across all 12 areas requiring attention on the site, no matter whether the surfaces were metal, concrete or tile.

The entire application was completed in 24 hours from when the final area was coated with Liquid Metal. The ease and speed of the installation has since led the maintenance company to use Liquid Metal for surface gritting at other plants, as well as for creating anti slip surfaces for delivery vans.

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: Domestic Malleable Iron Water Pipe Repair in a Restricted Space

Wrap & Seal Pipe Burst Tape used to repair a 20mm domestic malleable iron water pipe in a restricted space

No space, no problem – Wrap & Seal makes a repair to a malleable iron water pipe with severely restricted access

A 20mm domestic malleable iron water pipe undergoes a live leak repair using Wrap & Seal Pipe Burst Tape despite space being severely restricted by the leaking section’s position in close proximity to a wall.

Case Study Data

Site
Domestic property
Location
United Kingdom
Repair Type
Live leak pipe repair
Defect
Small hole in 20mm malleable iron water pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone tape which fuses to form a solid rubber band for high-pressure, live leak repairs

Case Study PDF

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Case Study Details

The malleable iron pipe had developed a small hole facing towards a brick wall in an outside area of a domestic property in the UK. Water was escaping at around 3 bar pressure and flow through the leaking section of pipe could not be isolated.

Because this was a live leak repair, epoxy putty was ruled out as a sealing material. Wrap & Seal Pipe Burst Tape would therefore have to be used, making the repair particularly challenging due to the restricted space on two sides of the pipe.

Between the pipe and the back wall behind, there was around only 30mm clearance. Approximately 150mm of space existed between the pipe and the ground. Clearly, there was not going to be enough room for the user making the repair to stretch the Wrap & Seal by three times its length whilst it was wrapped, as would have normally been the case.

Repair of a 20mm domestic malleable iron water pipe in a restricted space at a domestic property
To apply the tape, it was stretched towards the user where there was most space

The tape was anchored 50mm to the right of the leak and held tightly against the pipe by property owner carrying out the repair, using their thumb. They then stretched the tape as far towards them as space would allow with their other hand, before pulling it under the pipe and up through the restricted space between the pipe and the back wall.

As the first wrap around was completed, the tape was stretched half the width across the Wrap & Seal still being held down to the pipe with the thumb. This anchored the tape firmly to the pipe.

The wrapping process continued in this manner, with the tape being stretched as much as possible into the space away from the wall before the user looped it under the pipe and up through the gap at the back.

The tape was then wrapped under the pipe and up through the restricted space between the pipe and back wall

Despite the fact that it was not possible to stretch the tape by its maximum 300 percent, the self-amalgamating silicone still fused effectively to form a solid rubber band over the leak. The 3 bar pressure was easily held by the repair.

Once the end of the tape was reached, the pipe was dried off. No more water could be felt escaping, indicating that the repair had been a success.

The property owner was delighted to have been able to carry out a safe DIY pipe repair in spite of the initial challenges that seemed to come with the application, and at a fraction of the cost of hiring a plumber.

Wrap & Seal has WRAS approval, meaning it is certified as safe to British standards to use on pipes which carry drinking water.

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

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

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Case Study: ‘Impossible’ Repair of a 900mm Water Main Flange Leak in an Underground Chamber

A 900mm steel water main leaking in an undeground chamber undergoes repair using Superfast Steel Epoxy Putty

Mission impossible – the repair of a leaking 900mm steel water main flooding an underground chamber in Malaysia

Water escaping from cracks caused by corrosion around a flange on a 900mm steel water main had flooded an underground chamber, leaving a pipe repair to be considered impossible until a determined Malaysia engineering team spent two days on the scene

Case Study Data

Site
Underground water main
Location
Malaysia
Repair Type
Leak repair
Defect
Cracks caused by corrosion on a 900mm steel pipe flange

Products Used

Superfast Steel Epoxy Putty Stick
Fast working epoxy putty for sealing holes and cracks in pipework, filling gaps between joints and high-strength adhesion

Case Study PDF

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Case Study Details

Heavy corrosion had caused numerous cracks to appear on the 900mm steel pipe around a stub flange. The leak point was located in an underground chamber, which had subsequently filled with water escaping the pipe at high pressure.

