Category: News

Epoxy putty sticks for the global market made in the United Kingdom

Sylmasta have invested heavily in bringing the latest epoxy putty stick manufacturing machinery and technology to our site in the United Kingdom, meaning we are the only supplier currently making its own sticks in Europe.

These sticks are shipped worldwide from our HQ in Sussex, around 50 miles (80 kilometres) south of London. They are supplied under our Superfast brand and are trusted by some of the biggest names in maintenance adhesives.

The benefits of Sylmasta epoxy putty sticks made in the UK

Epoxy putty stick manufacturing was pioneered in the United States. It removed the need for precise measuring and mixing of separate components of resin and hardener by supplying pre-measured portions of each in the correct 1:1 ratio in a single, easy-to-use stick.

But recent global events have highlighted problems with overreliance on the US and Asian markets for importation.

Exports out of Asia were disrupted during the Covid-19 pandemic and its aftermath. In the USA, uncertainty over tariffs has made importing materials for making sticks and exporting the finished product challenging.

Epoxy putty sticks made in the UK by Sylmasta offer numerous advantages. In terms of the sticks themselves, we can provide customised formulations to meet client needs, including adjustments to cure times and colour.

We employ lean manufacturing principles, meaning everything is made to order – guaranteeing fresh product and low minimum order quantities.

Customers who use Sylmasta as their epoxy putty stick supplier enter a reliable supply chain with reduced lead times and expert technical help readily available for specific applications.bee

A good example of the benefits of Sylmasta epoxy putty sticks comes from 2024, when we produced and shipped a significant quantity of product to a local authority in Canada to repair a leaking underground water main.

Within five days of us receiving the order, the sticks were on-site and ready to be used by engineers in British Columbia.

The Sylmasta epoxy putty stick range

Sylmasta make the following epoxy putty sticks as standard:

• Steel Stick – Steel filled with a five-minute work time and WRAS approval for use with pipes and fittings carrying drinking water. Sets to a grey, metallic-like colour.
• Aluminium Stick – Epoxy putty formulated for the repair and bonding of aluminium, other alloys and different types of metalwork. Sets grey with a four-minute work time.
• Copper Stick – Copper-filled epoxy putty sets to that colour for the rapid repair of copper, brass, bronze and other non-ferrous metals. Has a three-minute work time.
• Aqua PW Stick – Specialist epoxy putty formulated for very high wet surface and underwater adhesion. Sets white, has a five-minute work time and WRAS approval for use with potable water.
• Titanium Stick – High temperature epoxy putty with resistance up to 280ºC. It sets to a golden colour, has a 90-minute work time and will bond to most materials operating under extreme heat.
• Concrete Stick – Concrete-filled epoxy putty which sets grey for the uniform repair of concrete, stone and masonry. Has a quick four-minute work time.
• Plastic Stick – Plastic-filled epoxy putty which bonds and repairs all major types of plastic, except polyolefins. It comes with a 20-minute work time and sets white.
• Wood Stick – Wood-filled epoxy putty cures to a material sharing an appearance, hardness and density similar to wood. Has a 15-minute work time, offering a little longer to shape and form the putty.
• General Purpose Epoxy Putty Stick – Sylmasta AB Original is ceramic-filled, bonds to all materials and comes with a two-hour work time for complex applications requiring longer to handle the putty before curing.

All Sylmasta epoxy putty sticks can be made as standard 200mm diameter sticks or 300mm diameter ‘fat’ sticks.

If you would like to learn more about our epoxy putties or discuss the possibility of having Sylmasta manufacture epoxy putty sticks for your business, please contact Sylmasta via email or on +44 (0)1444 831459

Repairs made using Sylmasta Epoxy Putty

Case Study: Restoration of Clan MacGregor Dalmally Burial Stones Dated 1390-1528

Sylmasta manufacture a specialist version of AB Original Epoxy Putty colour-matched to RAL 7037 to help with the restoration of the Clan MacGregor Dalmally Burial Stones

Case Study: Classical Composite Order Column Restoration at Former Cinema Built in 1920s

Damaged concrete classical composite order columns are returned to their detailed original state during the renovation of a 1920s neoclassical style former cinema

Case Study: Leaking Concrete Flood Defence Wall Repair at Major Scotland Dam

Gaps in a relatively new concrete flood defence wall at a multimillion pound dam in Scotland are sealed by a civil engineering company using AB Original Epoxy Putty

Case Study: Underground 600mm Concrete Water Pipe Break Repair in Canada

A city authority in Canada repair a break in an underground 600mm diameter concrete pipe at the point it passed through a wall, significantly reducing levels of water loss

Industry leading epoxy putty sticks manufactured in the UK

Epoxy putty sticks have been used throughout industry for decades, particularly in repair and maintenance. Their popularity stems from being easy-to-use and capable of making fast, permanent repairs to many different materials.

Most epoxy putty sticks focus on a particular substrate. These include steel, copper, and wet surfaces. Some epoxy putties are formulated for high temperature repairs and others will bond underwater. An epoxy putty stick exists for most applications.

The history of epoxy putty sticks

Epoxy putty stick technology and manufacturing originated in the United States. It has migrated to other sources in recent years, including Asia.

Whilst this has extended the supply chain, in some cases it has generated quality issues. The Covid-19 pandemic and its aftermath also highlighted the problems of an overreliance on importation, when there was an epoxy stick shortage across Europe.

