Category: Pipe Repair

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Case Study: Repair of Leaking & Corroded Shared Water Supplying Eight Cottages

Liquid Metal Epoxy Coating used in the repair of a corroded shared water supply pipe

Cottages counter corrosion – the Sylmasta Pipe Refurbishment System is used to repair and reinforce a water supply line shared by eight properties

Four cottages in a terrace of eight in London use the Sylmasta Pipe Refurbishment System to repair and reinforce their respective sections of a 48 metre long shared water supply pipe weakened and breached by corrosion.

Case Study Data

Site
Terraced cottages
Location
London, UK
Repair Type
Leak repair and pipe reinforcement
Defect
Heavily corroded 48 metre long steel shared water supply pipe breached in places

Products Used

Superfast Aqua PW Epoxy Putty Stick
Fast working, WRAS approved epoxy putty with excellent wet surface adhesion used to seal leaks in pipework

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

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

Case Study PDF

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Case Study Details

The row of eight terraced cottages were built in the middle of the 19th century. They were connected to the public water network at a later date, which led to a somewhat unusual setup involving an above-ground shared supply pipe.

This steel pipe connected with a water main underground at one end of the terrace. It rose up the side of the first cottage and was then fixed at a height of around three metres to the back wall of all eight properties, along which it ran for 48 metres.

The height of the line meant it was surrounded by extensions built onto the cottages, downpipes, guttering and other installations and improvements added to the buildings over time. Access to certain sections was therefore severely restricted.

Lagging being removed from the section of pipe climbing up the side wall. The line then ran for 48 metres along the back of the cottages.

Each cottage was responsible for the section of pipe outside their property, giving them around six metres to maintain and upkeep. Lagging had been added around all 48 metres of the line to protect it during winter.

Unfortunately, low-quality insulation material was used which soaked up moisture like a sponge, causing water and condensation to become trapped against the steel. Over time, this led to heavy corrosion and a weakening of the pipe.

When temperatures in London dropped as low as -8°C in an unusually cold spell and water inside the pipe froze, the brittle metalwork was unable to cope. Several cracks appeared outside one cottage, requiring repair.

The lagging was removed from the leaking section to access the pipe, at which point the extent of the corrosion problem became clear. The other seven cottages were inevitably going to suffer from bursts on their sections in future if something were not done.

Corrosion covered the pipe where it ran along the back wall of the cottages

Initially, the cottages contacted their water company for help. Because the pipe was a shared supply line and not part of the public network, the water company said they had no responsibility for it. It was therefore down to the eight property owners to find a solution themselves.

The cottages were quoted £22,000 to replace the entire line. Some of the property owners did not wish to contribute £2,750 towards the cost, preferring instead to take a chance their section would not burst.

It next became clear that replacing individual sections of pipe for those cottages wanting to avoid future leaks would not be practical either. New fittings would struggle to connect with old, brittle pipes not being replaced.

Installation would also be disruptive to those cottages not undertaking work, with shared electrical boxes and satellite dishes having to be taken out of service whilst new sections of pipe were fitted.

With no common route forward found, the cottage with the leaking section contacted Sylmasta for advice on sealing the holes on their part of the line. At this point, the owner also explained the complications caused by the shared water supply pipe and the concern about how it might deteriorate further.

Sylmasta suggested that in addition to sealing the cracked section of pipe outside one cottage, their Pipe Refurbishment System be used to reinforce individual sections along the line for those property owners wanting protection against future leaks.

Two cottages requested their sections be attended to, and so Sylmasta sent an approved contractor to London to carry out the repair and strengthening of the shared water supply pipe.

Superfast Aqua PW Epoxy Putty used to repair a crack in a heavily corroded shared water supply line
Superfast Aqua PW Epoxy Putty sealed the holes in the section of pipe which had burst

Once the lagging had been removed, the first stage of the Pipe Refurbishment System involved application of the leak sealant – in this case, Superfast Aqua PW Epoxy Putty.

Superfast Aqua PW was chosen for its excellent wet surface adhesion to alleviate concerns the pipe may have been weeping water. It has WRAS approval, meaning it is certified as safe to come into contact with potable water.

Aqua PW is supplied in a pre-measured 114g stick. The required amount of putty was cut from the stick, kneaded by hand and then pushed into the cracks and damage in the pipe whilst soft. Within 20 minutes, it cured to form a rock-hard sealing material.