Accessing the pipe was difficult even before the flooding of the chamber. A repair clamp could not be fitted because of the flange, and the main was so close to the ground that there was insufficient room for pipe repair tapes or bandages to be wrapped around the pipe.

There was no visible means of isolating the main either, meaning that pressure could not be turned off or reduced. Replacing the damaged section would have involved excavating the chamber and shutting down the main for a prolonged period, something not considered an option by the water company operating the system.

The flooded chamber prior to water being pumped out
As water was removed from the chamber, the scale of the leaks on the main became evident

As a result, repairing the main had been considered impossible. It had been allowed to leak unabated since the problem was discovered, save for a few cursory checks and the pumping out of water when flood levels became dangerously high.

That was until an engineering team arrived on site, accompanied by a technician from Sylmasta, who were determined to formulate either a method for repairing the main or a means of substantially reducing the amount of water being lost.

Before any repair could be attempted, water had to be pumped out of the chamber. Once this had been done, an engineer accessed the pipe and hammered a series of plastic plugs into the larger cracks along the flange.

Water escaping a 900mm underground water main in Malaysia prior to undergoing a Sylmasta repair
An engineer hammered plastic plugs into the significant cracks, reducing the amount of water being lost so that an inspection could take place

The plugs reduced the amount of water escaping from the pipe enough for a proper inspection to take place. The engineer in the chamber then spotted a stopcock a little further along the pipe.

They were able to reach the stopcock, preventing flow into the leak area. With pressure now turned off, it meant that Superfast Steel Epoxy Putty could be used to attempt to permanently seal the cracks in the main.

Numerous Superfast Steel Epoxy Sticks were used for the repair

Superfast Steel has a fast, 10 minute work time and comes in an easy-to-use 114g stick format. A large number of sticks had to be used in the application because of the size of the repair.

Each stick was kneaded by hand. Whilst soft, the putty was pushed into visible holes in the pipe where it hardened, filling the crack. Superfast Steel was also used to seal the flange and as a means of permanently fixing the rubber plugs in place.

An engineer applies Superfast Steel Epoxy Putty Stick to a cracked 900mm steel water main during a repair in Malaysia
Superfast Steel plugged the visible cracks in the pipe and permanently fixed the rubber plugs in place

Because of the diameter of the pipe and the size of the damage area, it took over an hour to apply the necessary Superfast Steel. With flow isolated, it was difficult to tell whether all the leaks in the pipe had been found and sealed.

Even after pressure was restored, it was still hard to identify remaining problem areas. As a result, the maintenance team decided to return 24 hours later to check the effectiveness of the repair.

With the main continuing to leak the following day, further Superfast Steel was used to plug remaining cracks and a valve fitted

Unfortunately, this inspection revealed that the main was again leaking, although nowhere near as seriously as before. There were several small leak areas which had not been suitably arrested the previous day, alongside a larger jet of water escaping from a gap between the flange and the pipe.

Further Superfast Steel was used to seal the smaller leak areas. The epoxy putty was worked into a sausage shape and pushed into the remaining cracks in the pipe.

Superfast Steel Epoxy Putty Stick used to plug holes in a cracked 900mm water main repair
With most of the leaks arrested, the valve funnelled any water still attempting to escape into one area

For the larger leak, the engineering team manager hit upon the idea of fixing a valve in place using more Superfast Steel. The water trying to escape the main would be channelled towards this valve. A tap would be fitted and closed, sealing the pipe shut.

A tap was then fitted, shutting off the valve
Successful repair of a leaking 900mm water main in an underground chamber carried out by Sylmasta
The successful repair

Tapping off the main ended up being a success, much to the delight of the water company and the engineering team. Normally, Sylmasta would recommended reinforcing the epoxy putty with SylWrap HD Pipe Repair Bandage, but that was just not possible in this application.

It may have taken two days, but the ‘impossible’ water main repair had been completed, reducing the levels of water being lost and preventing any further flooding of the chamber.

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