Category: Pipe Repair

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Case Study: Bilge Pipe Leaking Through Corroded Welded Joint Repair On Board Superyacht

SylWrap Pipe Repair Kit used to seal a pinhole leak in a steel bilge pipe onboard a superyacht

The seventy pound bilge pipe repair which kept a multimillion dollar superyacht sailing safely

A leaking bilge pipe on board a multimillion dollar superyacht undergoes repair after corrosion at a welded joint caused a hole to appear in an area of the steel line where it was impossible to fit a clamp.

Case Study Data

Site
Superyacht
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Hole in a steel bilge pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape fuses to form a solid rubber band, sealing high pressure leaks

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to reinforce and protect repairs

SylWrap Pipe Repair Contractor Case
Products supplied in a Contractor Case, enabling up to six live leak repairs to be made to pipes of different diameters

Case Study PDF

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Case Study Details

Bilge pumps are one of the most important systems on any boat for keeping the vessel dry and safe. Water naturally collects at the lowest point on board a boat from everyday sources like rainwater, waves when sailing rough seas and spray.

The bilge pump removes this excess water and other fluids which may have found their way to the bottom of the vessel – such as engine oil – by pumping it through a series of pipes and out via an exit hole in the hull.

This prevents flooding impacting the balance of the boat and causing overflow into other areas. Oily water coming into contact with machinery or electrics in the engine room for example can cause serious problems, potentially destroying a boat’s system.

In the event of a hull breach, a bilge pump removing water as it is being taken onboard buys time to slow or repair the leak. If major damage is obtained, the bilge pump allows for safe evacuation by helping keep the vessel afloat for longer than would otherwise be possible.

Corrosion had caused the leak in the superyacht bilge pipe by attacking the steel at a welded joint. The subsequent hole was close to a 90-degree elbow and the hull of the boat.

It was also surrounded by other pipes and equipment, making it impossible to repair with a clamp. With water jetting out the pipe whenever the bilge pump went into operation, the hole needed to be urgently sealed until a new pipe could be fabricated and installed.

Hole caused by corrosion in a bilge pipe onboard a superyacht leaking before a SylWrap repair
Corrosion attacking a welded joint had caused a hole to appear in the steel bilge pipe

The superyacht were sent a SylWrap Pipe Repair Contractor Case, from which Wrap & Seal Pipe Burst Tape was used to seal the leak. Wrap & Seal is a self-amalgamating repair tape with a unique tapered profile which stretches by three times its length.

As it was wrapped around the pipe, it fused to form a solid rubber band capable of containing the water sent through the line by the bilge pump at around 2 bar pressure.

The repair was then reinforced using a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin. It was wrapped and smoothed around the pipe, curing in minutes to form a rock hard, impact resistant sleeve.

SylWrap HD Pipe Repair Bandage used to seal a leaking bilge pipe onboard a superyacht
The pipe was repaired using Wrap & Seal Pipe Burst Tape before overwrapping with SylWrap HD Pipe Repair Bandage

Completing the bilge pipe repair took under 30 minutes at a material cost of a little less than £70. And having discovered how quick and easy a SylWrap repair is, the superyacht now permanently carries a Pipe Repair Contractor Case on board.

The Case contains enough products to make up to six live leak repairs to pipes of different diameters. It is easily stored onboard and means repairs can be made to any boat pipes on the superyacht as soon as leaks develop – even when sailing the high seas.

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 30-Metre Section of Sewer Force Main In Underground Vault Repair

A severely corroded sewer force main pipe in Hawaii undergoes repair and refurbishment using the Sylmasta Pipe Refurbishment System

Say aloha to a sewer force main in Hawaii restored from a corroded state by a repair made using the Sylmasta Pipe Refurbishment System

An engineering company in Hawaii refurbish a severely corroded 30-metre section of 450mm ductile iron sewer force main inside an underground vault, rectifying a previous repair attempt which ended up sandblasting a 75mm round hole in the pipe.

Case Study Data

Site
Sewer force main
Location
Hawaii
Repair Type
Pipe repair and refurbishment
Defect
Severely corroded 450mm ductile iron pipe, including 75mm round hole

Products Used

Industrial Metal Epoxy Paste
Metal-filled epoxy paste used to bridge large holes, rebuild weakened pipes and restore surface profile

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

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

Case Study PDF

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Case Study Details

The 450mm ductile iron pipe inside the vault was the final section of the sewer force main before it discharged into a manhole housing a gravity collection system. Its operating pressure was around 3 bar.