Liquid Metal could be easily painted onto difficult-to-access areas of the pipe

The second stage of the Pipe Refurbishment System saw Liquid Metal Epoxy Coating applied to strengthen the line and protect it from corrosion. Liquid Metal was painted on by brush to sections of the pipe outside every cottage who wanted their part of the line reinforced.

Repair of a shared water supply pipe made using Liquid Metal Epoxy Coating
Liquid Metal coated around a bend in the repair of a shared water supply line
Liquid Metal applied during the repair of a section of shared water supply running awkwardly behind a gutter down section
Liquid Metal coated onto the pipe to form a new metallic outer surface

Once cured, Liquid Metal formed a smooth, metallic, hard-wearing outer surface around the pipe to act as a shield against external corrosion. Should the brittle steel be breached from the inside by freezing temperatures in future, the Liquid Metal shell will contain the contents of the pipe.

Liquid Metal Epoxy Coating brush applied during the repair of a corroded shard water supply line
The cottages who did not wish for their sections of pipe to be reinforced were left with the original lagging and corroded pipe, contrasting with the refurbishment provided by Liquid Metal

SylWrap HD Pipe Repair Bandage was added as the final stage of the Pipe Refurbishment System, to provide the shared water supply pipe with another layer of protection. SylWrap HD is a composite repair wrap with a water-activated resin which sets rock-hard in minutes when wrapped and smoothed around pipework.

SylWrap HD Pipe Repair Bandage reinforces a shared water supply pipe during a repair
The pipe was given further protection using SylWrap HD Pipe Repair Bandage

Nine SylWrap Bandages were applied per cottage to build up thickness to four layers, with the application taking place whilst the Liquid Metal remained tacky to improve adhesion to the pipe. Once cured, SylWrap HD formed an impact resistant shell encompassing the pipe.

In addition to the two planned repairs, a third cottage owner asked for their section to be reinforced, having seen how straightforward and cost-effective the process was. Their part of the shared water supply pipe had not been as badly weakened by corrosion and therefore required only Liquid Metal for suitable strengthening.

All three cottages were completed in a single day, with the approved contractor also installing new lagging to replace the original insulation which had to be removed. A fourth cottage then requested the approved contractor return and attend to their part of the pipe, meaning half the 48 metres had been reinforced.

Lagging installed for insulation during the repair of a shared water supply pipe
Lagging added to complete the repair

Around one year after the original repair and a fifth cottage contacted Sylmasta. 12 months of further corrosion had left their section of the pipe on the verge of collapse.

Refurbishment of this section was now far more challenging and costly than the repair the other four cottages had opted for – highlighting the benefits of strengthening and protecting systems before more serious problems develop.

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: Luxury Portable Toilet Trailer Leaking Wastewater Holding Tank Repair

The wastewater holding tank of a luxury toilet trailer undergoes repair and refurbishment

Repair and refurbishment helps a portable toilet company avoid flushing two working luxury trailer units down the drain

Holding tanks with the capacity to store 3000 litres of wastewater underneath two luxury portable toilet trailers undergo repair and strengthening after the metalwork became weakened by corrosion, causing numerous holes to appear.

Case Study Data

Site
Luxury Portable Toilet Trailer
Location
United Kingdom
Repair Type
Tank repair and refurbishment
Defect
Heavy corrosion to two wastewater storage tanks

Products Used

Sylmasta AB Original Epoxy Putty
Epoxy putty pushed into holes and cracks in tanks and pipes, where it will cure to a rock-hard material which permanently seals leaks

Liquid Metal Epoxy Coating
Brush applied coating which strengthens and protects metalwork by forming a new metallic, hard-wearing surface

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Case Study Details

Luxury portable toilet trailers are mobile restroom facilities used for large outdoor occasions, such as music festivals and sporting events. They include flushing toilets, urinals, sinks with running water, mirrors and lighting, offering a much more comfortable experience than standard portable toilets.

Toilet trailers require no connection to permanent plumbing. Instead, the wastewater they produce is stored in holding tanks between the floor of the restroom and the undercarriage of the trailer. When the event has finished, the tanks are drained and the wastewater taken to a treatment site before the trailer is moved onto its next destination.

