Category: Surface Coating

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Case Study: Landscaping Materials Company Repair & Protect Warehouse Metal Pallets

Ceramic Brushable Blue Epoxy Coating is used to repair metal pallets damaged by impact, abrasion and wear

Ceramic Brushable Blue helps a landscaping materials supplier lay a path to metal pallets protection

A landscaping materials company use Ceramic Brushable Epoxy Coating to repair and protect metal pallets at their central warehouse left damaged by years of having heavy and abrasive items like driveway paving, garden slabs and natural stones stacked on them.

Case Study Data

Site
Landscaping materials supplier warehouse
Location
United Kingdom
Repair Type
Metal repair and protection
Defect
Metal pallets damaged and worn by storage of abrasive, heavy materials

Products Used

Ceramic Brushable Epoxy Coating
Epoxy coating reinforced with silicon-carbide which protects metal surfaces against wear, abrasion and impact

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Case Study Details

As one of the biggest suppliers of landscaping materials in the United Kingdom, the company had a vast central warehouse storing items which were then sent to distributors around the country.

These materials included driveway paving, garden slabs, kerbs, edges, porcelain, natural stone and bricks. All were stacked and stored on metal pallets.

The weight of these materials, their abrasive nature and the impact from moving them on and off the metal pallets meant that over time, the metalwork began to show visible signs of wear.

Removing all existing pallets from the warehouse and installing replacements would have been a time-consuming and expensive task.

The landscaping company therefore contacted a mechanical engineering specialist who used and distributed Sylmasta products for advice. They suggested Ceramic Brushable Blue Epoxy Coating to repair the metal pallets in the warehouse.

Ceramic Brushable is reinforced with silicon-carbide for hardness and an ultra-smooth finish. It is painted onto parts and surfaces to create an outer layer with extreme resistance to abrasion, corrosion, chemical attack, cavitation, erosion and pitting.

Ceramic Brushable Blue was painted onto the top parts of the metal pallet which came into contact with landscaping materials

Two coatings of Ceramic Brushable were applied to the top part of the pallets which the landscaping materials sat on. It cured to form a hardened shell, protecting the original metalwork against abrasion and impact damage caused by the materials.

Initially, only a few pallets were treated as a trial run to test the performance of Ceramic Brushable. Six months later and there were no visible signs of damage to any of the coatings applied during the trial.

Metal pallets in a landscaping materials supplier warehouse are coated with Ceramic Brushable Epoxy to repair them after impact and abrasion damage
Once cured, Ceramic Brushable formed a silicon-carbide reinforced layer which was ultra-smooth and offered high resistance against impact and abrasion

Satisfied with the performance of Ceramic Brushable, the landscaping company purchased 10kg to repair and protect more metal pallets throughout the warehouse.

They are also now considering opting for a two-layer wear indicator coating, whereby a topcoat of Ceramic Brushable Green or Black is applied over the existing Blue.

When the Blue layer begins to show through, it will indicate a new topcoat of Green or Black is required to maintain suitable protection levels for the pallet.

Having a clear system showing when to reapply Ceramic Brushable will help the company continually extend the lifespan of its metal pallets for years to come.

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

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

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Case Study: Corroded 30-Metre Section of Sewer Force Main In Underground Vault Repair

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

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

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

Case Study Data

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

Products Used

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

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

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

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Case Study Details

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

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

Water was pumped out of the flooded vault before repair

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Case Study: Copper Mine Repair Pump Housing Heavily Damaged By River Water Extraction

A copper mine in Bulgaria repair pump housing left heavily damaged after years of extracting water from a nearby river

Copper mine wear repair – refurbishing and protecting pump housing after river water damage

Pump housing at a copper mine left heavily damaged by many years of extracting river water containing sand, silt and other debris, undergoes repair and refurbishment after the cost of replacement was deemed too expensive.

Case Study Data

Site
Copper mine
Location
Bulgaria
Repair Type
Pump housing repair
Defect
Heavily damaged metalwork

Products Used

Ceramic Brushable Epoxy Coating
Epoxy coating reinforced with silicon carbide which sets to an ultra-smooth finish for sealing and protecting parts and surfaces

WearShield Epoxy Paste
Epoxy paste heavily filled with alumina beads used to create an impact resistant shell to protect metalwork in abrasive environments

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Case Study Details

The pump housing was part of a system which extracted water from a nearby river and transported it around the copper mine, where it was then used in a number of different processes.

Sand, silt, dirt, stones and other debris were all present in the water as it passed through the pump housing. Following years of exposure to the river water, the housing was now suffering from severe corrosion, abrasion and wear damage.