It was installed in the 1970s. Conditions inside the often-flooded vault over a period of nearly 50 years had led to severe exterior corrosion and a significantly weakened pipe.

Water was pumped out of the flooded vault before repair

A recent attempt to add structural strength and protect against further corrosion involved sandblasting the line prior to coating with epoxy. Unfortunately, the contractor failed to realise just how weakened the ductile iron had become.

Sandblasting to clean the pipe subsequently put a 75mm round hole in the top of the sewer between a flange and the concrete wall where the main entered the adjacent manhole. Wastewater could escape through this hole when the line was pressurised.

To seal the leak in the pipe, the contractors ordered a pipe repair clamp specifically fabricated for the line. But because the surface was so badly deformed by corrosion, it was impossible for the clamp to achieve a watertight seal. There were also concerns that tightening the clamp fully would further breach the brittle metalwork.

The pipe surface was severely corroded, leaving it weakened and brittle

The contractors contacted Sylmasta for assistance with the corroded sewer main repair. They needed to improve the surface profile of the pipe to make the clamp effective, before refurbishing the entire 30-metre section inside the vault to keep the line operational and protect against further degrading.

Any repair method had to take into account the weakness of the line and the damage already done by sandblasting. Sylmasta therefore recommended using Stages 2, 3 and 4 of their Pipe Refurbishment System.

The hole was attended to first. Wire mesh was used to bridge the gap. Industrial Metal Epoxy Paste was then applied around the entire diameter of the pipe between the flange and the wall, including over the hole. The wire mesh prevented any epoxy paste entering the pipe.

Sandblasting to clean the pipe during a previous repair attempt left a hole in the pipe, through which water could escape when the sewer main was pressurised

Industrial Metal is a two-part epoxy paste used to rebuild weakened metalwork and improve surface condition of pipes. In this application, 5kg of Industrial Metal filled in all imperfections caused by pitting and increased pipe thickness surrounding the hole.

Once cured, Industrial Metal sealed the hole and rebuilt the pipe, leaving it strong enough to withstand the clamp being fitted and smooth enough to ensure a watertight seal could now be achieved.

Industrial Metal Epoxy Paste used to repair a hole in a corroded sewer main line
Industrial Metal was applied to seal the hole and rebuild the area of pipe around it, enabling a repair clamp to be fitted

Industrial Metal could have held the leak of its own accord. The contractors though decided to take a belt and braces approach by also fitting the clamp, seeing as it had been specifically made for this sewer line.

Attention next turned to refurbishing the rest of the corroded sewer main. Loose material was carefully cleaned off using wire brushes before the sewer main was painted with Liquid Metal Epoxy Coating.

10kg of Liquid Metal was used to apply two coatings across the entire 30-metre pipe, the two flanges at either end and the coupling in the middle. Re-coat time was four hours, meaning the application of Liquid Metal took one day.

Corroded sewer main pipe in Hawaii before undergoing repair and refurbishment with Liquid Metal
Liquid Metal used to repair a heavily corroded sewer main ductile iron pipe
Liquid Metal refurbished the sewer main by creating a metallic external shield around the entire pipe

Liquid Metal cured to create a new, metallic, hard-wearing pipe exterior for the sewer main, providing a shield against corrosion and a waterproof barrier against future leaks.

The final stage of the repair saw the sewer main given further reinforcement using 20 x SYL866HD SylWrap Pipe Repair Bandage. SylWrap Bandage is a composite repair wrap with a water-activated resin.

It was wrapped and smoothed around the whole pipe, curing within minutes to form a rock-hard, impact resistant layer of further protection. Six layers of SylWrap Bandage were used based on the 3 bar operating pressure of the sewer main.

Application of SylWrap Pipe Repair Bandage to a heavily corroded sewer main pipe in Hawaii
SylWrap Pipe Repair Bandage forms a rock hard, impact resistant layer of protection for a sewer main ductile iron pipe in Hawaii
The repair was completed by wrapping the entire 30-metre pipe with SylWrap Bandage for a rock-hard, reinforced final layer of protection

From sealing the hole to reinforcement with SylWrap Bandage, the repair was completed over the course of one week. The contractors were impressed with how easy all three Sylmasta products were to apply given the cramped, wet and dirty conditions inside the vault.

