Category: Videos

About this Epoxy Paste Video

WearShield Epoxy Paste is used in some of the most abrasive working environments in the world to protect plant equipment and surfaces from damage caused by wear, impact, abrasion and corrosion.

It was originally formulated for the tough requirements of the South American mining industry. The increasing cost of American-made epoxy compounds led a mining company in Chile to approach Sylmasta about formulating an alternative.

The use of WearShield quickly spread across the continent. It is now used worldwide to protect heavy machinery including pumps, ash handling systems, scrubbers, silos, chutes, mineral nozzles, agglomerator drums, trunions and metal castings.

In the above video, we explain how the formulation of WearShield makes it so resistant. The epoxy paste is heavily filled with hard wearing alumina beads in a range of sizes. Large beards protect against bigger particles and little beads against smaller particles.

These beads combined with the high resin content of WearShield create a dense interlocking structure. Once cured, WearShield provides an alumina-reinforced, hardened shell up to 6mm thick for ultimate protection to the original substrate.

The video also shows product testing carried out at Sylmasta HQ. WearShield was applied to a metal demo piece. Once fully cured, it was attacked with an angle grinder for abrasion and impact testing. There was no chipping or fracturing of the cured WearShield.

Two grades of WearShield are available. Standard comes with a work time of between 30 and 60 minutes, a functional cure of 8–12 hours. and a 24-hour full cure.

It is used at higher ambient temperatures or where large amounts of WearShield are being mixed at once, removing the threat of premature curing from the application process.

WearShield Rapid is the fastest-working epoxy wear compound available. It begins to harden in just 10 minutes, significantly reducing system downtime and disruption.

WearShield Epoxy Paste

WearShield Impact Resistant Epoxy Paste
Alumina bead-filled epoxy paste which forms a toughened layer of protection against impact damage and wear

WearShield Rapid 5 Minute Epoxy Paste
Fast working version of WearShield with a three-hour full cure, reducing equipment downtime

About this Pipe Repair Video

Wrap & Seal Pipe Burst Tape is a self-amalgamating waterproof repair tape capable of sealing online leaks.

It stretches by three times its length when wrapped around a pipe, fusing to form a solid rubber band which creates a high-pressure seal containing pipe content.

This video was filmed during product testing at Sylmasta HQ in the United Kingdom. A 3mm pinhole was drilled into a stainless steel pipe test rig. Pressure was set at 3 bar whilst a Sylmasta technician carried out a live leak repair.

To start the repair, the release film was peeled back from the start of a 50mm x 4m Wrap & Seal Tape and anchored to the side of the leak. One full wrap around the pipe ensured the tape gripped to itself.

It was then wrapped towards the leak whilst being stretched as much as possible, up to the maximum 300 percent. The release film was removed as the application progressed with the tape overlapped by 50 percent per wrap.

Once the leak was reached, Wrap & Seal was applied directly over it with as much stretch as possible. The leak was not chased; even though water was weeping out the side of the repair, wrapping continued to concentrate over the pinhole.

Each layer increased the resistance of the repair, culminating in a thick rubber ridge bonded to the pipe and exerting maximum pressure to seal the pinhole and any potential leak paths.

The application continued until the entire Wrap & Seal was used. Had water still been escaping the pipe after one tape, another would have been applied on top to continue building up the ridge.

Multiple Wrap & Seal fuse to each other in the same way as a single tape amalgamates. Only when the leak is totally sealed should application of Wrap & Seal stop. It is possible to build a repair with pressure resistance up to 30 bar using multiple tapes.

Once the application had been completed, pressure through the test rig was increased to over 5 bar with no visible signs of leakage or any fluctuations.

Repairs made with Wrap & Seal can be reinforced by applying SylWrap HD Pipe Repair Bandage over the tape. SylWrap comes with a fast-working, water-activated resin.

It sets rock hard within minutes as is it is wrapped and smoothed around a pipe, curing to form an impact resistant outer sleeve.

Both Wrap & Seal and SylWrap HD have WRAS approval, meaning they are certified as safe to use on pipes and fittings carrying drinking water.

How to calculate the number of Wrap & Seal Tapes needed for a repair

The Sylmasta Wrap & Seal Calculator helps determine the number of tapes needed to repair a live leak up to a specified pressure resistance. Enter the diameter of the pipe in millimetres, water pressure and the size of the hole requiring seal.

A safety factor is a multiple to include a margin of safety. If pipe pressure is 3 bar for example and you want a safety factor of two, the calculate will formulate a repair for 6 bar.