Epoxy stick manufacturing in Europe

Sylmasta have invested in the latest manufacturing machinery and technology at their site in the United Kingdom. We are arguably the only manufacturer currently making our own epoxy putty sticks in Europe.

For customers, this means a reliable supply chain, reduced lead times, fresh product with guaranteed shelf life and almost zero minimum order quantities compared with importing from outside Europe.

In addition to manufacturing standard epoxy putty sticks like steel and damp surfaces, it also enables us to produce special formulations and unique products, such as Sylmasta AB Original.

Fast curing epoxy putty sticks

The main focus for epoxy putty sticks has tended to be on cure time, with an addiction to speed. The Sylmasta range of Superfast Epoxy Sticks includes Superfast Steel, Superfast Copper and Superfast Aqua PW, all of which have a fast work time of between five and 10 minutes.

This offers many advantages for small repairs, such as reduced downtime and minimal man-hours. For example, Superfast Epoxy Putt Sticks can be used in pipe repair applications to seal leaks quickly and easily.

They fill holes and cracks in pipework where pressure can be turned off, allowing systems to be put back into operation in one hour. Superfast Steel, Superfast Copper and Superfast Aqua PW all have WRAS approval for use with potable water.

When it comes to larger applications requiring greater quantities of putty to be mixed and applied, faster setting putties cure off too quickly. Such repairs normally require complicated, two-part epoxy pastes which can be carefully applied via a hand tool over the course of an hour.

Despite the desire for epoxy putty sticks to be fast working, it is clear that a slower curing epoxy stick can offer several benefits. Which is why Sylmasta have formulated AB Original.

Slower curing epoxy putty sticks

AB Original Epoxy Putty Stick offers an extended two-hour work time. It combines the easy application of an epoxy putty stick with the longer cure of a repair paste, enabling its use in larger and more complex applications.

Greater quantities of AB Original can be mixed and applied over hours rather than minutes without worry about premature curing. The stick format involves no mixing ratios or measuring out separate parts of resin and hardener.

AB Original is easily shaped, profiled and pushed into cracks and crevices. Its hand-led application means the user needs to mix only the quantity of putty needed for the repair, which can be applied without the use of any tools.

Being ceramic-filled, AB Original does not focus on one particular substrate. It bonds to most materials and offers excellent adhesion to wet, damp and underwater surfaces.

AB Original bridges the gap between an epoxy putty stick and two-part repair pastes. For complex and challenging repairs over larger areas where speed is not required, it is fast becoming the go-to product for industry.

To discover more about the Sylmasta range of epoxy putty sticks, please contact Sylmasta via email or on +44 (0)1444 831459

Epoxy putty repairs

Case Study: Restoration of Clan MacGregor Dalmally Burial Stones Dated 1390-1528

Sylmasta manufacture a specialist version of AB Original Epoxy Putty colour-matched to RAL 7037 to help with the restoration of the Clan MacGregor Dalmally Burial Stones

Case Study: Classical Composite Order Column Restoration at Former Cinema Built in 1920s

Damaged concrete classical composite order columns are returned to their detailed original state during the renovation of a 1920s neoclassical style former cinema

Case Study: Leaking Concrete Flood Defence Wall Repair at Major Scotland Dam

Gaps in a relatively new concrete flood defence wall at a multimillion pound dam in Scotland are sealed by a civil engineering company using AB Original Epoxy Putty

Case Study: Underground 600mm Concrete Water Pipe Break Repair in Canada

A city authority in Canada repair a break in an underground 600mm diameter concrete pipe at the point it passed through a wall, significantly reducing levels of water loss

Case Study: Rotted Wooden Beam Repair in Home Renovation Project

Large voids in a rotted wooden beam are filled to create a flat, smooth surface enabling the outside of a house to be rendered as part of a renovation project

Case Study: Pipe Joints Sealed in Cast Iron Rainwater Stack Repair at London Office Block

300 pipe joints left leaking by corrosion in an internal cast iron rainwater stack are sealed, avoiding a total system replacement during the refurbishment of an office block

Sylmasta add South East Regional Chamber of Commerce Business of the Year Award to their Sussex title

Sylmasta have picked up their second Chamber of Commerce Business Award of 2023, being named South East Regional Global Player Export Business of the Year.

The Global Player Award goes to a company that has demonstrated significant and sustained growth internationally through harnessing the opportunity of overseas markets, proving that exporting can power business growth. 

Sylmasta were eligible for the accolade having won the Sussex Chamber of Commerce Export Business of the Year back in June. The South East Region covers Sussex, Kent, Hampshire, Isle of White, Surrey and Thames Valley.

Being named South East Regional Global Player sees Sylmasta progress to the national finals to take on other Export Business of the Year winners from around the United Kingdom.

2023 saw Sylmasta bring online new distribution in Malaysia, the Philippines and Indonesia. This built on partnerships confirmed with several Latin American countries in 2022, meaning exports account for 45 percent of sales.

Sylmasta now supply pipe repair, refurbishment and maintenance products to more than 20 countries worldwide, working with water companies, oil refineries, desalination plants, wastewater treatment works, nuclear power stations, pumping stations, quarry wash plants, shipping, agriculture and within the hospitality and leisure industries.

Managing director Simon Bedding said: “We were especially pleased to win this particular award because exporting is so close to our hearts here at Sylmasta.” 