They had originally planned to encase the sewer main in concrete after refurbishment as an additional means of protection. This was no longer deemed necessary once they saw the strength and effectiveness of the repair.

At a total cost of just under $5000 including delivery to Hawaii, refurbishing the corroded sewer force main provided a significant financial saving compared to ripping out the pipe and replacing it.

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: Emergency Live Leak Pipe Repair Keeps Heating on at Nursing Home

SylWrap Universal Pipe Repair Kit seals a leaking heating pipe at a nursing home

Winter is coming – and a SylWrap Universal Pipe Repair Kit keeps the heating on at a nursing home

The maintenance manager of a nursing home drives to Sylmasta HQ, collects a SylWrap Universal Pipe Repair Kit and makes a live leak repair to a 150mm metal pipe to keep the heating system running and residents warm.

Case Study Data

Site
Nursing home
Location
United Kingdom
Repair Type
Live leak pipe repair
Defect
Pinhole leak in 150mm metal heating pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape seals live leaks by fusing together to form a solid rubber band

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap which sets rock hard in minutes to reinforce and protect repairs

SylWrap Universal Pipe Repair Kit
Kit containing products needed to make a single permanent live leak repair in under 30 minutes

Case Study PDF

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Case Study Details

Sylmasta offices received an early morning phone call from a panicked maintenance manager of a nursing home in the south of England. A 150mm metal pipe in the heating system running through loft space had developed a pinhole leak.

A constant, steady drip of water was escaping the pipe and saturating the surrounding loft space. Shutting off the pipe to stop the leak whilst waiting for a plumber or heating engineer to make a repair or replacement would have left the nursing home without heating. This was not an option with winter approaching.

The nursing home therefore needed to make a live leak repair that same day to ensure residents were kept warm and prevent significant water damage in the loft space.

Heating pipe at a UK nursing home leaking through a pinhole before undergoing repair with a SylWrap Universal Kit
A steady drip of water was escaping a pinhole in the metal heating pipe, saturating the surrounding loft space

Immediately after the phone call, the maintenance manager drove 20 miles to Sylmasta HQ in Sussex to collect a SYL-616-UP SylWrap Universal Pipe Repair Kit. A Universal Pipe Repair Kit seals leaking pipes even when pressure cannot be turned off by following a simple two-stage process.

Wrap & Seal Pipe Burst Tape was used to repair the pinhole leak. Wrap & Seal is a self amalgamating waterproof tape which stretches by three times its length. As it is wrapped and applied around a pipe, it fuses to form a solid rubber band containing pressurised live leaks.

One 25mm x 2m Wrap & Seal was applied to the heating pipe, easily withstanding the pressure the pipe was operating at to seal the leak. The second stage of the repair involved overwrapping the tape with a SylWrap HD Pipe Repair Bandage.

SylWrap Pipe Repair Bandage used to seal a leaking heating pipe at a nursing home in England
Wrap & Seal Pipe Burst Tape sealed the pinhole leak with the repair area reinforced with SylWrap HD Bandage

SylWrap HD is a composite wrap with a water activated resin which sets rock hard in minutes. It was wrapped and smoothed around the pipe, curing to form an impact resistant protective shell reinforcing the Wrap & Seal for a permanent repair.

It took the maintenance manager under 30 minutes to repair the leaking pipe once they arrived back at the nursing home, leaving residents none the wiser there was a problem with the heating system.

Not only did a SylWrap Pipe Repair Kit ensure there was no impact to residents, but it cost less than £80 – representing a significant saving compared with an emergency callout for a plumber at a time when many nursing homes in the UK are in deep financial trouble.

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: Narrowboat Engine Heat Exchanger Manifold Hole Repair With Superfast Titanium

A hole in a narrowboat engine heat exhchanger manifold undergoes repair with Superfast Titanium Epoxy Putty Stick

Cool engine heat exchange repair keeps a narrowboat sailing

A narrowboat owner uses Superfast Titanium Epoxy Putty Stick to make a high temperature repair to a 15mm x 15mm hole which appeared in the engine heat exchanger manifold of the vessel.

Case Study Data

Site
Narrowboat
Location
United Kingdom
Repair Type
Heat exchanger manifold repair
Defect
15mm x 15mm hole

Products Used

Superfast Titanium Epoxy Putty
Epoxy putty resistant to 280°C for making repairs to high temperature systems, equipment and parts

Case Study PDF

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Case Study Details

The narrowboat had a raw water system for cooling the engine, including a manifold mounted heat exchanger. It worked by pumping canal water into a tank containing a series of pipes on the exhaust manifold.

