Tag: AB Original

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

Clan MacGregor Dalmally Burial Stones Restoration featuring a custom coloured Sylmasta AB Original Epoxy Putty

Customised coloured putty restoration puts Clan MacGregor Dalmally Burial Stones back on display for first time in 400 years

Sylmasta manufacture a specialist version of AB Original Epoxy Putty colour-matched to RAL 7037, helping the Clan MacGregor Dalmally Burial Stones go on display inside Glenorchy Parish Church following restoration for the first time in 400 years.

Case Study Data

Site
Church
Location
Scotland
Repair Type
Burial stones restoration
Defect
Pieces missing from base of burial stones

Products Used

Sylmasta AB Original Epoxy Putty
Super-strength epoxy putty which bonds to all materials, filling in and rebuilding large areas of damage

Case Study PDF

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Case Study Details

In 1996, the Clan Gregor Society discovered that seven burial stones sunk into the ground in the churchyard of the Glenorchy Parish Church at Dalmally, near Loch Awe, Scotland, belonged to the ancient chiefs of Clan MacGregor.

The stones were originally placed around the high altar of the church to mark the burial spots of clan chiefs. The oldest belonged to John Macgregor of Glenurquay, who was buried on the north side of the High Altar of the original church in 1390. The most modern came from 1528.

Clan MacGregor fell from favour in the early 1600s. The name was banned by King James VI of Scotland following a particularly bloody bout of violence. It was one of his last acts before travelling to London to take up the British crown following the death of Elizabeth I.

The attempted erasure of Clan MacGregor by King James left them with no castle to call their own and the destruction of almost all their historical objects. The Dalmally Stones are therefore one of the few surviving examples of medieval heritage relating to the ancient Clan, whose proscription lasted 170 years.

It is believed the burial stones were removed from the high altar in 1615 when the church was rebuilt as part of The Reformation. They were taken outside and used to cover other grave plots in the churchyard.

By the time the Clan Gregor Society realised their importance, the burial stones had been on the ground for more than 350 years. Erosion, dirt ingress and other forms of damage as the stones sunk over the course of three centuries had left them in desperate need of conservation.

And so the Clan Gregor Society put together an ambitions plan to raise, restore and then return the Dalmally Stones to display inside the church.

It would take another 26 years until 2022 for the society to secure permissions from religious bodies, heritage societies, local and national government, as well as raising enough funds to make the project a reality.

After that time-consuming process was completed, Graciella Ainsworth Sculpture Conservation were commissioned to restore the stones. One challenge came from huge chunks missing from the base of the stones, leaving them unable to stand on display.

Sylmasta formulated a specialist version of AB Original Epoxy Putty colour-matched to RAL 7307, which the team at Graciela Ainsworth believed to be the closest match to the stones after they underwent thorough cleaning during the restoration process.

Dalmally Burial Stones restoration featuring Sylmasta AB Original Epoxy Putty used to repair missing chunks from base of stone
AB Original rebuilt missing areas at the base of the Dalmally Stones, creating a flat bottom edge to help them be upstanding on display in the church

AB Original was then used to create a flat, bottom edge on each stone, so that they could be placed standing inside the church. 30kg of AB Original was sent to Scotland. The putty was kneaded by hand and then applied to rebuild the bottom of each stone.

The two-hour work time of AB Original allowed for careful, precise application without the threat of premature curing. Once set, AB Original formed a ceramic-like material similar to the original stonework in both texture and colour.

AB Original was colour-matched to RAL 7307 to make the putty unobtrusive against the rest of the stone

After Graciella Ainsworth had completed their restoration of the Dalmally Stones, they were fixed in place inside the church for the first time in 400 years. A dedication ceremony was held as part of a weeklong Clan Gregor celebration, attended by society members who travelled to Scotland from around the world.

The beautiful carvings of knights and delicate patterns decorating the stones – which are considered fine examples of the Loch Awe School – can now be fully appreciated and are preserved for future generations to admire.

Display item at the New Perth Museum similar to the Dalmally Stones which underwent restoration with Sylmasta AB Original Epoxy Putty
Graciella Ainsworth have since used AB Original to create supporting bases for other similar display pieces at the New Perth Museum

AB Original has since been used by Graciella Ainsworth in similar applications, including creating supporting shoes for a series of display pieces at the New Perth Museum.

Sylmasta’s investment in the latest epoxy putty stick manufacturing technology at their site in the United Kingdom means other colour-customised putties can be quickly and easily made for future conservation and restoration projects depending on client requirements.

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

Concrete classic composite order column repair using Sylmasta AB Original Epoxy Putty

Back to the movies – repair of composite order column tops restores a former cinema facade to its 1920s heyday

Heavily damaged composite order column capitals made from concrete are returned to their highly detailed original state in a Sylmasta AB Original Epoxy Putty repair during the renovation of a neoclassical style former cinema in Portsmouth built during the 1920s.