Constructing a portable toilet trailer is expensive, and so when one of the United Kingdom’s leading suppliers discovered holes starting to appear in the wastewater holding tanks of two of their units, they contacted Sylmasta for advice on whether a repair was feasible.

Damage to the underneath of the first portable toilet trailer
The second trailer was suffering from more extensive corrosion and surface damage

The plumbing, fixtures and fittings in each of the trailers were otherwise in perfect working order. The company therefore wanted to avoid decommissioning the two trailers if the holes in the wastewater tanks could be plugged and the weakened metalwork strengthened against future damage.

Sylmasta recommended a two-stage repair, starting with Sylmasta AB Original Epoxy Putty and finished with Liquid Metal Epoxy Coating. The first trailer was jacked up, enabling access underneath the wastewater holding tank. The metalwork was then ground down to remove rust, dirt and grime.

AB Original Black was supplied in stick format for the plugging of the holes. An AB Original Stick combines the resin and hardener pre-measured rather than in a tub of Part A and a tub of Part B, eliminating the need for weighing out and mixing separate components. This makes a repair quicker and easier.

AB Original Epoxy Putty used to seal leaks in a portable toilet trailer wastewater tank repair
Wastewater tank underneath a portable toilet trailer undergoes repair and sealing using Sylmasta AB Original Epoxy Putty
A significant number of holes underneath trailer one sealed with AB Original Black Epoxy Putty.
Holes underneath trailer two sealed with AB Original Black

The required amount of putty to fill a hole was cut from the stick and kneaded by hand. Once the putty had turned a uniform black colour but was still soft, it was pushed into the hole. After two hours, AB Original cured to form a rock-hard sealing material. Every hole in the tank was permanently filled in this way.

Once all the holes had been attended to, the entire bottom of the trailer – an area 1.3 metres by 2.5 metres – was painted with Liquid Metal Epoxy Coating. Also painted were the metallic box and pipe fitted to the bottom of the holding tank, through which wastewater was removed. Two coatings of Liquid Metal were brush applied, curing to form a smooth, metallic, hard-wearing surface.

This new surface repaired and strengthened the weakened metalwork to increase structural integrity. It acted as a protective shield against further external corrosion and encased the wastewater tank in a new outer shell, capable of containing the wastewater if the original metalwork became fully breached in future.

Trailer one coated with Liquid Metal to complete the repair
Liquid Metal coated onto the wastewater storage tank of a portable toilet trailer to complete a corrosion protection repair
Liquid Metal Epoxy Coating used to protect a portable toilet trailer from corrosion during a repair and refurbishment
Trailer two having been reinforced and refurbished with Liquid Metal

After the repair of the first toilet trailer was completed, the second was jacked up and fixed by following the exact same process. Each trailer could go back into service 24 hours after the second coating of Liquid Metal had been applied.

In total, 10kg of AB Original and 10kg of Liquid Metal were used to repair the two portable toilet trailers at a cost of under £800, representing a huge saving on replacing the units. The company are now planning to use the repair method on other units when they become weakened by corrosion, potentially extending the lifespan of their entire fleet by up to 10 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: Repair of Hairline Crack Around Diameter of Porcelain Toilet Soil Pipe

Wrap & Seal Pipe Burst Tape seals a hairline crack in a porcelain toilet waste pipe repair

Soil pipe sealing – Wrap & Seal forms a rubber ring to repair a porcelain toilet

A homeowner carries out a DIY pipe repair to a porcelain soil pipe which developed a hairline crack around its entire diameter after an unstable bathroom floor caused the toilet to shift away from the wall it was connected to.

Case Study Data

Site
Bathroom
Location
United Kingdom
Repair Type
Leak repair
Defect
Hairline crack in porcelain soil pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape which formed a watertight rubber ring to encompass and seal the pipe

Case Study PDF

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Case Study Details

The porcelain soil pipe connected the bowl of the toilet with the sewer pipe behind. The increasingly unstable bathroom floor meant that whenever anyone sat on the toilet, it tilted forward and pulled the pipe away from its fixed connection to the back wall.

Eventually, the stress being put on the pipe by the frequent movement of the toilet caused a hairline crack to appear around the entire diameter, through which water dripped whenever the toilet was flushed. This had the potential to make the floor even more unstable.