Inside these pipes ran engine coolant, circulated around the engine block by another pump. The canal water in the tank passed over the pipes, cooling the engine coolant in the same way a fan does in a car. The water was then expelled through the exhaust.

The narrowboat was moored on a canal in Hertfordshire, around 30 miles north of London, when the owner discovered a 15mm x 15mm hole had appeared in the heat exchanger manifold.

A 15mm x 15mm appeared in the engine heat exchanger manifold

They decided to repair the manifold using Superfast Titanium Epoxy Putty Stick. Superfast Titanium was selected because of its high temperature resistance, enabling it to withstand up to 280°C.

Within 24 hours of the narrowboat owner contacting Sylmasta, Superfast Titanium had been delivered to a collection point close to where the vessel was moored.

Before the repair, the narrowboat owner cleaned and rubbed down the heat exchanger manifold to improve adhesion with the epoxy putty. Aluminium mesh was placed over the hole as a precautionary measure to prevent any epoxy putty entering the manifold exchanger.

Aluminium mesh was placed over the hole as a precautionary measure to prevent any Superfast Titanium entering the manifold exchanger

Enough Superfast Titanium to cover the hole was then cut from the stick and kneaded by hand until it turned a uniform, golden brown colour to indicate successful mixing.

The putty was applied over the mesh and surrounding area. It was pushed firmly onto the manifold to ensure maximum contact before being smoothed off with a little water.

Superfast Titanium Epoxy Putty used to seal a hole as part of a narrowboat engine heat exchanger manifold
The hole was sealed by encompassment with Superfast Titanium

Superfast Titanium has a work time of 90 minutes. It reached working strength in eight hours and achieved a full cure after 72 hours.

The narrowboat engine could have gone back into service after eight hours, but the owner was in no rush to set sail again and so remained moored for the full cure 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: Oil Refinery Repair Cooling Pipe System Attacked by Microbially Induced Corrosion

An oil refinery repair welded joints leaking due to microbially induced corrosion in the stainless steel water cooling pipe system

MIC at oil refinery – leaking joints in a water cooling system undergo repair to keep facility online despite microbially induced corrosion

A significant pipe repair programme at an oil refinery seals leaks in a stainless steel water cooling system after microbially induced corrosion caused the failure of welded joints across the site.

Case Study Data

Site
Oil refinery
Location
Middle East
Repair Type
Live leak pipe repair
Defect
Leaking welded joints in stainless steel water cooling system caused by microbially induced corrosion

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating repair tape which fuses together to form a solid rubber band, sealing high pressure live leaks

SylPad Pressure Resistance Multiplier
Increases the pressure resistance of Wrap & Seal by up to three times when making live leak repairs to pipes over 150mm diameter

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap sets rock hard, reinforcing and protecting the initial Wrap & Seal repair

SylWrap Pipe Repair Contractor Case
Easy-to-store Case containing enough Wrap & Seal and SylWrap to make multiple live leak repairs on pipes of various diameters

Case Study PDF

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Case Study Details

The stainless steel water cooling system at the oil refinery was meant to have a lifespan of up to 50 years, yet numerous welded joints across the site were already starting to fail after less than half that time.

Microbially induced corrosion was found to be the cause, a type of corrosion relatively little is known about compared to other forms. It occurs when microbes fix to a surface, producing a biofilm layer where multiple bacteria combine to accelerate the corrosive process.

This biofilm affects the electrochemical environment in multiple ways, including changing ion concentrations, pH values, oxidation levels and creating hydrogen sulphide.

As more biofilm layers form, the bacteria and microbes are given greater protection from treatment methods such as biocides, chemicals and temperature treatments. It becomes increasingly difficult to slow corrosion or eliminate microbes from the pipe system.

Stainless steel normally has enhanced protection against corrosion thanks to its passivation layer, which prohibits microbes attaching and makes a surface less prone to developing biofilms. But if the passivation layer is damaged, microbially induced corrosion will take place.

Installation of the water cooling system at the oil refinery included welding joints together. Unbeknown to the refinery, this had weakened the internal passivation layer of the stainless steel pipework.

When the water cooling system went live, microbes in the water were able to settle on the uneven surface at each welded joint. Bacteria collected and a corrosive action began between the metal and the microbes, attacking the stainless steel from the inside.