Case Study Data

Site
1920s neoclassical former cinema
Location
Portsmouth
Repair Type
Concrete restoration
Defect
Heavily damaged classical composite order column capitals

Products Used

Sylmasta AB Original Epoxy Putty Stick
Super-strength epoxy putty which bonds to all materials and can be easily carved and shaped to hold intricate details

Case Study PDF

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Case Study Details

Renowned local Portsmouth architect Arthur Edward Cogswell designed the building in neoclassic style. It opened in 1921 as a cinema and remained in use as a picture house through several names changes for 52 years, until 1973.

It reopened as a snooker hall in 1976 and played host to budding local Stephen Hendrys and Ronnie O’Sullivans until the 2000s. More recent uses included a martial arts centre, a lounge bar, a short-lived return to snooker and darts, and a karaoke bar.

The uncertainty over what to do with the inside of the building over the past 20 years was reflected by a lack of maintenance and care for the outside.

By the time the karaoke bar heard its final song, the facade had become an untidy mess of different coloured paints peeling away, damaged concrete and broken windows.

An ambitious project was launched to renovate the building for community use. This included restoring the dilapidated facade as close to its original 1920s state as possible.

The facade of the building was an untidy mess. The capitals of the classical composite order columns had suffered heavy damage and had large parts missing

The most challenging part of the refurbishment was repairing the tops of four composite order columns – known as capitals – which were in a sorry state. Faded red and blue paint was flaking off. Much of the intricate carved detail had crumbled away and been lost.

With its super strength, long work time and ability to hold shape after being carved, Sylmasta AB Original Epoxy Putty proved the ideal repair material to restore the columns.

Each column was blowtorched as part of the cleaning process

The columns were first thoroughly cleaned, including using a blowtorch to burn off any remains of old paint. AB Original was then mixed by hand, after which the installers had around two hours to carve the putty into the original style of A.E. Cogswell and apply it to the column before it set.

Damaged concrete classic composite order column before undergoing repair with Sylmasta AB Original Epoxy Putty
Sylmasta AB Original Epoxy Putty used to create intricate carvings for the repair of a concrete composite order column
AB Original was carved and sculpted to restore details missing from the columns

Because AB Original sets harder than other epoxy putties, it easily held the highly intricate detail needed to match a classic composite order column. Each sculpted piece of AB Original adhered directly to the concrete, forming a permanent bond.

All four columns were repaired in this way before the entire facade was painted a dignified white. The end result was a seamless restoration of each column. AB Original was so effective, it left no trace that a significant repair and rebuild had taken place.

Classic composite order column repair made using Sylmasta AB Original Epoxy Putty
The columns and entire front facade of the building were painted white to complete the renovation

If A.E. Cogswell came back to life and visited his cinema, even he would have struggled to tell the detailing on the columns was not the original work.

The entire renovation project took around 12 months to complete and included modernising the inside of the building. It now serves the local community, looking almost identical from the outside as it did when first opened as a cinema a century ago.

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

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

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

Gaps in a concrete flood defence wall repair made using Sylmasta AB Original Epoxy Putty

Dam good repair – Sylmasta AB Original Epoxy Putty seals gaps in a concrete flood defence wall

Gaps left in a relatively new concrete flood defence wall by an ineffective sealing compound washing out are resealed in a Sylmasta AB Original Epoxy Putty repair made by a civil engineering company.

Case Study Data

Site
Flood defence dam
Location
Scotland
Repair Type
Gap repair
Defect
Gaps between concrete slabs in section of flood defence wall

Products Used

Sylmasta AB Original Epoxy Putty Stick
Super-strength epoxy putty effective on wet surfaces which comes with a two-hour work time for complex gap filling

Case Study PDF

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Case Study Details

A valley in Scotland at the confluence of three rivers had been flooding for over a century, affecting homes and business in three towns and the railway line connecting them.

With climate change making flooding a more regular occurrence, a multimillion pound flood defence project was commissioned. This involved the construction of a large earth storage dam and concrete flood defence walls.

The state-of-the-art dam was designed to retain water from the rivers when levels were high, reducing the risk of flooding in the towns downstream whilst leaving flow unaffected at other times.

Alongside the dam, flood defence walls were built to protect the railway line and the residential estates closest to the river which had suffered the most from water damage over the past 25 years.

Not long after the project finished and one section of the defence walls began leaking. It was made up of concrete slabs sealed together by a grout compound. This compound was now being washed out by floodwater, causing large gaps to appear between the slabs.