“We consider it a win for everyone in our team, who continually work hard to ensure that we manufacture and deliver our SylWrap pipe repair solutions and Sylmasta epoxy repair compounds to customers around the globe.”

“From conversations with these customers, they see British-made goods as a badge of quality and our reputation remains for trust and fair dealing – something we in Britain don’t perhaps fully appreciate ourselves.” 

“In fact, many have demanded that we put ‘Made in UK’ on our packaging, and we have been happy to oblige. Being based in Sussex, we are fortunate to be in a great location for exporting goods as we are near to major ports and international airports. This enables us to respond to urgent orders quickly and meet the demands of our customers, no matter where in the world they are.”

Building on their success in 2023, Sylmasta are putting a renewed focus on product innovation looking ahead to 2024. New lines in pipe repair bandages and epoxy repair putty are set to be offered to the global distribution network.

These products will improve and increase the Sylmasta product range, allowing contractors worldwide to repair and maintain ageing pipework more quickly and easily than ever before. In doing so, Sylmasta are helping to reduce water loss at a time when climate change makes conserving every drop more critical than ever.

Worldwide repair and maintenance solutions

Case Study: Complex in UAE Approves SylWrap for Chilled Water System ABS Pipe Repair

Following vigorous testing, Superfast Aqua PW and SylWrap HD are approved for repairing leaking ABS pipe joints in a chilled water system at a luxury complex in the UAE

Case Study: Leaking HVAC Cooling Tower Repair at Production Facility in USA

After several failed repair attempts, a leaking HVAC cooling tower at a production facility is sealed within a matter of hours to restore full efficiency to the temperature control system

Case Study: Repair of Underground Clay Drainage Pipe Cracked During Building Work

Two cracks in an underground clay drainage pipe – one of which was severe enough to almost split the pipe into two – are sealed by a UK homeowner making a DIY repair

Increasing growth into overseas markets sees Sylmasta pick up prestigious award from Sussex Chamber of Commerce

Sylmasta have been named Global Player Export Business of the Year at the Sussex Business Awards 2023.

Held annually by the Sussex Chamber of Commerce, the Sussex Business Awards are considered amongst the most prestigious in the county with hundreds of high-performing businesses put forward.

The Global Player Award goes to a Sussex-based company that has demonstrated significant and sustained growth internationally through harnessing the opportunity of overseas markets, proving that exporting can power business growth. 

From their headquarters in West Sussex, Sylmasta manufacture industry-leading repair and maintenance products for the purpose of extending the working life of parts and equipment.

The Sylmasta Pipe Refurbishment System is at the core of the Sylmasta range, and is built around a flexible four-stage process enabling a wide variety of complex repairs to be made to pipework of all diameters and types.

Sitting alongside the Sylmasta Pipe Refurbishment System is the SylWrap range of leak repair solutions, a series of products used to permanently fix leaking pipes in under 30 minutes even when pressure cannot be turned off.

Away from pipe repair, Sylmasta manufacture additional epoxy putties, pastes and coatings which repair and protect machine parts and equipment from problems including corrosion, abrasion and impact damage.

Whilst Sylmasta has a strong presence in the United Kingdom including working with several water companies to repair live leaks on the public supply network, exports accounted for 45 percent of the company’s business in 2022.

That figure is set to grow through new distribution in the Philippines, Indonesia and Australia over the coming months. Sylmasta have made great inroads into Latin America, building on long-established distribution in the likes of Argentina and Puerto Rico with SylWrap gaining approval for use on the public water network in Mexico.

The majority of Sylmasta products are made-to-order, enabling rapid turnaround. An epoxy wear compound manufactured in Sussex on a Monday can be in use at a mine in Chile by Friday, repairing and protecting plant equipment.

Managing director Simon Bedding collected the award on behalf of the Sylmasta team, which has grown in size by over 40 percent since 2020 thanks largely to the increased focus on the export market.

Mr Bedding said: “What an honour it was for Sylmasta to receive the Global Player award, especially when up against such strong competition. We are grateful to Sussex Chamber of Commerce for the opportunity and for putting on such a fabulous awards ceremony, we had a terrific evening.”

The award was celebrated back at Sylmasta HQ with a few bottles of English Sparkling Wine – also made in Sussex! Sylmasta will now move onto the South East Regional Business Awards, where they will be up against fellow Global Player Winners from Kent, Hampshire, Isle of Wight, Surrey and Thames Valley.

Worldwide repair and maintenance solutions

Case Study: Complex in UAE Approves SylWrap for Chilled Water System ABS Pipe Repair

Following vigorous testing, Superfast Aqua PW and SylWrap HD are approved for repairing leaking ABS pipe joints in a chilled water system at a luxury complex in the UAE

Case Study: Leaking HVAC Cooling Tower Repair at Production Facility in USA

After several failed repair attempts, a leaking HVAC cooling tower at a production facility is sealed within a matter of hours to restore full efficiency to the temperature control system

Case Study: Repair of Underground Clay Drainage Pipe Cracked During Building Work

Two cracks in an underground clay drainage pipe – one of which was severe enough to almost split the pipe into two – are sealed by a UK homeowner making a DIY repair

Case Study: SylWrap Leak Repair Passes ASME PCC-2 402-III Qualification Standard

A leak repair using Superfast Aqua PW Epoxy Putty and SylWrap HD passes testing for ASME PCC-2 402-III Qualification – Validation for Repair of Leaking Component

Case Study: SylWrap Pipe Repair Passes ASME PCC-2 401-III Qualification Standard

A pipe repair using SylWrap HD and Industrial Metal is independently tested to exceed 309.6 bar, passing ASME PCC-2 401-III qualification

WearShield – for ultimate resistance against impact, abrasion, corrosion and chemical attack

Sylmasta are delighted to introduce WearShield, their new high-performance, toughened epoxy wear compound, heavily filled with alumina beads for ultimate resistance against impact, abrasion and wear.