Eventually, a series of leaks appeared at welded joints throughout the water cooling system. This represented a major problem at a relatively new and expensively built facility. Replacing the stainless steel pipework was not an option due to the cost and disruption it would cause.

With every welded pipe joint now a potential point of failure, the oil refinery contacted Sylmasta to find a repair solution. Sylmasta recommended the refinery stock a range of different sized Wrap & Seal Pipe Burst Tape and SylWrap HD Pipe Repair Bandages, which permanently seal live leaks when used in conjunction.

Online pipe repair capability was essential to the oil refinery as draining the system would result in at least five days loss of production, along with vast costs for diversion of water.

Over 500 SylWrap HD Bandages and 1,700 Wrap & Seal Tapes were sent to the refinery. Sylmasta also flew to the Middle East and spent a week training, testing and certifying refinery installers and supervisors on using the products.

Workers were shown how to apply Wrap & Seal for high-pressure live leak repair. Wrap & Seal stretches by three times its length and amalgamates together, fusing to form a solid rubber band containing pipe content.

Wrap & Seal Pipe Burst Tape used to repair leaking welded joints in a water cooling pipe system
Multiple Wrap & Seal Tapes applied to leaking welded joints in the water cooling system built repairs with pressure resistance up to 10 bar

Multiple Wrap & Seal Tapes applied on top of each other amalgamate in the same way, building pressure resistance up to 30 bar. This was more than suitable for the cooling system, operating at a maximum 10 bar pressure.

For pipework 150mm diameter or above, workers were also trained in using SylPad Pressure Resistance Multiplier. SylPad is applied alongside Wrap & Seal when making live leak repairs to pipes 150mm diameter and above.

It better concentrates the pressure resistance of Wrap & Seal directly over the leak by directing more of the Tape’s elastic force downwards. Depending on pipe size, nature of the leak and repair quality, SylPad can increase the pressure resistance of Wrap & Seal by up to three times.

The final stage of repair involves overwrapping with SylWrap Bandage. SylWrap is a composite repair wrap with a water-activated resin which sets rock hard in minutes. It provides an impact resistant protective sleeve, reinforcing the repair.

SylWrap Pipe Repair Bandage applied to leaking welded joints on a stainless steel water cooling system at an oil refinery
SylWrap HD provided a rock hard, impact resistant protective sleeve around repairs – which could be made to difficult sections of pipes, including where the water cooling system ran overhead

Since Sylmasta visited, the refinery have used their extensive supply of SylWrap products to repair numerous leaks in the water cooling system – including to sections of overhead and difficult-to-access pipework where the system passes through constrained spaces.

With eliminating microbially induced corrosion from the system impossible, instant live leak repair has proven the best solution for the refinery.

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: 6 Bar Live Leak Repair to 300mm Steel Pipe at Malaysia Water Treatment Plant

A live leak in a 300mm steel pipe at a wastewater treatment plant in Malaysia live leak repair

6 bar sealed – water company in Malaysia seal online leak on 300mm pipe after two weeks of leaking

Just one week after Sylmasta carried out a series of demonstrations and site visits in Malaysia, a water company make their first repair using a SylWrap Contractor Case to seal a 6 bar live leak on a 300mm steel pipe at a water treatment plant.

Case Study Data

Site
Water treatment plant
Location
Malaysia
Repair Type
Live leak pipe repair
Defect
4mm hole in 300mm steel pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating repair tape which seals high pressure live leaks by fusing together to form a solid rubber band

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap which sets rock hard, reinforcing and protecting the initial repair

SylWrap Pipe Repair Contractor Case
Easy-to-store Case containing enough products to make multiple live leak repairs on pipes of various diameters

Case Study PDF

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Case Study Details

The pipe had been leaking for around two weeks through a 4mm hole. It could not be shutdown because of its importance to operations at the treatment plant, leaving a steady 6 bar jet of water escaping and saturating the floor.

Such a leak would normally be sealed by the water company using a pipe repair clamp. The hole though was located on a section of pipe with a saddle joint welded on, sitting approximately 15mm above the original line. A clamp would therefore be ineffective.

