Category: Case Studies

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

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

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

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

Case Study Data

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

Products Used

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

Case Study

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Case Study Details

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

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

A helicopter belonging to the Puerto Rico Power Authority

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

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

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

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

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

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

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

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

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

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

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Case Study: Oil Refinery Repair of a Leaking Underground GRP Seawater Return Pipe

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

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

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

Case Study Data

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

Products Used

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

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

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

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

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

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

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

For the bigger cracks, a putty with a longer work time was needed so that greater quantities could be mixed and then applied over larger areas without the threat of premature curing. Sylmasta AB Original Epoxy Putty was used for its two-hour cure.

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

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

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

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

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

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

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

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

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

Case Study Data

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

Products Used

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

Case Study PDF

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Case Study Details

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

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

A new, robust steel frame constructed for the gates

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

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

Sylmasta AB Original Epoxy Putty was chosen for the application because of its waterproof qualities and two-hour work time, offering long enough for the putty to be carefully shaped and formed into the shape of a bevelled edge before curing off.

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

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

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

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

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

Since being installed, the new gates have proven to be far more robust against the extreme Scottish weather. The application constituted a fine piece of engineering involving some out-of-the-box thinking which should last a very long time.

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

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

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Case Study: Repair & Refurbishment of Corroded 20 Metre Long Porth Pipe Bridge

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

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

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

Case Study Data

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

Products Used

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

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

Case Study

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Case Study Details

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Case Study Data

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

Products Used

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Case Study Data

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

Products Used

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


Case Study Details

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

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

The shaft on the mill wheel had been damaged by abrasion

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

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

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

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

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

The shaft underwent an extreme mechanical clean prior to repair

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

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

Titanium Supergrade Epoxy Paste was mixed and applied to the shaft

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

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

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

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

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

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

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

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

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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 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 layer as 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, 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 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 Pipe Repair Bandage 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. Wrap & Seal stretches by 300 percent and self-amalgamates 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 the worry of 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, the speed and ease with which they had been able to complete the repair – and obviously, the cost saving.

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