A hairline crack in a porcelain toilet waste pipe caused by an unstable floor
The crack caused by movement of the toilet pulling the porcelain soil pipe away from its connection to the bathroom wall

The homeowner was planning a full bathroom renovation to address the floor issue, which would include replacing the toilet. They therefore wanted a quick, easy and cost-effective DIY method to repair the porcelain soil pipe until said renovation took place.

There were several challenges with the repair. The crack was too thin to force epoxy putty into and was located on a bend in a difficult position, close to the back wall and with minimal space between the pipe and floor.

The continued movement of the toilet also had to be taken into account. Any repair needed to offer a degree of flexibility, as rigidly fixing the pipe back in place would leave the potential for cracks to develop elsewhere.

Sylmasta recommended encompassing as much of the pipe as possible with Wrap & Seal Pipe Burst Tape to create a watertight rubber ring bonded to the porcelain. This would seal the leak, allow the pipe an element of movement to reduce stress, and prevent water escaping from any other cracks which developed elsewhere in the porcelain.

A hairline crack in a porcelain toilet soil pipe having undergone repair with Wrap & Seal Pipe Burst Tape
Wrap & Seal Pipe Burst Tape created a rubber ring around the entire leak area, sealing the crack

Wrap & Seal is made from self-amalgamating silicone which fuses to itself to form a solid rubber band as it is wrapped around a pipe. One 50mm x 4m tape was enough to cover the leak and the surrounding area susceptible to future cracks.

Despite the space constraints between the back wall, the floor and the toilet bowl, the homeowner was able to stretch the tape to three times its length whist wrapping, creating maximum tension.

The tape easily fused, fully sealing the leak and preventing any more water escaping when the toilet was flushed. Completing the porcelain soil pipe repair took less than 15 minutes and cost under £30, including delivery of the Wrap & Seal Pipe Burst Tape.

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: 3 Metre Section of Corroded Steel Gas Pipe in CHP System Repair & Refurbishment

A heavily corroded steel pipe in a CHP system carrying natural gas undergoes repair with the Sylmasta Pipe Refurbishment System

Combined Liquid Metal and SylWrap HD repair combined heat and power system natural gas pipe

An industrial plant repair and refurbish a three-metre section of steel pipe carrying natural gas in a combined heat and power system after water trapped between the line and an incorrectly installed PVC tape caused heavy corrosion.

Case Study Data

Site
Industrial Plant
Location
Puerto Rico
Repair Type
Pipe refurbishment
Defect
Three metre section of corroded 100mm steel pipe in CHP system

Products Used

Liquid Metal Epoxy Coating
Brush applied coating which cures to form an ultra-smooth, hard wearing, metallic surface over pipes and structures

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

Case Study PDF

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Case Study Details

The pipeline was 100mm in diameter and ran for 365 metres through the plant, carrying natural gas produced by a combined heat and power system. It was hung on a series of U-shaped supports welded to I-beams suspended from the roof of the building.

When originally installed, the pipe had been wrapped with a protective PVC tape. Unfortunately, incorrect application of the tape had left a three-metre section where it was possible for water and condensation to become trapped between the tape and the line.

Removal of the yellow PVC tape revealed very heavy corrosion to the steel pipe

This had led to heavy corrosion, which was particularly prevalent at the bottom of the pipe and the area where the section in question rested on its U-shaped support. The weakened three metres of the natural gas pipe now required strengthening and repair before the steel became breached.

The pipe was cleaned of paint and grime before repair of the corroded surface

The plant decided to use the Sylmasta Pipe Refurbishment System to bring the damaged section of the line back up to specification, by reinforcing the metalwork and giving the pipe greater protection against future corrosion.

First, the U-Shaped support was cut away from the I-beam to enable better access to the corroded area. The PVC tape was removed and rust, grime and paint ground off. Alcoholic cloths were then used to remove any remaining residue from the grinding process.

Liquid Metal applied to repair a natural gas pipe suffering from heavy exterior corrosion
Liquid Metal was brush applied across the three metres of the pipe suffering from corrosion

To repair the damage and restore the pipe exterior, the three-metre section was coated in Liquid Metal Epoxy Coating. Liquid Metal is brush applied and cures to form a smooth, metallic, hard-wearing outer surface which acts as a shield against external corrosion and chemical attack.