6 bar live leak at a wastewater treatment plant in Malaysia before repair using a SylWrap Pipe Repair Contractor Case
Water was escaping the pipe through a 4mm hole at 6 bar pressure, saturating the surrounding floor

After a visit and presentation from Sylmasta a week earlier, the water company operating the treatment plant had taken a supply of SYL-PRO-866 SylWrap Pipe Repair Contractor Cases for sealing multiple leaks on pipework between 300mm and 600mm diameter.

One of the water company’s maintenance teams who Sylmasta had worked with whilst in Malaysia were tasked with using a Contractor Case to make a live leak repair to the pipe at the water treatment plant.

The leak was sealed with Wrap & Seal Pipe Burst Tape. Wrap & Seal stretches by three times its length and fuses together as it is wrapped around a pipe, forming a solid rubber band which seals the leak.

Applying multiple Wrap & Seals on top of each other builds pressure resistance. In high pressure repairs, tapes continue to be added until no water is seeping through and the user is satisfied the leak has been fully arrested.

Three 50mm x 11m Wrap & Seals were used by the maintenance team until the repair could withstand the 6 bar pressure. A SYL866HD SylWrap HD Pipe Repair Bandage was then applied to reinforce and protect the Wrap & Seal.

SylWrap Pipe Repair Bandage applied to a live leak in 300mm steel pipe at a wastewater treatment plant in Malaysia
Wrap & Seal was used to build a repair pressure resistant to 6 bar before overwrapping with a SYL866HD SylWrap HD Bandage

SylWrap HD has a fast-working, water activated resin. It was wrapped directly over the repair area, where it set rock hard within minutes to form an impact resistant outer shell.

Completing the repair took one hour. Having seen how quickly and easily it is to make a live leak repair when maintenance teams are equipped with a Contractor Case, the water company is already planning to expand their use – including onto the public supply network.

All the products in the Case have WRAS approval, meaning they are certified to British standards as safe to use with drinking water.

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: Underground 600mm Concrete Water Pipe Break Repair in Canada

A break in a 60mm underground concrete water pipe in Canda is repaired using Sylmasta products

BC pipe break repair – reducing water loss from an indefinable leak for a city in western Canada

A city authority in Canada repair an underground 600mm diameter concrete pipe with a difficult break at the point it passed through a wall, reducing a 2 bar leak losing significant amounts of water down to a slow and steady drip.

Case Study Data

Site
Public Water Network
Location
British Columbia, Canada
Repair Type
Leak Repair
Defect
Crack in a 600mm diameter concrete water supply pipe

Products Used

Sylmasta AB Original Epoxy Putty Stick
Epoxy putty offering excellent wet surface adhesion for sealing pipework which cannot be made dry before repair

SylWrap HD Pipe Repair Bandage
Composite wrap with water activated resin which sets rock hard to reinforce repairs by forming an impact resistant outer sleeve

Case Study PDF

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Case Study Details

The 600mm diameter pipe ran beneath a road in a city in British Columbia. A break was detected and with other concrete pipe bursts making headline news across Canada, the city authority carried out an immediate excavation to assess the problem and repair the leak.

A steady, hard spray of water was discovered jetting out of the pipe through a joint at the exact point the line passed into a solid concrete wall. This made identifying the exact source of the leak impossible.

The city authority contacted Sylmasta for help with what was a very challenging application. Not only was the precise leak point unknown, but the pipe was unable to be fully shutdown.

An underground water pipe in Canada with a break through which water was leaking at 2 bar pressure
The pipe was leaking from a break somewhere beneath a joint at the point it passed into a solid concrete wall

A further complication came with the break being so close to the wall, meaning the normal live leak repair method of applying Wrap & Seal Pipe Burst Tape would be ineffective.

There was insufficient space to stretch the tape by the required 300 percent to ensure it successfully amalgamated to form a solid rubber band.

Sylmasta suggested reducing the pressure as much as possible from the 2 bar the pipe operated at, followed by using AB Original Epoxy Putty to seal around the entire joint.

AB Original was recommended because it has excellent underwater adhesion, meaning it could bond to the pipe even if wet from the ongoing leak. Its two-hour work time also offers longer to work the putty without worrying about premature curing during application.

The importance of the pipe to the city network meant pressure could only be reduced between midnight and 5am, giving the two maintenance workers making the repair a five-hour window in which to work.

Sylmasta AB Original Epoxy Putty Stick used in the repair of a concrete water main pipe break in Canada
Two maintenance workers mixed AB Original Epoxy Putty by hand inside the hole dug to access the pipe before applying it to the leak area

Just under 8kg of AB Original was used in the repair, supplied in 200g sticks. Each stick was mixed by hand until it turned a uniform colour. It was then packed around the leaking joint, building a repair which encompassed the entire break area.