A civil engineering company were called in to inspect the problem and formulate a repair. After consultation with Sylmasta, it was decided the gaps in the flood defence wall should undergo repair using AB Original Epoxy Putty.

AB Original is a ceramic-filled, high-strength epoxy putty with an extended work time and excellent underwater and wet surface adhesion.

The engineering company were confident in the suitability of AB Original having seen a previous case study where the Environment Agency sealed a large crack in a wall between a river and a trout farm.

Flood defence wall at a UK dam undergoes repair using Sylmasta AB Original Epoxy Putty after gaps appeared
Sylmasta AB Original Epoxy Putty packed into cracks in a flood defence wall, sealing the gaps
The original sealing compound between concrete slabs had washed away, with the subsequent gaps packed with AB Original

45kg of AB Original Epoxy Putty were delivered to site in 200g sticks. Supplying the putty in sticks formatted to the correct mix ratio removed the need to measure out separate components of resin and hardener from tubs, speeding up the repair.

Each stick was mixed by hand until it turned a uniform colour. Whilst still soft, the putty was pushed into the gaps between slabs. The two-hour work time of AB Original meant the engineers making the repair could take their time mixing and carefully applying the putty without the threat of premature curing.

Once cured, AB Original formed a rock-hard material and a watertight seal much more effective than the original grout compound. With its wet surface properties, the putty easily bonded to the saturated concrete.

Gaps in the concrete flooring were also sealed thanks to the underwater curing properties of AB Original

Gaps had also appeared between slabs making up a floor, which was now underwater because of the flooding. AB Original cured below the water line, sealing the floor in the same manner as the wall.

Such a straightforward repair ensured the construction of the flood defence wall being completed with an ineffective sealing compound did not cause long-term issues.

AB Original allowed the problem to be remedied quickly and easily, avoiding a costly rebuild or significant reinforcement of the structure within only a few years of completion of the project.

The putty is now playing a small part in protecting homes, businesses and transport infrastructure in the valley against flooding.

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: Underground 600mm Concrete Water Pipe Break Repair in Canada

A break in a 60mm underground concrete water pipe in Canda is repaired using Sylmasta products

BC pipe break repair – reducing water loss from an indefinable leak for a city in western Canada

A city authority in Canada repair an underground 600mm diameter concrete pipe with a difficult break at the point it passed through a wall, reducing a 2 bar leak losing significant amounts of water down to a slow and steady drip.

Case Study Data

Site
Public Water Network
Location
British Columbia, Canada
Repair Type
Leak Repair
Defect
Crack in a 600mm diameter concrete water supply pipe

Products Used

Sylmasta AB Original Epoxy Putty Stick
Epoxy putty offering excellent wet surface adhesion for sealing pipework which cannot be made dry before repair

SylWrap HD Pipe Repair Bandage
Composite wrap with water activated resin which sets rock hard to reinforce repairs by forming an impact resistant outer sleeve

Case Study PDF

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Case Study Details

The 600mm diameter pipe ran beneath a road in a city in British Columbia. A break was detected and with other concrete pipe bursts making headline news across Canada, the city authority carried out an immediate excavation to assess the problem and repair the leak.

A steady, hard spray of water was discovered jetting out of the pipe through a joint at the exact point the line passed into a solid concrete wall. This made identifying the exact source of the leak impossible.

The city authority contacted Sylmasta for help with what was a very challenging application. Not only was the precise leak point unknown, but the pipe was unable to be fully shutdown.

An underground water pipe in Canada with a break through which water was leaking at 2 bar pressure
The pipe was leaking from a break somewhere beneath a joint at the point it passed into a solid concrete wall

A further complication came with the break being so close to the wall, meaning the normal live leak repair method of applying Wrap & Seal Pipe Burst Tape would be ineffective.

There was insufficient space to stretch the tape by the required 300 percent to ensure it successfully amalgamated to form a solid rubber band.

Sylmasta suggested reducing the pressure as much as possible from the 2 bar the pipe operated at, followed by using AB Original Epoxy Putty to seal around the entire joint.

AB Original was recommended because it has excellent underwater adhesion, meaning it could bond to the pipe even if wet from the ongoing leak. Its two-hour work time also offers longer to work the putty without worrying about premature curing during application.

The importance of the pipe to the city network meant pressure could only be reduced between midnight and 5am, giving the two maintenance workers making the repair a five-hour window in which to work.

Sylmasta AB Original Epoxy Putty Stick used in the repair of a concrete water main pipe break in Canada
Two maintenance workers mixed AB Original Epoxy Putty by hand inside the hole dug to access the pipe before applying it to the leak area

Just under 8kg of AB Original was used in the repair, supplied in 200g sticks. Each stick was mixed by hand until it turned a uniform colour. It was then packed around the leaking joint, building a repair which encompassed the entire break area.