After entering the repair data, selecting the size of Wrap & Seal to be used will determine the number of that specific tape for the application.

Repars to pipes in excess of 150mm diameter using Wrap & Seal PB-50x4m or PB-50x11m should be made in conjuntion with SylPad Pressure Resistance Multiplier.

(Calculations serve as a guide to potential maximum pressure resistance only. Actual pressure resistance depends upon pipe material, condition, hole size, leak type and tension maintained during wrapping.)

Live Leak Pipe Repair Products

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

Wrap & Seal 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: 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: 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: 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

About this Epoxy Coating Video

Liquid Metal is a metal-filled epoxy coating used to refurbish and protect metalwork and plastics against corrosion and chemical attack.

It is brush-applied onto pipework, equipment and other surfaces. It sets to form a smooth, metallic, hard-wearing outer shield which acts as a barrier protecting the original substate from attack.

For this demonstration video filmed at Sylmasta HQ, we took a heavily corroded carbon steel industrial barrel and refurbished it using Liquid Metal. The repair strengthened the brittle metalwork and helped prevent future corrosion.

Before application of Liquid Metal, the carbon steel underwent surface preparation. A power brush was used to remove as much rust, grime and remains of previous coatings as possible.

The two parts of Liquid Metal were then easily mixed by pouring the hardener (Part B) straight into the resin (Part A) container. The coating was stirred using a spatula until streak-free and a consistent grey colour.

Liquid Metal was then painted onto the barrell using a brush. Its high initial tack and adhesion enabled it to easily adhere to the steel barrel.

The coating applied was 1mm thick. Liquid Metal has a gel time of 90 minutes and a re-coat time time of between five and eight hours. To speed up the cure, a hot air gun was used evenly across the entire repair.

Once Liquid Metal had cured, the barrell was left with a high gloss, corrosion resistant coating. Additional layers of Liquid Metal could have been painted on, each building up the thickness of the outer shield

In pipe repair applications, Liquid Metal can be further reinforced by overwrapping with SylWrap Pipe Repair Bandage. SylWrap is added whilst Liquid Metal remains tacky. The epoxy coating will then improve adhesion between the pipe and the bandage.

SylWrap will cure within minutes to form a thickened, rock hard, impact-resistant shell around the pipe for even more enhanced protection levels.

This repair method using Liquid Metal and SylWrap is regularly used by water and wastewater companies to refurbish severely weakened pipe bridges.

The expense of removing and replacing such huge structures can otherwise reach six figures and require complex projects which take months to complete.

Liquid Metal and SylWrap in contrast will refurbish many metres of pipe bridge more cost-effectively and in a fraction of the time.

Liquid Metal

Liquid Metal Epxy Coating
Brush-applied epoxy coating forms a smooth, hard-wearing, metallic layer to protect original parts and surfaces

Liquid Metal Case Study

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

About this Pipe Repair Video

CrackSeal is a moisture-curing pipe sealant which quickly and easily seals cracks in cast iron waste, drain and soil pipes. It can also be used on other pipe materials where pressure is off, including steel and concrete-lined pipework.

This demonstration video was filmed at Sylmasta HQ. A 450mm long split was cut into a cast iron pipe.

Before repair, the cast iron was cleaned with Non-Flammable Degreaser to improve the bond between the cast iron and the sealant.

CrackSeal was extruded directly into the split until it was totally filled using a standard sealant gun. It was smoothed off using a spatula before it began to fully harden.

Within 10 minutes, CrackSeal had formed a skin. It was then overwrapped with SylWrap HD Pipe Repair Bandage for added reinforcement.

SylWrap Bandage was activated with water and wrapped around the pipe. It quickly cured to form a rock-hard, impact resistant layer of protection over the repair.

The demonstration was completed by pouring a bucket of water into the pipe. No water leaked through, showing the strength of Crack & Seal and SylWrap Bandage in containing pipe content.

CrackSeal is supplied in a 310ml cartridge. One cartridge fills approximately one metre of cracked pipework based on a 1cm wide crack.

Both CrackSeal and SylWrap HD can be purchased together as part of the SylWrap Cast Iron Pipe Repair Kit.

The Kit also contains Superfast Epoxy Putty, enabling the user to permanently repair any type of crack or hole in a cast iron pipe.

For users who regularly repair cast iron pipework such as drain companies or facilities management teams, Sylmasta also manufacture the SylWrap Drain & Waste Pipe Repair Kit.

It contains enough products to make multiple repairs to drain, waste and soil pipes between 32mm and 150mm diameter, even when water is leaking through.