As it appeared the pump housing was beyond repair, the mine sought quotes for fabrication and installation of a replacement part from several companies. When these were deemed too expensive, it was decided to attempt refurbishment.

The pumping house was heavily damaged after years of extracting water from a river

The mine contacted Sylmasta’s approved supplier in Bulgaria. The supplier had recently spent several days completing a comprehensive product training programme at Sylmasta HQ in the United Kingdom, including a module on restoring damaged metalwork.

They recommended using Ceramic Brushable Epoxy Coating and WearShield Epoxy Paste in conjunction to both repair the existing damage and protect the pump housing from further deterioration.

Ceramic Brushable is a ceramic-filled epoxy coating reinforced with silicon carbide. It seals and protects parts, machinery and surfaces by forming an ultra-smooth, hardened layer of protection.

WearShield is an epoxy paste heavily filled with alumina beads and a high resin content. The dense alumina structure of the cured material enables it to offer the ultimate resistance against all types of impact in the most abrasive environments.

The pump housing was thoroughly cleaned before the repair took place

The pump housing was taken apart and thoroughly cleaned to remove as much rust, dirt and grime as possible. An initial coating of Ceramic Brushable Blue was painted all over the metalwork using a brush, sealing the original surface.

Ceramic Brushable Blue and WearShield use in conjunction to repair heavily damaged pump housing metalwork
WearShield Epoxy Paste applied during the repair of pump housing at a copper mine to created an alumina-reinforced layer of protection
Ceramic Brushable Blue was applied to the pump housing followed by a thick layer of WearShield. The alumina beads are visible in the material

Once Ceramic Brushable had cured, WearShield was applied on top with a spreader. The composition of WearShield makes it easy to build significant, dense layers of protection quickly. In this case, WearShield cured to form a 30mm thick alumina-reinforced shell over the pump housing.

Ceramic Brushable Epoxy Coating provides an ultra-smooth, low-friction finish during pump housing repair in Bulgaria
A top coating of Ceramic Brushable left an ultra-smooth, low-friction finish to complete the repair

Because the alumina beads make cured WearShield a slightly rough material, it was decided to topcoat with more Ceramic Brushable. The ultra-smooth, low-friction finish provided by Ceramic Brushable would improve flow through the pump housing, making it more efficient once it went back into service.

Completing the repair took just two days and saved the mine a substantial amount of money, The pump housing will remain in service for many more years thanks to the significant protection provided by WearShield and Ceramic Brushable.

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

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

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

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

Case Study Data

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

Products Used

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

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Case Study Details

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

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

A helicopter belonging to the Puerto Rico Power Authority

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Case Study Data

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

Products Used

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

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

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

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

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Case Study Details

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

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

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

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

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

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

Large holes appeared in the tank during the surface preparation process

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

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

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

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

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

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

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

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

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

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

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

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

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

Case Study Data

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

Products Used

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Case Study: Creating an Abrasion Resistant Surface for Pug Mill Extruder Barrels

Ceramic Brushabkle Blue Epoxy Paste created an abrasion resistant surface for worn aluminium barrels in a pug mill putty extruder

Putty in their hands – Ceramic Brushable provides an abrasion resistant surface coating to improve pug mill putty extruder efficiency

Aluminium barrels in several pug mill putty extruders suffering from both abrasive wear and a rough initial finish are given an ultra-smooth, abrasion resistant surface coating to improve their efficiency

Case Study Data

Repair Type
Abrasion Protection
Defect
Worn aluminium barrels in pug mill putty extruders

Products Used

Ceramic Brushable Blue Epoxy Coating
Ceramic-filled epoxy coating painted onto surfaces and parts to create a smooth, abrasion resistant layer

Case Study PDF

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Case Study Details

Silica-filled putty was extruded from the pug mills via aluminium barrels. Over time, the silica in the putty had caused abrasive wear to the surface of the barrels as it passed through.

This wear combined with the initial rough cast finish of the aluminium had caused the flow rate of putty from the pug mills to slow dramatically, impacting on efficiency.

A badly worn putty extruder had become inefficient because of abrasion
Barrels in the putty extruders were suffering from heavy wear

To help the extruders run more efficiently, a means of improving the flow rate through the barrels by filling in existing damage and creating an ultra-smooth finish was sought.

After researching cost and ease of repair, machining the barrels was ruled out as it would have been difficult, expensive and too time consuming.

Instead, it was decided to paint the aluminium barrels in every putty extruder with a low friction coating for increased extrusion rate. The coating used in the repair also needed to be abrasion resistant to protect the aluminium from further wear.

