Category: Pipe Repair

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Case Study: Filler Repair of 50mm Crack Between Toilet Waste Pipe & Bathroom Floor

Cracks left during the installation of a toilet waste pipe undergo repair using Sylmasta AB Epoxy Putty as a filler material

No falling through the cracks – Sylmasta AB Repair Epoxy Putty connects a toilet waste pipe during bathroom renovation work

A hole cut into a bathroom floor during renovation work was made too big for the toilet waste pipe it was to house, meaning a waterproof repair material was needed to permanently fill gaps of up to 50mm width between the pipe and the floor.

Case Study Data

Site
Bathroom
Location
United Kingdom
Repair Type
Filler repair
Defect
50mm wide crack between toilet waste pipe and bathroom floor

Products Used

Sylmasta AB Original Epoxy Putty
Waterproof, hard-wearing epoxy putty with a longer work time used to permanently fill all gaps between the pipe and the floor

Case Study PDF

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Case Study Details

Renovations at a property in the United Kingdom involved the toilet being moved to a new location within an improved bathroom. To prepare for the move, the contractors carrying out the work cut a hole out of the floor where the toilet waste pipe was to connect with the sewer pipe.

When the toilet waste pipe was fitted in place, it was discovered that the hole which had been cut was too big. This left gapping all the way around between the base of the pipe and the floor. At its largest, the gapping extended to 50mm wide.

Large gapping between the pipe and the floor needed to be filled

The contractors wanted a straightforward method to fill the cracks so that the plumbing in of the toilet waste pipe could be completed. Sylmasta recommended the use of Sylmasta AB Original Epoxy Putty.

AB Original is a ceramic-filled, general purpose, waterproof epoxy putty which is the hardest wearing available. It comes with a two-hour work time for use in larger and more complex repairs.

It was calculated that around 1kg of AB Original would be needed to repair the toilet waste pipe. This was delivered to the property, where the resin and the hardener were mixed in equal measures and kneaded by hand.

Epoxy putty used to full in cracks between a toilet waste pipe and a bathroom floor in a repair required during renovation work
AB Original was worked and pushed into the crack
The putty was smoothed off using water

Once the putty had turned an off-white colour to indicate successful mixing, it was pushed into the gapping between the waste pipe and the floor whilst it remained soft enough to shape and manipulate.

The longer cure time of Sylmasta AB meant that more of the putty could be mixed in one go without the threat of premature curing. As the putty was applied, it was smoothed off with a little water and a filling knife and then left to harden.

Completed epoxy putty filler repair of cracks between a toilet waste pipe and the floor
The completed repair with all gapping successfully sealed

A full cure was achieved in 24 hours, leaving the cracks permanently filled with a waterproof material sharing similar properties to the floor. The renovation of the bathroom was able to continue with virtually no disruption to timeframe.

When it came to the installation of a new bathroom floor surface further along the renovation process, AB Original would withstand being tapped, drilled, screwed, sawed, ground, filed, painted and any other treatment needed to complete the improvements.

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: Leak Repair of a Bathroom Sink PVC Plastic Drain Pipe

Superfast Plastic Epoxy Putty Stick used to repair a leak in a PVC plastic pipe connected to a bathroom sink

Stopping that sinking feeling – Superfast Plastic plugs a leak in a DIY bathroom plastic pipe repair

A homeowner used Superfast Plastic Epoxy Putty Stick to make a quick and easy DIY leak repair to cracks in a PVC plastic drain pipe located in a cupboard underneath their bathroom sink.

Case Study Data

Site
Domestic bathroom
Location
United Kingdom
Repair Type
Leak repair
Defect
Cracks in a PVC plastic sink drain pipe

Products Used

Superfast Plastic Epoxy Putty Stick
Specially formulated epoxy putty used to permanently seal holes and cracks in all types of plastic pipe

Case Study PDF

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Case Study Details

The homeowner was alerted to the problem when they noticed that the bathroom floor next to the cupboard below the sink was wet. After inspecting inside the cupboard, it was discovered that several small cracks had developed in the PVC plastic drain pipe at the point where it connected with the sink.

The homeowner did not want to go to the expense of hiring a plumber to fix what they considered a minor problem. They instead purchased a Superfast Plastic Epoxy Putty Stick from Sylmasta to carry out a DIY repair of their own.

Cracks in a PVC plastic bathroom sink pipe before undergoing repair with a Superfast Plastic Epoxy Putty Stick
Several cracks had appeared in the pipe where it met the sink fitting

Superfast Plastic is a semi-flexible epoxy repair putty in an easy-to-use 114g stick format. It sets white and has been specifically formulated for the repair and bonding of all major plastic types, including PVC.