The Kit comes in a robust red case which is easily kept on-site or on the van, enabling instant repairs to take place as soon as problems are identified.

Cast Iron Pipe Repair Products

CrackSeal Pipe Sealant
Moisture curing pipe sealant extruded into cracks in cast iron pipework, where it sets almost instantly

SylWrap Cast Iron Pipe Repair Kit
Contains CrackSeal, Superfast Steel Epoxy Putty and SylWrap HD for fast, permanent cast iron pipe repair

SylWrap Drain & Waste Pipe Repair Kit
Specialist kit makes multiple repairs to drain, waste and soil pipes made from cast iron and plastic

About this Pipe Repair Video

SylPad is used for repairing holes on pipework over 150mm diameter. It works by better concentrating the elastic force of Wrap & Seal directly over the hole in the pipe, increasing pressure resistance by up to three times.

This demonstration video was filmed at Sylmasta HQ. A 7.2mm hole was cut into a 450mm steel pipe with operating pressure set at 3 bar. Such a repair without SylPad would normally require four Large Wrap & Seal (PB-50x4HD) to seal the leak.

The repair began by drawing a line on the pipe to mark where the hole was. This meant the exact location of the leak could be identified once the tape was wrapped around the pipe.

Wrap & Seal was anchored around 50mm to the side of the leak. The tape was then wrapped towards the hole with a 50 percent overlay. Once the hole was reached, the application continued directly over it.

After two layers of Wrap & Seal were built, SylPad was pushed onto the tape directly above the hole as marked by the pen. SylPad stuck without the need for any adhesive.

Wrap & Seal was then wrapped over SylPad, securing it in place and forming a ridge over the hole. Greater pressure was now being directed down onto the hole rather than spread outwards, as would be the case had SylPad not been used.

By the complete application of only one PB50x4HD tape, the leak was successfully sealed. SylPad had reduced the number of Wrap & Seal required from four to one, speeding up the repair significantly.

To further showcase the increase in live leak pipe repair pressure resistance possible using SylPad, a second tape was added and pressure through the demo rig pushed to 6 bar.

A third Wrap & Seal then achieved 9 bar pressure; resistance which would have needed 12 x PB50x4HD tapes without the use of SylPad.

SylPad is available to be as an individual product. It is also included in is as standard in SylWrap Universal Pipe Repair Kits 633 and 866 and all SylWrap Pipe Repair Contractor Cases covering pipework 150mm upwards.

Because SylPad is contained within layers of Wrap & Seal and does not come into contact with pipe contents, it does not require WRAS approval for use in high pressure live leak pipe repair on supply lines carrying potable water.

Live Leak Pipe Repair Products

SylPad Pressure Resistance Multiplier
Increases the pressure resistance of Wrap & Seal by up to three times when repairing live leaks on pipes in excess of 150 diameter

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

SylPad Case Study

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

About this Pipe Repair Video

A large hole was cut into the 150mm steel pipe close to a flange joint, meaning the test rig could not be repaired with Wrap & Seal Pipe Burst Tape, SylWrap Pipe Repair Bandage or any type of clamp. Pressure was set at 5 bar.

To seal the leak, a plastic PVC fitting was cut to shape and then bonded to the pipe using Superfast Aqua PW Epoxy Putty. Superfast Aqua PW has a fast five-minute work time and offers excellent wet surface adhesion, enabling it to permanently bond with the pipe despite it being saturated by the continued escape of water.

Three 114g Superfast Aqua PW Sticks were used to ensure a high-strength repair and a watertight seal between the fitting and the leak. Heat was used to accelerate the cure of the epoxy putty so that it fully hardened within a few minutes; otherwise, it would have needed to be left overnight for up to eight hours to achieve working strength.

Once fully cured, Superfast Aqua PW channelled the leak path through the fitting. An end cap and valve was then screwed on, containing pipe content and stopping the leak.

In this demonstration, the screwing of the cap resulted in a pinhole leak appearing where a weakness in the putty repair existed. This often happens and is easily dealt with by applying more Superfast Aqua PW around any pinhole or other leak areas which appear.

Pressure on the repair was relieved by unscrewing the cap. Another 114g stick of Superfast Aqua PW was then applied to seal the newly identified pinhole. When the cap and valve were screwed back on, the leak was fully arrested.

To demonstrate the strength and resilience of the repair, the cured epoxy putty was then attacked with a hammer after the demonstration had been completed.