The 90-minute gel time of Liquid Metal allowed significant amounts of epoxy to be mixed and painted on without the threat of premature curing. A SylWrap HD Pipe Repair Bandage was then wrapped around the area of the line which had contact with the U-shaped support.

SylWrap HD Pipe Repair Bandage applied to a heavily corroded steel natural gas pipe
SylWrap HD was wrapped around the area of the pipe which came into contact with the U-shaped support, which was to be welded back in place to the I-beam above

SylWrap HD is a composite repair wrap with a water-activated resin. It was applied whilst the Liquid Metal remained tacky and cured within minutes to form a rock-hard, impact resistant outer shell around the pipe. This further increased the thickness of the weakened section and provided an additional layer of protection.

A second layer of Liquid Metal was applied across the three-metre section, including over the SylWrap HD. Although an additional coating on top of the composite bandage is not a required step of the Sylmasta Pipe Refurbishment System, the plant wanted to make the line look aesthetically pleasing with a final metallic finish.

A second Liquid Metal coating was applied over the SylWrap, the U-support welded back in place and the pipe fixed to it via a support clamp

Once the pipe had been refurbished, the removed U-shaped support was welded back to the I-beam. The line was then fixed to the U-shape via a new pipe support clamp fitted to prevent movement caused by vibration. The clamp was also coated in Liquid Metal.

Refurbishing the pipe was carried out with no impact to operations at the plant. It prevented an expensive and disruptive future repair or replacement being needed when corrosion eventually ate through the line.

The ultra smooth finish provided by Liquid Metal compared to the pitting caused by corrosion

The plant were very happy with the outcome and how easy their maintenance team found the application. They are now intending to use Liquid Metal to extend the lifespan of other pipes and structures at both this facility and across other sites.

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

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

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Case Study: Leaking Welded Saddle Joint Repair on 150mm Steel Pipe at Pumping House

A leaking saddle joint welded on a 150mm steel pipe undergoes repair after being found to be leaking from both ends

Saddle up for a complex repair – sealing a leaking welded saddle joint with a 20mm step using Wrap & Seal Pipe Burst Tape

A 150mm steel pipe connected to a pumping house in Malaysia which was leaking from both ends of a welded saddle joint is sealed in a successful repair built up and over a 20mm step between the line and the joint.

Case Study Data

Site
Pumping house
Location
Malaysia
Repair Type
Live leak repair
Defect
Leaking saddle joint on a 150mm steel pipe with a 20mm step

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating repair tape which sealed up and over the leaking saddle joint weld

Case Study PDF

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Case Study Details

The 150mm steel pipe ran water out of the pumping house. The saddle joint had been welded in place to reinforce a capped tee and sat approximately 20mm higher than the original line. One end of the joint was suffering from heavy corrosion.

Water had been found seeping from both ends of the joint, leaving the pipe surface noticeably wet and the ground beneath the pipe sodden. The pipe could not be isolated or replaced because this would involve shutting down the pumping station.

Several repair attempts had failed, including a clamp
A 150mm steel pipe with a heavily corroded saddle joint prior to undergoing leak repair
One end of the saddle joint was suffering from heavy corrosion whilst water was seeping from both

Several repair attempts had been made using different methods by the water company operating the facility, including the use of a clamp and epoxy putty, but none had been successful. The pipe had therefore been left to leak.

Whilst on a visit to Malaysia, a technician from Sylmasta was asked to accompany a engineering team to inspect the pipe and see if a solution could be formulated. They recommended using Wrap & Seal Pipe Burst Tape to start a repair on the original steel pipe and build it up and over the weld, encompassing and sealing either end of the saddle joint.

The pipe was cleaned and prepared before repair

First, an angle grinder was used to sand down the pipe, clean it of loose material and remove corrosion. A first Wrap & Seal Tape was then applied directly next to the step. Wrap & Seal is self-amalgamating and stretches by three times its length, fusing together to form a solid rubber band.

Diagram explaining how to repair a leaking saddle joint weld with a step using Wrap & Seal Pipe Burst Tape
Wrap & Seal application started on the pipe next to the saddle, was built up until level with the step and then continued across onto the joint

With each rotation, the Tape moved closer to being level with the top of the saddle joint. The application continued until enough Wrap & Seal had been applied to bridge the 20mm step between the pipe and the saddle.