Despite water pouring out the top of the pipe during the repair, AB Original bonded successfully. After two hours, the putty had set to form a watertight material which reduced the amount of water being lost down to a slow drip.

The pipe was then wrapped with SylWrap HD Pipe Repair Bandage for added reinforcement. Two SYL866HD were used, creating a rock-hard outer shell to further protect the pipe and help increase the effectiveness of the repair.

SylWrap Pipe Repair Bandage used to reinforce a break in a concrete water main pipe in Canada
AB Original was packed around the break in the pipe, encompassing the leak area. The repair was then overwrapped with SylWrap HD Bandage.

Completing the application took around three hours. The city authority were particularly impressed with Symasta’s efficiency. It took under five days from initial contact for a repair method to be devised, the goods shipped from the UK to British Columbia and the leak reduced to an acceptable level until the section of pipe can be replaced.

The need for speed in addressing the leak before it could escalate into a major problem was particularly important at a time when Canada’s pipe network is under scrutiny following high-profile bursts in Calgary and Montreal which led to flooding and the rationing of public water supplies.

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

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

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Case Study: Repair of 1.05-Metre Long Crack in Cast Iron Downpipe at UK Hospital

Repair of a crack in a cast iron downpipe at a UK hospital through which rainwater had previously been leaking

Emergency operation at UK Hospital… to repair a crack in a cast iron downpipe

A 1.05-metre long crack through which rainwater leaked from a cast iron downpipe located in a constrained wall cavity is sealed in under 30 minutes, with the ease and speed of repair limiting disruption to patients and staff at a busy UK hospital.

Case Study Data

Site
Hospital
Location
United Kingdom
Repair Type
Leak Repair
Defect
1.05-metre longitudinal crack in cast iron downpipe

Products Used

CrackSeal Pipe Sealant
Sealant extruded directly into cracks in cast iron pipework, setting almost instantly for rapid sealing and repairs

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

SylWrap Drain & Waste Pipe Repair Kit
Specialist Kit containing products for repairing low-pressure cast iron and plastic waste, sewer and drain pipes

Case Study PDF

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Case Study Details

The hospital contained an internal 150mm diameter cast iron pipe system for taking away rainwater. The system was reaching the end of its lifespan, but budget restraints and the possibility of new facilities being built in the future meant replacing the ageing pipework was not considered viable.

Instead, the hospital was told to find cost-effective repair methods in the event of the system failing. Which is what happened when a 1.05-metre longitudinal crack developed in one section of pipework.

The leak was located in a constrained wall cavity where the pipe passed downwards through plasterboard on its way to the ground floor. The length of the crack meant it extended far enough on the pipe to also pass through the plasterboard.

Longitudinal crack in a cast iron downpipe before undergoing repair using a SylWrap Cracked Pipe Repair Kit
A 1.05-metre longitudinal crack had developed in the cast iron downpipe

When it rained, water escaped the pipe and saturated the plasterboard. This eventually led to rainwater dripping into a ward full of patients, at which point the hospital became aware of the problem. To ignore it would risk a significant leak developing into the ward, and damaging consequences for the ceiling and wall structure.

A specialist drainage engineer was called in. After accessing the wall cavity, removing some of the plasterboard and inspecting the crack, they decided to use the products in the SylWrap Drain & Waste Pipe Repair Kit to permanently seal the leak.

The Drain & Waste Pipe Repair Kit has been designed for repairing cracks and splits in low-pressure cast iron and plastic waste, soil and drain pipes. It comes in a robust red case which is easily kept on-site or on the van by facilities management teams, drain companies and others regularly required to repair such pipework.

Whenever a problem is identified, the user simply retrieves their Kit where everything needed to make multiple repairs quickly and easily is stored.

For this application, CrackSeal Pipe Sealant was used to fill the crack in the pipe. CrackSeal is a high-performance moisture curing sealant specially formulated to fill longitudinal cracks and splits in cast iron pipework.

Crack in a cast iron downpipe filled as part of a repair involving CrackSeal Sealant
CrackSeal Sealant was extruded directly into the crack

Sufficient CrackSeal was extruded directly from its cartridge into the crack until it was totally filled. Although CrackSeal hardens almost instantly, it was left for 10 minutes to form a skin before the repair was reinforced with SylWrap HD Pipe Repair Bandage.