Superfast Aqua PW has WRAS approval, meaning it is certified to British standards as safe to use on pipes and fittings carrying drinking water. It will bond to steel, iron, copper, PVC plastic, GRP, ceramic and concrete for effective online pipe repair where wrapping or clamping is not possible.

Wet Surface Epoxy Putty

Superfast Aqua PW Epoxy Putty Stick
WRAS approved epoxy putty in a 114g stick with a fast five minute work time for making quick wet surface and underwater repairs.

About this Epoxy Putty Repair Video

Sylmasta AB Original Epoxy Putty has a wide range of uses in pipe repair, refurbishment and maintenance applications. It is made by Sylmasta at their UK site using the latest in epoxy stick manufacturing technology.

Each 200g stick and contains resin on the outside and hardener in the middle. Combining the two removes the need to measure out resin and hardener from separate components.

Instead, the user simply cuts off the required amount of putty from the stick and kneads it by hand for around five minutes, until the material is a uniform colour and streak free.

AB Original comes with an extended two-hour work time. It enables more material to be mixed and longer taken when shaping and applying compared to fast working epoxy putties which cure off in minutes.

It comes in white, grey and black and bonds to metal, wood, brick, masonry, concrete, porcelain, ceramics, clay and most plastics. AB Original even cures underwater and has high wet surface adhesion.

Because of its versatility, AB Original is used in a variety of different applications. These include sealing leaking pipes, filling holes and cracks, rebuilding small areas of damage and high-strength bonding between parts.

Once cured, AB Original can be tapped, drilled, screwed, sawed, machined, ground, filed, or painted.

This demonstration video was filmed at Sylmasta HQ and shows AB Original Epoxy Putty being used to repair wood. A corner was cut away and three large, deep holes drilled into a wooden demo piece.

The corner was rebuilt with AB Original and each of the holes filled with a different colour of the epoxy putty. Water was used to show the ultra smooth finish AB Original achieves, followed by the cured material being sanded.

AB Original can be used to make repairs in interior and exterior settings. It achieves a full cure in 24 hours and is resistant to water, chemicals, and temperature extremes. It also insulates parts and can be used as a sacrificial layer against corrosion and chemical attack.

Sylmasta AB Original Epoxy Putty

Sylmasta AB Original Epoxy Putty Stick
Ceramic-filled, super-strength epoxy putty with a two-hour work time offering longer to mould, shape and apply

About this Epoxy Paste Video

Industrial Metal is a metal-filled epoxy repair paste used to protect and reinforce metalwork, repair large holes and cracks and rebuild areas weakened by corrosion, chemical attack, wear and impact.

It is filled with corrosion-resistant platelets which provide excellent protection, whilst also giving Industrial Metal a smoother finish than other epoxy pastes when machined.

For this demonstration video filmed at Sylmasta HQ, a large hole was drilled into a metal demo piece. It was then repaired with Industrial Metal before being machined and undergoing strength tests.

First, the metal surface was cleaned and prepared using Sylmasta Non-Flammable Degreaser and an abrasive disc, revealing white metal.

The two parts of Industrial Metal were easily mixed and applied using a wooden stirrer. The hole was filled with Industrial Metal and the epoxy paste pushed firmly into the surface to ensure maximum contact and avoid trapping air.

A full cure was achieved in 24 hours, leaving the hole seamlessly repaired with a new metallic material. The cured Industrial Metal was then drilled and tapped, demonstrating its high machinability.

Next, a bucket was filled with 21kg of sand and suspended from the demo piece to showcase the strength and hardness of Industrial Metal.

Finally, the demo piece was struck with a hammer whilst still holding the bucket of sand to highlight Industrial Metal’s resistance to shock.

Two grades of Industrial Metal are available. Standard comes with a 60-minute work time. It is used at higher ambient temperatures or where significant amounts of epoxy paste are being mixed at once, removing the threat of premature curing from the application process.

Industrial Metal Rapid has a five-minute work time, achieves a functional cure in 60 minutes and a full cure after 24 hours. It enables metal repair to take place more quickly than the standard grade, minimising downtime and disruption.

In pipe repair applications. Industrial Metal rebuilds and strengthens degraded pipelines by increasing outer wall thickness and fills damage caused by impact and pitting, restoring surface profile.

Industrial Metal

Industrial Metal
Metal-filled epoxy paste for large damage repairs, rebuilding worn equipment and protecting machine parts and surfaces

Industrial Metal Rapid
Faster working version of Industrial Metal with a five-minute gel time for applications where speed is desired

About this Pipe Repair Video

The 150mm steel pipe was leaking through a flange. Sylmasta sealed the leak whilst the pipe remained live and operating pressure was set via the test rig at 2 bar, meaning a stream of water was escaping the flange throughout.