WearShield protects and repairs a diverse range of processing and plant machinery. Originally formulated to meet the tough requirements of maintenance and equipment protection in mines in South America, it is suitable anywhere impact damage and wear are common.

Other industries to use WearShield include power plants and quarries. It is ideal for the maintenance and repair of ash handling systems, scrubbers, silos, chutes, mills and metal castings. It can be applied to metal, wood and most plastics.

The formulation of WearShield is easy to mix. It is spread over the area requiring protection or repair using a putty knife, built up to a thickness of at least 6mm.

Once cured, WearShield provides a highly toughened, alumina reinforced shell capable of withstanding intense processes. The cured epoxy wear compound is a dark grey colour with the alumina beads it is filled with visible.

Two versions of WearShield are available. WearShield Standard has a work time of up to 60 minutes, a functional cure of 16 hours and a full cure of 24 hours. It is formulated so more epoxy can be applied in one go without the threat of premature curing, such as when covering large areas or in warm climates.

WearShield Rapid has a 5 minute work time, a functional cure of 45 minutes and a full cure of 3 hours. It enables equipment to go back into service quickly, reducing downtime and disruption. This makes it ideal for patch repairs between major overhauls.

To speak to a Sylmasta technician for more information on WearShield, please contact Sylmasta via email or on +44 (0)1444 831459.

Browse WearShield Epoxy Wear Compound Variations

WearShield Epoxy Wear Compound
Alumina bead-filled epoxy paste applied to equipment to create a highly toughened layer of protection against impact damage and wear

WearShield Rapid Epoxy Wear Compound
Fast working version of WearShield with a three hour full cure for rapid protection against impact and wear, reducing equipment downtime

Quick and easy permanent pipe repair without hiring an expensive plumber

When pipes burst or start leaking, the money involved in repairing them can soon add up. Hiring a plumber is not cheap, which is why more people are turning to DIY pipe repair kits when they need the tools and know how to fix a leaking pipe.

The Covid-19 pandemic and the lockdowns it brought saw an increase in those willing to take on DIY repairs in all kinds of areas, including pipes. Homeowners sought out pipe repair kits to permanently fix leaks and bursts without requiring a plumber to enter their property.

DIY repairs have remained popular in the post-lockdown world – and it is easy to see why. Whereas a plumber can charge up to £60 an hour plus an emergency call out fee of £120 (according to Checkatrade), a SylWrap Pipe Repair Kit capable of sealing a live leak on your average domestic copper pipe is available for under £20 including delivery.

Repairs are quick and easy to make and permanent with no training required. You simply follow the instructions provided and within 30 minutes, leaking pipes of any size and material can be sealed – even when pressure cannot be turned off should be unable to locate your stopcock or isolate the pipe for another reason.

We will now take you through the two-stage process of how to fix a leaking pipe using a SylWrap Pipe Repair Kit. All the products contained within the Kit are WRAS approved, meaning they have been certified to British standards as safe to use on pipes and fittings which come into contact with drinking water.

Stage one: Seal the leak

Stage one of making a DIY pipe repair involves sealing the leak. If you can turn the pressure off and the pipe is dry, then this is done using Superfast Epoxy Putty. If you cannot turn the pressure off and water is leaking from the pipe, then this is done using Wrap & Seal Pipe Burst Tape.

Firstly, the no pressure repair method. Epoxy putty consists of two components, resin and hardener. Both these parts are soft until mixed together, after which a chemical reaction takes place to turn the putty into a material as hard as steel.

Superfast Epoxy comes with the resin and hardener in a pre-formatted stick. To use, you simply cut enough putty from the stick to cover the hole or crack in the pipe and knead it by hand.

Within a few minutes, the putty will turn to a uniform colour. Whilst soft, it is then pushed into the hole or crack. After 5 to 10 minutes, it will harden, filling the hole or crack and sealing the leak.

Epoxy putty is pressure resistant up to 30 bar. The highest that most home water systems operate at is 3 bar, so Superfast is more than capable of repairing any domestic and most industrial pipes, easily withstanding the pressure.

For live leaks, Wrap & Seal is instead used. This waterproof repair tape is made from self-amalgamating silicone and stretches by up to 3 times its length. When wrapped around a leaking pipe, it will fuse to form a solid rubber band over the hole or crack, sealing it.

The more Wrap & Seal Tapes you use, the greater the pressure resistance. One Tape is normally more than capable of holding 3 bar on a domestic pipe. To know how many Tapes are needed to fix a leaking pipe of larger diameters, Sylmasta have produced a Wrap & Seal Calculator for calculating the quantity needed for bigger repairs.

One Wrap & Seal Tape will take less than 10 minutes to apply. Once you have completed stage one of the repair using either the Tape or Epoxy Putty, then comes stage two – reinforcement.