Before the repair began, the pipe was dried and cleaned. The required amount of putty was cut from the stick and kneaded by hand. Superfast Plastic starts out blue before the dye within the putty turns white to indicate successful mixing, after which it can be applied.

Superfast Plastic formed into a sausage shape and pushed into the cracks

Once the putty had become white, it was formed into a sausage shape and pushed against the cracks in the PVC pipe. After 25 minutes, it began to harden. Within 45 minutes, the putty had cured to provide a watertight seal, filling all cracks in the pipe.

Superfast Plastic achieves full properties in two hours, at which point the homeowner ran the tap on their sink. With no water escaping from the pipe into the bathroom cupboard as the sink drained, the leak repair had been a success.

Completed leak repair of a plastic PVC pipe suffering from cracks where it connected to a bathroom sink
The completed repair with the pipe successfully sealed

Carrying out a DIY PVC pipe repair using Superfast Plastic cost less than £20, including shipping. The repair was permanent and the putty blended in unnoticed with the PVC plastic – just in case a future homeowner was a perfectionist and wanted a pipe in a darkened cupboard under the bathroom sink to look aesthetically pleasing.

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

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

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Case Study: Reinforcement of 6 Metres of Corroded Steel Pipe in a Fire Station Pumping House

A steel water pipe suffering from heavy corrosion undergoes repair and refubishment in a protection application carried out using SylWrap HD Pipe Repair Bandage

Pump it up – the SylWrap reinforcement of a corroded steel water pipe which kept a fire station pumping water

A six metre long section of steel pipe – which included two 90 degree elbow bends – operating in a water pumping house at a fire station in Saudi Arabia required urgent reinforcement before the heavy corrosion the pipe was suffering from breached the line.

Case Study Data

Site
Fire station pump house
Location
Saudi Arabia
Repair Type
Pipe reinforcement
Defect
Six metre long section of steel pipe suffering from heavy corrosion

Products Used

SylWrap HD Pipe Repair Bandage
Composite repair wrap which was wrapped and moulded around the pipe, forming an impact resistant protective sleeve

Case Study PDF

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Case Study Details

The 150mm steel pipe brought water from a reservoir on the lower levels of the pumping house up to the top levels, where it was required for different operations at the fire station.

After many years of service, the pipe was suffering from heavy corrosion. The damage was particularly bad on the section of pipe beneath the surface of the reservoir, where it was exposed to constant contact with water.

The pipe was suffering from heavy corrosion, particularly towards the bottom of the line

Although the pipe had not yet been breached, the metalwork had been weakened to the point where it was only a matter of time before corrosion caused cracks and holes to appear. Replacing the six metre section after this happened would have been difficult because of the shape of the pipe.

There were two 90 degree elbow bends in the pipe. The first changed the pipe direction from running vertically up and out of the reservoir to horizontally at the point where the line reached the upper levels of the building. The second was some 50cm further along, taking the pipe off to the right to connect with valves and equipment.

A steel pipe suffering from corrosion prior to undergoing reinforcement using SylWrap HD Pipe Repair Bandage
Two 90 degree bends in the pipe meant replacing the damaged section would be difficult

The complex shape meant that replacing the line would require specially fabricated parts at considerable expense. Not only was the cost prohibitive, but there was the possibility the station might be decomissioned in several years time.

With resources stretched, spending money on the expensive installation of a replacement pipe only for the pump house to be taken out of service within a decade would not have been a good use of funds.

The station therefore sought to carry out pipe reinforcement of the existing steel line instead, strengthening it and protecting it against further corrosion. This would extend the lifespan of the line until a decision was made about the future of the pump house and the station.

SylWrap HD is applied to a steel pipe at a fire station as part of a reinforcement application
SylWrap HD could be easily moulded around the complex shape of the pipe

It was decided to wrap the entire six metre section in SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets in minutes to provide an impact resistant protective sleeve around pipes and structures.

Starting from the upper level of the pump house, SylWrap HD was applied to the pipe with a 50 percent overlay. More water was used to smooth the bandage as it was wrapped, moulding it tightly to the line and around both of the bends.

The reinforcement of a steel pipe at a Saudi Arabia fire station made using SylWrap HD Repair Bandage
Completed reinforcement of the top level of the pipe
Completed reinforcement of the bottom level, including the underwater section

The repair continued in this manner as the line headed down to the lower levels of the pump house, including when the pipe went beneath the surface of the reservoir.

SylWrap can be applied and sets underwater, enabling every part of the pipe to be refurbished. Once fully cured, the bandage formed a rock hard shell encompassing the entire line and offering new strength to the pipe.

Within two hours, the repair had been completed and the entire line reinforced. The SylWrap sleeve surrounding the pipe prevented further external corrosion attacking the exterior and weakening the line, reducing the chances of future failure.