Superfast Aqua PW Epoxy Putty was used to permanently bond a valve fitting over the leak area. This fitting channelled the leak path directly through the valve, which was then tapped off to contain pipe content.

The specialist formulation of Superfast Aqua PW offers very high wet surface and underwater adhesion. It bonds to metal, most plastics, ceramic, GRP and fibreglass in damp, wet, saltwater and freshwater conditions.

Superfast Aqua PW was kneaded by hand for three minutes until it turned a uniform white colour, indicating successful mixing. It was then attached to the bottom of the valve, before being fitted to the leak area.

The epoxy putty was pushed firmly against the pipe and flange before it hardened. Despite water continuing to saturate the pipe, Superfast Aqua PW formed a permanent bond and a watertight seal once it cured around 10 minutes after mixing began.

Once the valve had been fitted, all water leaving the pipe was directed through it. Tapping the valve ensured no more water could escape the pipe through the flange, completing the repair.

To showcase the effectiveness of a leaking pipe flange repair made with Superfast Aqua PW, Sylmasta increased pressure through the test rig from 2 bar up to 18 bar. The repair continued to hold.

The fast five minute work time of Superfast Aqua PW makes this a quick and easy repair method to seal a leaking flange when water pressure cannot be turned off.

Superfast Aqua PW has WRAS approval, meaning it is certified to British standards as safe to use on pipes and fittings carrying drinking water.

A similar repair could be made using Sylmasta AB Original Epoxy Putty. AB Original comes with a two-hour work time, making it more suitable for larger, complex repairs where longer is needed to apply the putty before curing begins.

Whilst AB Original offers the same excellent wet surface and underwater adhesion as Superfast Aqua PW, it does not have WRAS approval and so should not be used on pipes or fittings carrying drinking water.

Wet Surface Epoxy Putty

Superfast Aqua PW Epoxy Putty Stick
WRAS approved epoxy putty in a 114g stick with a fast five minute work time for making quick wet surface and underwater repairs.

Sylmasta AB Original Epoxy Putty Stick
Super-strength epoxy putty in a 200g stick with a longer two-hour work time for use in complex wet surface and underwater repairs.

About this Epoxy Paste Video

WearShield is applied to machinery and equipment subjected to intense processes in highly abrasive environments.

Its dense alumina bead structure and high resin content enable WearShield to offer ultimate resistance against impact, wear, corrosion and chemical attack by forming an alumina-reinforced outer shell up to 6mm thick over parts and surfaces.

Originally formulated for the tough requirements of the South American mining industry, WearShield is now used worldwide in power plants, quarries and mills.

It protects a wide range of processing and plant equipment including ash handling systems, scrubbers, silos, chutes, mineral nozzles, agglomerator drums, trunions and metal castings.

This video was filmed as part of a WearShield demonstration at Sylmasta HQ. A metal test piece underwent surface preparation, being roughened up to improve adhesion with WearShield and then cleaned.

WearShield was mixed and applied using a metal spatula. Solvent was sprayed onto the spatula to smooth off the epoxy paste after it had been coated onto the test piece. WearShield was left to cure.

Once a full cure had been achieved, the test piece was attacked with an angle grinder and hammer for abrasion and impact testing. There was no chipping or fracturing of the cured WearShield.

Lastly, the demonstration showed the benefits of top coating WearShield with Ceramic Brushable Blue Epoxy Coating to create a low-friction surface over the initial repair.

Ceramic Brushable is silicone-carbide filled, giving it an ultra-smooth finish. When used in conjunction with WearShield, it further reduces abrasion damage by limiting friction between parts. It also makes clean up more effective.

Two grades of WearShield are available. Standard comes with a work time of between 30 and 60 minutes, a functional cure of 8–12 hours. and a 24-hour full cure.

It is used at higher ambient temperatures or where large amounts of WearShield are being mixed at once, removing the threat of premature curing from the application process.

WearShield Rapid has a five-minute work time, a functional cure of 45 minutes and a full cure of three hours. It allows an abrasion resistant repair to be made quickly, minimising downtime and disruption.

WearShield Epoxy Paste

WearShield Impact Resistant Epoxy Paste
Alumina bead-filled epoxy paste which forms a toughened layer of protection against impact damage and wear

WearShield Rapid 5 Minute Epoxy Paste
Fast working version of WearShield with a three hour full cure, reducing equipment downtime