Stage two: Reinforce the pipe repair

The repair is made permanent by reinforcement using a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water-activated resin. It is dipped in water, wrapped and then smoothed around the area of the pipe which had been leaking.

Within minutes, the bandage will begin to harden. Once fully wrapped and cured, it provides a rock hard, impact resistant sleeve encompassing the pipe and protecting the initial seal.

Choosing the right Kit for your pipe repair

There are two SylWrap Pipe Repair Kits – the Standard Kit contains only Superfast Epoxy Putty and SylWrap HD Bandage and makes repairs to pipes where pressure can be turned off.

The Universal Kit includes Wrap & Seal Pipe Burst Tape along with Epoxy Putty and the Bandage. This Kit repairs live leaks where pressure cannot be turned off.

Once you have identified which Kit you need, then each product page contains a drop down list with various pipe diameters. Simply select the size of the pipe you are wanting to fix, and it will tell you the specific sized Kit you need.

Step-by-step instructions are supplied with every Kit and if you need any further assistance, then there are several videos showing how to fix a leaking pipe on each of the Kit pages.

If you have any questions about which product is most suitable for your repair or require technical assistance, then please contact Sylmasta via email or on +44 (0)1444 831459 and a technician will be happy to advise you.

DIY Pipe repairs – from homes to businesses to industry

Case Study: Leaking Dishwasher 50mm Plastic Pipe Repair in Golf Clubhouse Kitchen

A dishwasher pipe in a golf clubhouse discovered to be leaking on Sunday morning is repaired in under 30 minutes, ensuring no disruption to the busy luchtime service

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

A leaking bilge pipe on board a multimillion dollar superyacht is repaired after corrosion caused a hole to appear in a welded joint where it was impossible to fit a clamp

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

A nursing home avoids having to shut down its heating system in winter by making a live leak repair to a 150mm metal pipe which otherwise would have flooded a loft space

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

A sugar mill in Costa Rica seal a 70mm pipe running vertically up a tower after alcohol juice extracted during cane fermentation was found spraying out a pinhole

Case Study: Live Leak Repair of 150mm Cement Coated Steel Pipe on Water Network in Mexico

A live leak repair is made to an underground cement coated steel pipe supplying potable water in Mexico after removal of the outer shell revealed a 80mm split in the line

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

A leaking stainless steel pipe damaged inside a biodigester tank at a pig farm is sealed after an initial repair attempt via patch welding was discovered to have failed

Case Study: Live Leak Pipe Repair of Above and Below Ground Water Supply Pipelines

Water pipes located above and below ground as part of a network servicing a town in Libya required live leak repair to seal cracks without disrupting supplies

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

A steel pipe suspended in the ceiling of a building as part of a district heating system undergoes a live repair after a pinhole leak began causing substantial water damage

Universal Pipe Repair Kits now available to buy in London

Sylmasta are pleased to announce that Battersea-based Fraser & Ellis have become London stockists of the SylWrap Universal Pipe Repair Kit range.

Established as one of the premier plumbing merchants in London for over 100 years, their dedicated and knowledgable staff will be a great addition to the SylWrap family in helping those in the capital with pipe repair applications.

The Universal Pipe Repair Kit enables any user to permanently repair a leaking pipe without the need for any formal training. Full instructions are provided with the Kit for carrying out the two-stage process which is effective on pipes made of copper, steel, iron, PVC plastic, lead and other materials.

A repair begins by using a sealing material to plug the hole in the pipework. When pressure can be turned off, this is done with Superfast Epoxy Putty, which is hand kneaded and applied to damage areas whilst soft. Within 5 to 10 minutes, it will harden to fill the crack.

When pressure cannot be turned off, Wrap & Seal Pipe Burst Tape is instead used. Made from self-amalgamating silicone, it stretches by 300 percent and fuses to form a solid rubber band over a leak area, creating a pressure-resistant repair.

The initial repair is then overwrapped with a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin. It sets rock hard in minutes, providing an impact resistant layer of protection which reinforces the repair.

All the products in the Universal Pipe Repair Kit have WRAS approval, meaning that they are certified for safe use with drinking water. The Kit makes pressure resistant repairs up to 30 bar, is temperature resistant to 200ºC, and is effective on pipes carrying hot and cold water and chemicals.

Ample parking is available at Fraser & Ellis’ convenient location near Chelsea Bridge, where they have been based since 2016. For emergency pipe repair enquiries in London, they can be contacted via phone on 020 7228 9999 or email at sales@fraserellis.co.uk. You can also view the Fraser & Ellis website by clicking here.

Universal Kit Case Studies

Case Study: Leaking Dishwasher 50mm Plastic Pipe Repair in Golf Clubhouse Kitchen

A dishwasher pipe in a golf clubhouse discovered to be leaking on Sunday morning is repaired in under 30 minutes, ensuring no disruption to the busy luchtime service

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

A leaking bilge pipe on board a multimillion dollar superyacht is repaired after corrosion caused a hole to appear in a welded joint where it was impossible to fit a clamp

Brush up on your knowledge of brushable epoxy

Imagine if you could do something as a simple as paint a pipe, a part or a structure to provide it with a metal layer of armour capable of resisting corrosion, abrasion and chemical attack. Welcome to the world of the epoxy coating.