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 a Leaking 150mm Steel 90 Degree Elbow Bend at a Quarry Wash Plant

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

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

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

Case Study Data

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

Products Used

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

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

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Case Study Data

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

Products Used

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

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

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

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

Case Study PDF

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Case Study Details

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

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

The three metre diameter FRP pipe prior to undergoing repair

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Case Study: Steel District Heating System Pipe Suspended in Ceiling Live Pinhole Leak Repair

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

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

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

Case Study Data

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

Products Used

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

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

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

Wrap & Seal successfully applied to seal the pinhole

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Case Study Data

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

Products Used

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

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

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Case Study: Domestic Malleable Iron Water Pipe Repair in a Restricted Space

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

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

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

Case Study Data

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

Products Used

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Case Study Data

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

Products Used

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

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

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

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

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

Numerous Superfast Steel Epoxy Sticks were used for the repair

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Case Study: Snapped Nozzle on a 1500mm Seawater Cooling Line Repair & Reinforcement

A 1500mm line in a seawater cooling system undergoes repair after it began leaking from a broken off nozzle

Keeping it cool – the repair and reinforcement of a leaking 1500mm seawater cooling system supply line

A petrochemical plant in Saudi Arabia needed an urgent repair to the 1500mm main supply line in their seawater cooling system after a nozzle snapped off, leaving a 50mm hole discharging water 5 metres vertically at a pressure of 3 bar.

Case Study Data

Site
Petrochemical plant
Location
Saudi Arabia
Repair Type
Leak repair and reinforcement
Defect
Snapped nozzle in a 1500mm seawater cooling pipe

Products Used

Sylmasta AB Original Epoxy Putty
Epoxy putty used alongside a PTFE plug to fill the 50mm hole left by the snapped nozzle

SylWrap HD Pipe Repair Bandage
Composite wrap reinforced the repair and was then applied around the diameter to strengthen the line

Case Study PDF

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Case Study Details

Seawater cooling systems allow water taken from the sea to be used for the cooling of machinery and other processes in industrial plants and factories.

The petrochemical plant were extracting from the Red Sea. A nozzle on the 1500mm diameter main line supplying the cooling system had snapped off from the flange, causing a jet of pressurised water to shoot 5 metres into the air from a 50mm hole.

An engineer fits the PTFE plug to the leaking line

When this seawater returned to ground, it saturated the surface of the pipe, causing external damage, discolouration, mould to form and a suspected weakening of the line.

Losing so much water also had a serious impact on the efficiency of the system. The plant therefore decided to call in a maintenance team to attempt to fix the problem as a matter of urgency.

The supply line was shut off whilst the repair took place. The application began by securing the hole left in the pipe by the snapped nozzle with a plug made from PTFE.

Sylmasta AB Epoxy Putty used to repair a seawater supply line by fixing a PTFE plug in place
Sylmasta AB Original was used to fix the plug in place, creating a watertight seal

To create a watertight seal around the PTFE plug and fix it in place permanently, the nozzle was then encompassed using Sylmasta AB Original Epoxy Putty.

Sylmasta AB is a smooth-setting putty capable of bonding to all materials, including wet surfaces. It has a two hour work time, allowing more of the putty to be mixed, shaped and applied without premature curing that may have otherwise been caused by the hot Saudi climate.

SylWrap HD Pipe Repair Bandage applied to a snapped nozzle in a seawater supply line repair
The plug and AB Original were encompassed with SylWrap HD

Further reinforcement of the plug and the surrounding AB Original was provided by SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets rock in hard in minutes.

Seven layers of SYL412HD were wrapped and smoothed around the nozzle, creating an impact resistant layer of protection. This completely sealed the hole with a repair pressure resistant up to 30 bar.

SylWrap HD Pipe Repair Bandage being applied to a 1500mm seawater supply line
Further SylWrap reinforced the weakened section of pipe around the plug

When the line was put back into operation, the engineers who had carried out the repair noticed during their inspection that the pipe around the nozzle had indeed weakened as suspected.

Although no major leaks were present, the surface could be seen bubbling with air and water. They therefore decided to reinforce the entire area of pipe underneath the nozzle by wrapping the 1500mm diameter with four SYL616HD Pipe Repair Bandages.

Repair and reinforcement of a 1500mm seawater supply line after a nozzle snapped off
The repair was completed in two hours, leaving the line sealed and strengthened

This provided a protective sleeve around the weakened section of the line, strengthening it against potential future breaches and thus extending the lifespan of the pipe.

Completing the repair of the nozzle and the reinforcement of the line took less than two hours, after which the seawater cooling system was able to operate at full capacity once again.

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

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