Once this had been achieved, Wrap & Seal was applied 50mm across the saddle to achieve a good connection. It was then returned to directly over the edge of the joint.

Once Tape had been built up and over the saddle, wrapping continued immediately over the leak area
Wrap & Seal Pipe Burst Tape applied to a leaking saddle joint in a successful repair despite a 50mm step being present
The finished repair with both ends of the saddle joint sealed

Here, a ridge was created directly over the leak area to increase the pressure resistance of the repair. It was estimated that three Wrap & Seal Tapes needed to be used to seal one end, after which the process was repeated at the other end of the saddle joint.

Because the welded saddle joint had been seeping water slowly, the only way to check whether the application had been effective was to inspect several days later. When the pipe surface was found to be dry, the repair was deemed a success.

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

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

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Case Study: Burst Copper Pipe Repair in Portable Horse & Dog Shower Unit

A copper pipe burst during freezing winter weather undergoes repair with a SylWrap Standard Pipe Repair Kit

Replacement? Hold your horses – the repair of a burst copper pipe which had a horse shower running again in no time

When freezing winter weather led a copper pipe in a portable horse and dog shower to burst, it required a quick and simple repair method capable of being effective inside the cramped space of the unit.

Case Study Data

Site
Portable horse and dog shower
Location
United Kingdom
Repair Type
Leak repair
Defect
Split in copper pipe caused by freezing temperatures

Products Used

Superfast Copper Epoxy Putty Stick
Fast-working epoxy putty pushed into the crack in the copper pipe to seal it

SylWrap HD Pipe Repair Bandage
Composite repair wrap applied over Superfast Copper to reinforce the initial repair

SylWrap Standard Pipe Repair Kit
Superfast Epoxy and SylWrap HD are supplied together in the Standard Pipe Repair Kit

Case Study PDF

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Case Study Details

Showerking are a Sussex-based supplier of portable hot shower units designed for horses and dogs. Units are typically stored in unheated outbuildings. Although designed to handle winter weather, copper pipe in the unit which has not been fully drained becomes prone to bursting during periods of exceptionally cold weather.

When temperatures in the United Kingdom dropped as low as -15°C, several Showerking owners reported burst pipes which rendered their units unusable. If they turned the shower on, water would spray out of the large crack created in the copper pipe.

Freezing temperatures had created a split in the copper pipe

Fortunately, Showerking had already contacted Sylmasta about the possibilities of pipe repair for horse showers. The SylWrap Standard Pipe Repair Kit provided the most suitable method as units would be turned off in the event of leaks or bursts, meaning no pressure to the pipe.

It had been established that the smallest Standard Pipe Repair Kit (SYL-106-NP) was ideal for application because of both the cramped space inside the unit and the difficult shape of the pipework. There were many bends which were unrepairable with a clamp.

Through the relationship between Showerking and Sylmasta, users whose horse showers had suffered burst pipes were directed to the exact product they needed to fix the problem, and had the straightforward repair process explained to them.

Superfast Copper Epoxy Putty used to repair a burst in a horse shower copper pipe caused by freezing temperatures
Superfast Copper Epoxy Putty was used to cover the split

Loose material was removed from the burst copper pipe before repair. Superfast Copper Epoxy Putty Stick was then used to seal the crack. Enough putty to cover the crack was cut from the stick and kneaded by hand until it turned a uniform colour.

Whilst soft, the putty was pushed onto the pipe, encompassing the entire crack. This completed the first stage of the repair. The second stage involved applying a SylWrap HD Pipe Repair Bandage over the Superfast Copper.

A burst copper pipe in a portable horse shower unit repaired and reinforced with SylWrap HD Pipe Repair Bandage
The repair was finished with reinforcement via a SylWrap HD Pipe Repair Bandage

SylWrap HD is a composite repair wrap with a water-activated resin which sets rock hard. The bandage was wrapped and smoothed around the pipe as the Superfast Copper began to harden, forcing the putty into the crack to create a permanent, watertight seal.

Within five minutes of SylWrap HD being applied, the bandage had cured to form a rock hard shell reinforcing the pipe, and which also offered protection from expansion in the future. The completed repair was resistant to 30bar, making it more than capable of holding the pressure the horse shower unit operated at.