They say prevention is better than a cure and prevention of degrading surfaces does not come any better than epoxy coating. Within a couple of hours, a smooth, hard surface can be created that repairs existing wear and tear and prevents against future damage.

Here is the Sylmasta guide to epoxy coatings and how they can help you refurbish and extend the lifespan of systems, with potential savings of thousands and thousands of pounds.

What is an epoxy coating?

Epoxy coatings are made up of two separate liquid parts, one containing resin and the other containing hardener.

When these parts are mixed together, a chemical reaction takes place which results in the epoxy coating setting to form a hard wearing, ultra smooth coating.

What are epoxy coatings used for?

Epoxy coatings have two main uses. The first is for protecting and refurbishing structures, pipes, machinery and surfaces by providing them with an ultra-hard outer layer.

New parts which are coated with a brushable epoxy are protected against corrosion, abrasion, chemical attack, pitting, erosion and cavitation.

Old, worn or damaged parts are restored when an epoxy coating is applied via the creation of a new, hard layer which extends the lifespan of parts.

Take this repair made to aluminium extruder barrels in a pug mill putty machine for example. The rough initial finish of the barrels combined with the silica-filled putty causing damage as it was extruded had caused the aluminium to become worn.

This in turn was impacting on the efficiency of the machinery, as putty was being extruded at a reduced rate. Cleaning of the barrels also took longer because of the damage to the surface.

Applying an epoxy coating to the barrels repaired the worn surfaces, protected them from future abrasion caused by the putty and created an ultra-smooth layer for the putty to slide down, improving extrusion rate.

Epoxy coatings are also used for high-strength bonding of materials. Whilst still a liquid, they remain gel-like and sticky, during which components can be bonded to them.

When used in floor repair, ant-slip grit can be added to a floor painted with epoxy coating to create a non-slip surface. In pipe repair applications, an epoxy coating improves adhesion between the pipe and composite repair wrap.

How does an epoxy coating work?

Applying an epoxy coating is as simple as painting a wall. Once the two parts have been mixed to the prescribed ratio, a traditional paintbrush is used to coat the surface requiring protection.

The formulation of the epoxy coating will determine the cure time. Sylmasta epoxy coatings come with a 90 minute gel time, enabling more of the epoxy to be mixed without the threat of premature curing.

This is particularly useful in warmer climates, where heat accelerates the work time, reducing how long is available to carry out an application.

To create a pinhole free coating, it is recommended that two coats are used. The re-coating time is 5-8 hours after applying and a full cure is achieved in 24 hours.

Types of epoxy coating

Epoxy coatings can be filled with different materials to improve their effectiveness for use in specific applications, such as corrosion protection or prevention of abrasive wear.

Liquid Metal Epoxy Coating is metal-filled, setting to provide a layer of metallic armour to pipes, structures, machine parts and surfaces. It is formulated to offer excellent protection against corrosion and chemical attack.

Painting worn and damaged parts with Liquid Metal refurbishes them, extending the lifespan of systems. As well as metalwork, Liquid Metal can be used to give most plastics a metal coating.

For protection against surface wear, it is desirable to have an even harder epoxy coating. Ceramic Brushable Blue is ceramic-filled and reinforced with silicone carbide, enabling it to resist and repair damage caused by abrasion.

Sylmasta Epoxy Coatings

If you have any question about which product is most suitable for your repair or require technical assistance, then please contact Sylmasta via email or on +44 (0)1444 831459 and a technician will be happy to advise you.

Epoxy coating applications

Case Study: Repair of Domestic Water Main Pipe Leaking Due to Stone Damage and Corrosion

Corrosion and stone damage left a domestic water main pipe leaking underneath a driveway until the homeowner repaired and refurbished a 2-metre section of the line

Case Study: Heat Exchanger Plenum Chamber Corrosion Protection at Power Plant

After years of annually applying a standard epoxy to the inside of a plenum chamber, a power plant in Thailand seek a longer lasting method for corrosion protection

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

An engineering company in Hawaii refurbish a 30-metre section of corroded 450mm ductile iron sewer main after a previous repair attempt left a 30mm hole in the pipe

Case Study: Corrosion Protection of 600mm Ductile Pipe & Outlets in Underground Pumping Station

Corrosion protection measures are made to a ductile pipe system including three outlets and six flanges in an underground pumping station operated by a UK water company

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

A landscaping materials supplier repair metal pallets at their warehouse damaged by having heavy and abrasive items like paving, slabs and stones stacked on them

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

Ceramic Brushable Blue is used to coat pug mill putty extruder barrels, creating an abrasion resistant surface to increase extrusion efficiency and protect against future wear

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

Pump housing left with corrosion, abrasion and wear damage after years of extracting river water full of sand, silt and other debris is repaired at a copper mine in Bulgaria

Case Study: Power Station Repair Damage to Alloy 20 Pump Lid Caused by Impeller

A pump lid made from Alloy 20 at a power station treatment plant undergoes repair instead of a $4000 replacement after being damaged by a falling impeller

Industrial Process News Magazine recognise Sylmasta’s contribution to leak reduction through composite pipe repairs

Sylmasta have been named as Pipe Maintenance Company of the Month in the July 2021 edition of Industrial Process News Magazine.

The editorial team were impressed with the work Sylmasta have carried out on reducing leakage on the United Kingdom’s water network and in other industries worldwide through their SylWrap range of pipe repair products.