Two SYL616HD Bandages were wrapped along the entire length of the 1.05-metre crack, creating a two-layer repair. The water-activated resin set rock-hard in minutes, providing an impact resistant sleeve protecting both the CrackSeal and the rest of the downpipe.

SylWrap Pipe Repair Bandage applied during the repair of a crack in a cast iron downpipe
Two SYL616HD Bandages were applied around the pipe to create a two-layer repair, completing the application

Sylmasta normally recommend 10 layers of SylWrap HD Bandage be used for full reinforcement. Only two were needed for this application because the pipe took rainwater away at such low pressure.

The cast iron crack repair was completed in under 30 minutes with no disruption to patients or staff in the ward impacted by the leak. Numerous other repairs have now been using the Drain & Waste Pipe Repair Kit made to pipework across the hospital which has since failed.

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 Joints Sealed in Cast Iron Rainwater Stack Repair at London Office Block

A 250-metre cast iron rainwater pipe undergoes repair after it was found to be leaking through corroded joints

Three hundred not out – 300 joints are sealed in a leaking rainwater stack which threatened to derail the timeframe of an office block refurbishment

The refurbishment of a five-floor office block in central London is kept on track thanks to Sylmasta AB Original Epoxy Putty sealing 300 pipe joints in the repair of a 250-metre long internal cast iron rainwater stack leaking due to corrosion.

Case Study Data

Site
Office block
Location
London, UK
Repair Type
Leak repair
Defect
Corroded joints in cast iron rainwater stack

Products Used

Sylmasta AB Original Epoxy Putty Stick
Waterproof epoxy putty with a two-hour work time for thorough leak sealing without the threat of curing before application is complete

Case Study PDF

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Case Study Details

With the entire office block stripped out as part of the refurbishment, the internal cast iron rainwater stack was accessed for the first time in many years. This revealed that 30-year-old rubber seals used to attach different sections of pipe together had begun to fail and would need replacing.

When these rubber seals were removed, the pipe ends underneath were discovered to be badly corroded where water had become trapped. Because of the uneven pipe surface, pitting and breaches caused by corrosion, it was now impossible to achieve a watertight seal.

Corrosion had left the pipe ends pitted, uneven and breached,, making it impossible to create a watertight joint using seals or clamps

The engineering company carrying out the office refurbishment tried new rubber seals, metal seals, pipe repair clamps and pipe repair clamps with teeth. When the joints continued to leak, it appeared the only option was to replace the entire 250 metres of pipework at considerable cost and with significant delay to the office refurbishment.

Sylmasta were called in to see if there was a better solution to repair the rainwater stack rather than total replacement. It was soon established the newly installed clamps could be removed and Wrap & Seal Pipe Burst Tape used to reconnect the pipe joints together, sealing them much more effectively.

However, the rainwater stack system running close to walls, floors and ceilings made it awkward in some areas to apply Wrap & Seal with the required 300 percent stretch. Removing every clamp would also be a time-consuming task.

It was instead decided to seal each clamp with Sylmasta AB Original Epoxy Putty Stick. Enough putty was cut from the 200g stick and kneaded by hand. Whilst soft, AB Original was forced into both ends of the clamp, filling the gaps between it and the corroded pipe surface.

Pipe repair clamp holding together a corroded joint in a cast iron rainwater stack sealed with AB Original Epoxy Putty
AB Original Epoxy Putty was pushed between the newly installed clamps and the pipe surface, filling all gaps to seal the leaks

Once AB Original had hardened, it permanently sealed any leak paths. The repair was so effective that the engineering company decided to apply AB Original to all 300 joints on the rainwater stack, giving them full confidence the system would have no leaks once it was boxed back in and inaccessible.

The extended two-hour work time of AB Original allowed the engineers to thoroughly seal every joint at a reasonable pace without fear the putty would set before being properly applied.

120kg of AB Original was used for the repair. Supplying the epoxy putty in stick format eliminated the need to measure out separate components of Part A and Part B, making application quicker and more straightforward.

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

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

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

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

Case Study Data

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

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape seals live leaks by fusing together to form a solid rubber band

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap which sets rock hard to reinforce and protect repairs

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

Case Study PDF

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Case Study Details

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

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

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

Previous repairs made by the mill using Contractor Cases

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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