The repair took less than 30 minutes from start to finish and the SYL-106-NP Standard Pipe Repair Kit cost under £25 including delivery, returning the £180 Showerking unit to service the same day.

For more information about portable horse and dog showers, please see the Showerking website.

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 Repair of 150mm Cement Coated Steel Pipe on Water Network in Mexico

An underground cement coated steel pipe leaking through an 80mm long split is repaired using a SylWrap Pipe Repair Contractor Case

Contractor Case calling – the cement coated steel pipe repair carried out by engineers in Mexico equipped for every leak

An underground cement coated steel pipe on a water network in Mexico undergoes a live leak repair after excavation followed by the removal of the outer coating revealed a 80mm long split in the line.

Case Study Data

Site
Underground water network
Location
Mexico
Repair Type
Live leak pipe repair
Defect
80mm split in a cement coated steel pipe carrying potable water

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, providing an effective replacement for the removed cement coating

SylWrap Pipe Repair Contractor Case
Products were supplied as part of a Contractor Case, capable of making up to six live leak repairs

Case Study PDF

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Case Study Details

A potential leak was identified on a section of the water supply network running beneath a street. Excavation took place and revealed a cement coated steel pipe suffering from a crack around 15mm wide across the diameter of its outer coating.

There was no sign that any water had escaped through this crack. To inspect the condition of the pipe inside, engineers removed the cement using a hammer and chisel. As the coating was chipped away, water began spraying out from a 80mm long split in the steel pipe.

A cement coated steel pipe suffering from a 15mm crack before undergoing repair with a SylWrap Pipe Repair Contractor Case
A 15mm wide crack had appeared in the cement coating around the steel pipe
As the coating was removed, water began spraying out from a split in the steel pipe

By the time the cement coating had been fully removed from around the leak area, enough water had escaped into the excavation hole to half-submerge the pipe. There was no means of isolating this section of the network and so the only option was to make a live leak repair.

The specialist company involved in the identification of the leak and excavation of the pipe equip all their engineering teams with SylWrap Pipe Repair Contractor Cases, meaning everything needed to seal the pipe was already on-site.

Contractor Cases contain enough WRAS approved products to make up to six permanent live leak repairs to pipes of all diameters and materials. WRAS approval was necessary for this application because the pipe carried potable water.

A split discovered in cement coated steel pipe before undergoing repair with a SylWrap Pipe Repair Contractor Case
Engineers were equipped with a SylWrap Pipe Repair Contractor Case which they used to seal the split once the cement coating had been fully removed

A bucket was used to remove enough water from the hole to enable the repair to take place. Wrap & Seal Pipe Burst Tape was used to seal the leak in the line, with several Tapes applied to cover the entire length of the split in the steel.

When stretched and wrapped around a pipe, Wrap & Seal fuses to itself to form a solid rubber band. Multiple Tapes can be applied over each other to build pressure resistance up to 30bar. For this repair, the requirement was around 3bar.

Enough Wrap & Seal Tapes were applied until the leak had been fully arrested. A SylWrap HD Pipe Repair Bandage was then wrapped over the top for the purpose of reinforcing and protecting the initial repair.

The completed repair of a leaking cement coated steel pipe in Mexico using a SylWrap Pipe Repair Contractor Case
The pipe was successfully sealed in under an hour

SylWrap HD is a composite wrap with a water-activated resin. After being wrapped and smoothed around the pipe, the bandage set rock hard in minutes. The impact resistant sleeve formed by SylWrap provided an effective replacement for the removed cement coating.

The application was completed in under an hour. Having all the products required to repair the cement coated pipe ready and available via the Contractor Case made a significant difference to response time and how quickly the leak could be sealed, reducing the amount of water lost and disruption to 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: Trenchless Pipe Installation Protection of 150mm Steel Natural Gas Pipeline

SylShield is used to offer protection to welds and joins in a steel natural gas pipe to undergoe trenchless installation in Czech Republic

Czech mate – SylShield protection enables the trenchless installation of a natural gas pipeline in south east Czechia

In its first deployment in the field, SylShield was used for the protection of welded joints on a 150mm diameter steel pipeline carrying natural gas when it was rerouted beneath a road and river via horizontal directional drilling, a form of trenchless pipe installation.