Ceramic Brushable Blue is an easy to use epoxy coating used to create abrasion resistant surface to machines, parts and surfaces of all materials
Ceramic Brushable Blue was easy to mix and apply to the extruder barrels

Ceramic Brushable Blue was the obvious solution. It is ceramic-filled and reinforced with silicon carbide for ultimate hardness. It is used on both new and old machines and parts in highly abrasive environments.

Coating new surfaces with Ceramic Brushable Blue provides a toughened, reinforced layer of protection from wear, extending the lifespan of parts.

When used on older machine parts and surfaces such as the putty extruder barrels, Ceramic Brushable Blue repairs damaged areas as well as offering protection against abrasion.

Ceramic Brushable Epoxy Coating applied to provide an abrasion resistant surface to a putty extruyder to improve efficiency
The epoxy coating gave a low friction surface to the barrels

Ceramic Brushable Blue was easy to apply. The parts were mixed and then the coating painted on using a conventional paintbrush. The 90 minute work time allowed larger quantities of epoxy to be mixed and applied in one go without the threat of premature curing.

It took one day to coat every pug mill putty extruder barrel with the required amount of Ceramic Brushable Blue. A full cure was achieved 24 hours after the final coat, meaning that there was minimal disruption to production.

Sylmasta Ceramic Brushable Epoxy Coating used to create an abrasion resistant surface for a pug mill putty extruder aluminium barrel
Ceramic Brushable Blue provided a low friction, ultra-smooth finish

The non-stick, smooth finish of Ceramic Brushable also enabled quicker and easy cleaning of the barrels. Less time needed for the maintenance of the extruders resulted in even greater efficiency for the pug mills.

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: Creating a Flexible Expansion Joint Filler for a Residential Property in the UK

Liquid Rubber used as an expansion joint filler to fill 25mm gaps between glass panels on a roof terrace at a residential property in Essex

Sealing the Dream – Sylmasta Liquid Rubber used as a flexible expansion joint filler eliminates problematic balcony drips at a dream home

An unexpected issue hit a dream home being built in Essex when water began to drip through glass panel expansion joint gaps in a roof terrace onto a balcony below – leading the homeowner to come up with a creative flexible filler solution to seal the joints

Case Study Data

Site
Residential Property
Location
Essex, United Kingdom
Repair Type
Expansion Joint Filler
Defect
Water dripping through expansion gaps in a roof terrace onto a balcony below

Products Used

Liquid Rubber 80
Rubber elastomer compound which was poured into the expansion joints to offer a water resistant and flexible filler

Case Study PDF

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Case Study Review

The striking property overlooking the Thames Estuary featured a roof terrace with panoramic views. Surrounding the terrace were 26 glass panels with 25mm expansion gaps either side. Below the roof terrace was another balcony where electrical installations such as LED lights and speakers had been added.

Whenever it rained or spray blew in off the Thames, water would drip through the expansion gaps and onto the balcony below, causing issues with the electric equipment.

A residential property in Essex required a flexible expansion joint filler to eliminate drips from a roof terrace onto a balcony below
The residential property. The troublesome expansion gaps were allowing water to pass from the roof terrace onto the balcony below

To prevent this happening, the homeowner needed to find an expansion joint filler material which was both waterproof to eliminate the drips and flexible enough to allow the glass panels to expand.

After speaking with Sylmasta, the homeowner decided to fill the expansion gaps with a packing material which was then encapsulated with Sylmasta Liquid Rubber 80.

A 25mm expansion joint between panes of glass on a roof terrace
25mm expansion joints between the glass panels

Liquid Rubber is a tough but flexible repair compound which can also be used to refurbish conveyor belts, make moulds, and add noise-reducing and abrasion-resistant linings to equipment.

The packing material was first pushed into the expansion gaps. Once the material was in place, the homeowner mixed the two parts of Liquid Rubber together, pouring it into the joints to seal everything.

Liquid Rubber used as a filler for a 25mm expansion joint between glass panels on a roof terrace at a residential property in Essex
Each expansion gap was filled with a packing material which was then encapsulated with Liquid Rubber

Within 16 hours, the Liquid Rubber cured to provide a water resistant filler which could also cater for glass expansion.

Liquid Rubber sets to black, which meant that it blended in seamlessly with the resin which had been used on the rest of the roof terrace’s balustrade. Even on close inspection, you could not tell that two different materials had been used.

The Liquid Rubber blended in seamlessly with the existing resin used on the roof terrace
Sylmasta Liquid Rubber used as an expansion gap filler between glass panels on a roof terrace in Essex
The completed repair of the expansion joint gaps

The use of Liquid Rubber as an expansion joint filler was a complete success and eliminated all drips from the roof terrace to the balcony below.

The homeowner contacted Sylmasta after the repair had been completed, saying he was delighted that a solution had been found to complete the building work on his dream home.

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