Sylmasta have partnered with several of the UK’s water utilities company, supplying them with SylWrap Pipe Repair Contractor Kits. Each kit enables any contractor to make up to six WRAS approved live leak repairs to pipes of all types and diameters without the need for any formal training in under 30 minutes.

The Case is designed to be easily stored on a van. As soon as a burst is identified by a water company on their network, they can send a vehicle equipped with everything needed to fix the problem. This rapid response time reduces the amount of water lost.

A SylWrap repair is effective on complex sections of pipe such as tees and elbows where pipe repair clamps cannot be deployed. The materials involved are also more lightweight, making them easier to manoeuvre and transport than heavy, bulky clamps.

Carrying out a SylWrap repair is a simple two-stage process. The leak is sealed with Superfast Epoxy Putty if pressure can be turned off or Wrap & Seal Pipe Burst Tape if pressure cannot be turned off. The initial sealing material is then overwrapped with a SylWrap HD Pipe Repair Bandage.

SylWrap HD is a water-activated composite wrap which sets rock hard in minutes, reinforcing the repair and providing an impact resistant protective sleeve over pipework.

Repairs made using SylWrap are permanent and they offer a cost-effective alternative to replacing damaged sections of pipeline.

Sylmasta’s recognition by Industrial Process News comes at a time when there is growing pressure to reduce leaks across all industries, with the water industry under particular scrutiny.

A report by the House of Commons Public Accounts Committee released in 2020 said that unless urgent action was taken to cut water wastage, Britain could experience water shortages by 2040.

The water industry have been set ambitious targets when it comes to leak reduction by the regulator Ofwat and the Department for Environment, Food and Rural Affairs (DEFRA).

In England and Wales, leaks must be reduced by 16 percent by 2025, a saving of 561 million. Longer-term targets are to cut water loss from 2020 levels by a third before 2030 and by half before 2050.

Whilst water companies are focused on identifying bursts which may otherwise leak for weeks, months or even years without ever been noticed, there is a growing realisation that this is only half the battle.

Companies also need to be able to repair these leaks quickly and efficiently to reduce leakage levels. The quick repair time of SylWrap can play an important role in doing so.

Away from water, Industrial Process News highlighted the work that Sylmasta do in helping other sectors repair and maintain their own systems, saving water and helping to reduce downtime.

SylWrap pipe repair solutions are used in wastewater treatment, nuclear power stations, petrochemical plants, quarries, agriculture, and by facilities management companies responsible for hotels, leisure facilities and hospitals to name but a few.

SylWrap pipe repair kits are already used on a worldwide scale with several countries in Africa, South America and Asia adopting composite repair.

They are approved by the national water supplier for use on Kuala Lumpur’s vast pipe network and have been used on the water network of Mexico.

With the importance of preserving water for the good of the planet likely to become a more pressing issue in the years to come, the reach of Sylmasta and the SylWrap range of pipe repair kits is only going to extend.

Click here to read issue 702 of Industrial Process News in which Sylmasta were named Pipe Maintenance Company of the Month

Sylmasta Leak Repair Case Studies

Case Study: Repair of Leaking Expansion Joint Fitted to Water Main Pipe on UK Road Bridge

An expansion joint on a 225mm steel water main carried over a river by a major road suspension bridge is repaired after it began leaking from a split between two bellows

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

A leaking bilge pipe on board a multimillion dollar superyacht is repaired after corrosion caused a hole to appear in a welded joint where it was impossible to fit a clamp

Case Study: Oil Refinery Repair Cooling Pipe System Attacked by Microbially Induced Corrosion

An oil refinery carry out a significant pipe repair programme after microbially induced corrosion caused welded joints in the stainless steel water cooling system to fail

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

One week after a series of demonstrations and site visits from Sylmasta in Malaysia, a water company repair a 6 bar live leak on a 300mm steel pipe at a treatment plant

Water is precious – the more we can save, the better for our planet

Every year on April 22nd, the world marks Earth Day to demonstrate support for environmental protection. When we talk about pipe repair, it is mostly in the context of saving money or protecting homes and properties from water damage, but fixing a leaking pipe quickly and easily can also help save the environment.

Planet Earth has a water problem which is mainly attributed to climate change. Hotter, dryer summers have brought on widespread, record-breaking droughts to put extreme stress on supplies.

Eastern Australia experienced its worst ever drought in 2019. Water shortages became so bad in São Paulo in 2015 that it caused rioting and looting. An official state of calamity had to be declared and the army was on standby to restore order.

California meanwhile was in a constant state of drought between 2011 and 2017, the most extreme known in 1200 years. 95 percent of the state’s winter salmon were killed in 2013, 62 million trees were lost in 2016 and residents were frequently placed under mandatory water restrictions of 25 percent.

In the United Kingdom, the House of Commons Public Accounts Committee warned in a September 2020 report that taps could run dry by 2040 unless more was done to protect supplies in the face of not only climate change, but population growth. More people on Earth results in more water being drawn from nature.

To help the environment, the world cannot afford to waste water. Every drop is precious. One of the biggest contributors to water waste – arguably the biggest – is leakage on public supply networks. In 2019-20, 2.95 billion litres of water were lost every day to leaks on the UK water network.