Case Study Data

Site
Natural gas pipeline
Location
Czechia
Repair Type
Pipe and weld protection
Application
Protecting 150mm steel pipeline undergoing trenchless installation via horizontal directional drilling

Products Used

SylShield Pipe & Weld Protection Wrap
Composite repair wrap three times thicker than standard SylWrap HD for protecting pipes during trenchless installation

Case Study PDF

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Case Study Details

Horizontal directional drilling involves connecting together sections of a pipeline above ground via welding or a similar process, digging a borehole and pulling the completed line through to install it.

This removes the need to dig huge and disruptive trenches across vast swathes of land. It also allows pipes to be installed beneath roads, rivers, seas and other areas which would otherwise be challenging to pass. In some cases, pipes many kilometres in length are dragged through the ground and installed using horizontal direction drilling.

The pipeline arrived on site in numerous separate sections before behind welded together

The high-pressure natural gas pipeline in the south of Czechia was being rerouted to improve energy security for the country. It was to pass under a local road and stream, meaning that horizontal directional drilling was the most suitable form of trenchless installation.

Pipes undergoing trenchless installation are given protection against the potential damage caused by dragging them underground. The 150mm diameter steel pipe being used in this application was coated in both epoxy and a 3mm thick fibreglass composite.

A 150mm natural gas pipeline to undergo trenchless pipe installation prior to having SylShield protection wrap applied
Joins on the pipe (black section) where welding had taken place could not be protected by epoxy or fibreglass, as the rest of the steel was

Joins on the pipe are more challenging to protect. The points at which sections are welded together cannot be covered with epoxy, fibreglass or any other type of factory applied protection. This is where SylShield came in.

The company installing the line were a long-time client of Sylmasta. They got in contact to ask if there was a potential solution for protecting the joints in the pipe, in addition to the heat shrink sleeves used as standard.

SylShield was activated with water and then applied over the joins in the pipe

SylShield Pipe & Weld Protection Wrap is the toughest, most robust composite wrap in the SylWrap range three times the thickness of a standard SylWrap HD Pipe Repair Bandage. It has been specifically designed for the protection of pipelines during trenchless pipe installation.

Working to a tight deadline, Sylmasta were able to produce the required number of SylShield wraps at their factory in England on the Thursday and deliver them to Czechia. The installation team collected the products from a DHL depot on Monday morning and set to work immediately.

SylShield was smoothed with water, curing to form an ultra hard shell protecting the welds in the pipe

Each welded joint and heat shrink sleeve was overwrapped with SylShield. The resin was activated with water and SylShield wrapped and smoothed around the pipe. Within minutes, it cured to form a rock-hard sleeve encompassing the joint to protect it from the rigours of horizontal directional drilling.

As each section was wrapped with SylShield, shrink wrap was applied over the top to secure the composite against the pipe and improve lamination. The shrink wrap was then spiked, ensuring that the carbon dioxide released during the curing of SylShield could escape rather than becoming trapped.

SylShield used for the protection of a natural gas line ahead of trenchless pipe installation
A natural gas line given protection before trenchless pipe installation with SylShield Pipe & Weld Protection Wrap
Once the joins in the line had been protected, the pipe was ready to be pulled through the ground and installed via horizontal directional drilling

By Monday evening, the entire line had been welded together, protected with SylShield and pulled through the borehole under the road and stream to complete the trenchless installation. Sylmasta had played a small but important part improving natural gas supplies to Czechia.

Afterwards, the team leader responsible for the project emailed to say: “The installation was a success and we particularly appreciated the timely delivery of the SylShield wraps. Big thanks to Sylmasta for meeting the tight deadline, which even we thought would be unrealistic.”

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

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

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

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

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

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

Case Study Data

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

Products Used

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

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

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Applying Wrap & Seal and SylWrap HD took less than one hour. The biodigester tank was put back into service the following day and with no issues regarding the efficiency or performance of the system noticed, the pipe repair was deemed a success.

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

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

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

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

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

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

Case Study Data

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

Products Used

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

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

SylWrap Standard Pipe Repair Kit
Superfast Epoxy and SylWrap HD are supplied together in the Standard Pipe Repair Kit

Case Study PDF

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Case Study Details

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

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

The hose was in a confined space making a repair difficult

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

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

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

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

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

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

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

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