That might seem like an eye-watering amount, but it is actually the lowest ever leakage figure since records began in the mid-1990s, when 4.5 billion litres of water was lost. A combination of new leak detection technology, innovative pipe repair methods and a firm focus on saving water from government and stakeholders has been responsible for the drop.

Still, there is clearly much to do if the UK is to avoid running out of supplies by 2040, as forecast by the Public Accounts Committee. Ofwat used its PR19 five-yearly review into the water industry to demand water companies in England and Wales reduce leaks by 16% by 2025, saving enough water to supply every person in the cities of Birmingham, Bristol, Cardiff, Leeds, Liverpool and Sheffield.

The Department for Environment, Food and Rural Affairs have gone further, saying that leakage must be cut by half its 2020 levels by 2050. That would mean nearly 1.5 billion litres of water being saved via pipe repair, a huge boost to supplies in the UK, the environment and the planet.

Detecting and fixing leaking pipes is not always easy. Bursts and leaks often occur deep underground and can go unnoticed for months. Even when they are discovered, many are not straightforward to repair. Access may be difficult, the problem could be on a challenging joint, or the only solution considered might be replacement.

For particularly challenging leaks and bursts, water companies may consider it too costly and disruptive to carry out a repair or replacement. Instead, they will simply leave pipes to leak water for many years. One example of this comes from a burst water main which had been leaking for 15 years.

The traditional means of repair used by water companies is a pipe repair clamp. Whilst extremely effective in the right situations, clamps are hefty and bulky. They cannot be applied around elbows or tees, and are not always flexible enough to be fitted in confined spaces.

This was the problem faced by the company responsible for the burst water main. Only one worker could access the hole at a time, there was no room for a clamp, and to replace the main would have meant severe disruption caused by shutting off supplies and digging up the surrounding area. As a result, it was considered unrepairable.

That was until a Sylmasta Live Leak Pipe Repair came along. Using a SylWrap Universal Pipe Repair Kit, the latest contractors hired by the water company to find a solution were able to carry out a permanent live leak repair in under an hour.

A SylWrap repair consists of a simple two-stage process. The leak is first sealed using either Wrap & Seal Pipe Burst Tape (if pressure cannot be isolated) or Superfast Epoxy Putty (if water can be turned off). A SylWrap HD Pipe Repair Bandage is then applied over the initial leak sealant to complete the repair. 

SylWrap HD is a water-activated, resin impregnated fibreglass tape which sets rock hard to provide an impact-resistant, protective shell around damaged pipework, strengthening it and extending its lifespan. Repairs can be made to pipes of any diameter or type, to leaking elbows, tees, rivet joints and other challenging sections of pipework, all without the need for any formal training.

Pipe repair becomes a task any person can carry out using a SylWrap Kit – including in domestic settings. A SylWrap Pipe Repair Kit means that a small leak on a bathroom or kitchen pipe not worth paying a plumber to look at can now be fixed by the property owner in less than 30 minutes for under £20.

The speed and ease with which repairs can be made using SylWrap has seen several of the UK’s water companies approve the SylWrap Contractor Case for use on their networks. The national supplier in Malaysia is also using the Contractor Case to fix leaks on the vast pipe network of Kuala Lumpur. SylWrap is a global solution to a worldwide leak problem.

Each case contains enough products to make up to six repairs and can be easily stored on a van. Whenever a leak is detected, a contractor simply has to reach for their case, where everything they require to make a live leak repair can be found.

Pipe repair is not the only way to save water and protect the environment. We can all do more to reduce the amount of water we use through simple, everyday lifestyle changes such as spending less time in the shower and not leaving the tap running when brushing our teeth. Those savings may seem like a drop in the ocean compared to the near-3 billion litres lost to leaking pipes every year, but every little helps.

A concerted push from the whole world can help preserve water supplies and play a part in saving the environment, and pipe repair should be at the forefront of it.

To speak to a Sylmasta technician about how your company might benefit from using SylWrap Pipe Repair solutions for carrying out pipe repairs, then please contact Sylmasta via email or on +44 (0)1444 831459.

SylWrap Pipe Repairs

Case Study: Repair of Leaking Expansion Joint Fitted to Water Main Pipe on UK Road Bridge

An expansion joint on a 225mm steel water main carried over a river by a major road suspension bridge is repaired after it began leaking from a split between two bellows

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

A leaking bilge pipe on board a multimillion dollar superyacht is repaired after corrosion caused a hole to appear in a welded joint where it was impossible to fit a clamp

Case Study: Oil Refinery Repair Cooling Pipe System Attacked by Microbially Induced Corrosion

An oil refinery carry out a significant pipe repair programme after microbially induced corrosion caused welded joints in the stainless steel water cooling system to fail

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

One week after a series of demonstrations and site visits from Sylmasta in Malaysia, a water company repair a 6 bar live leak on a 300mm steel pipe at a treatment plant

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

A sugar mill in Costa Rica seal a 70mm pipe running vertically up a tower after alcohol juice extracted during cane fermentation was found spraying out a pinhole

Case Study: Live Leak Repair of 150mm Cement Coated Steel Pipe on Water Network in Mexico

A live leak repair is made to an underground cement coated steel pipe supplying potable water in Mexico after removal of the outer shell revealed a 80mm split in the line

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

A leaking stainless steel pipe damaged inside a biodigester tank at a pig farm is sealed after an initial repair attempt via patch welding was discovered to have failed