Despite water pouring out the top of the pipe during the repair, AB Original bonded successfully. After two hours, the putty had set to form a watertight material which reduced the amount of water being lost down to a slow drip.

The pipe was then wrapped with SylWrap HD Pipe Repair Bandage for added reinforcement. Two SYL866HD were used, creating a rock-hard outer shell to further protect the pipe and help increase the effectiveness of the repair.

SylWrap Pipe Repair Bandage used to reinforce a break in a concrete water main pipe in Canada
AB Original was packed around the break in the pipe, encompassing the leak area. The repair was then overwrapped with SylWrap HD Bandage.

Completing the application took around three hours. The city authority were particularly impressed with Symasta’s efficiency. It took under five days from initial contact for a repair method to be devised, the goods shipped from the UK to British Columbia and the leak reduced to an acceptable level until the section of pipe can be replaced.

The need for speed in addressing the leak before it could escalate into a major problem was particularly important at a time when Canada’s pipe network is under scrutiny following high-profile bursts in Calgary and Montreal which led to flooding and the rationing of public water supplies.

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

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

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Case Study: Rotted Wooden Beam Repair in Home Renovation Project

Rotten wooden beam repair made using Sylmasta AB Original Epoxy Putty during a home renovation in Wales

Home facade is made ready for rendering thanks to a rotten wooden beam repair made with Sylmasta AB Original Epoxy Putty

Sylmasta AB Original Epoxy Putty is used to repair a rotted wooden beam, filling in large voids to help create a flat surface which enabled the outside of a home to be rendered as part of a renovation project.

Case Study Data

Site
Residential home
Location
Wales
Repair Type
Wood repair
Defect
Oak beam heavily rotted

Products Used

Sylmasta AB Original Epoxy Putty Stick
Epoxy putty with a two-hour work time applied to wood for repairing damage and filling in voids caused by rotting

Case Study PDF

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Case Study Details

A property owner in Wales was renovating a house they had inherited, including improving its exterior appearance. The facade consisted of an untidy mix of concrete breeze blocks, painted brick and a large oak beam.

The intention was to render the entire wall with cement. Doing so required a flat, sound surface for the cement to be applied to. Unfortunately, the ancient oak was badly rotted in places with large voids which made it impossible to render successfully.

To overcome the problem, the property owner decided to repair the rotted wooden beam using Sylmasta AB Original Epoxy Putty. AB Original was chosen for its super strength, ease of application and two-hour work time, meaning more of the putty could be mixed in one go and carefully applied without needing to rush through fear of premature curing.

Sylmasta AB Original used as a filler repair material for a rotten oak wooden beam
AB Original was used to fill the damage left where the oak beam had rotted

30kg of AB Original were delivered to the site. The putty was supplied in 200g sticks, whereby the resin and hardener are pre-measured. This eliminated the need to measure out separate components of Part A and Part B, making application quicker and more straightforward.

Each stick was kneaded by hand until it turned a uniform white colour. Whilst soft, AB Original was pushed into the voids left where the oak had rotted away, easily bonding to the damaged wood. The homeowner was particularly attracted to AB Original because no tools or equipment were needed for the repair.

Sylmasta AB Original Epoxy Putty used to bond hardwood to a rotten wooden beam as part of a house renovation
Hardwood inserts were bonded to AB Original in areas of the beam with significant damage

Where the gaps left by rot were particularly big, the homeowner added hardwood inserts on top of the putty to reduce the amount of AB Original required.

These inserts were pressed directly into the putty whilst it remained soft. A permanent bond was created between the putty and the hardwood once AB Original had cured to its final rock-hard, watertight material.

Home successfully rendered after rotten wooden beam underwent repair with Sylmasta AB Original Epoxy Putty
The repair helped create a smooth exterior facade which was then rendered

For the AB Original which remained exposed, a little water was used to create an ultra-smooth finish as the putty set. The cured material itself could be rendered onto directly, helping to make adding the cement coating a straightforward task.

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

A 250-metre cast iron rainwater pipe undergoes repair after it was found to be leaking through corroded joints

Three hundred not out – 300 joints are sealed in a leaking rainwater stack which threatened to derail the timeframe of an office block refurbishment

The refurbishment of a five-floor office block in central London is kept on track thanks to Sylmasta AB Original Epoxy Putty sealing 300 pipe joints in the repair of a 250-metre long internal cast iron rainwater stack leaking due to corrosion.

Case Study Data

Site
Office block
Location
London, UK
Repair Type
Leak repair
Defect
Corroded joints in cast iron rainwater stack

Products Used

Sylmasta AB Original Epoxy Putty Stick
Waterproof epoxy putty with a two-hour work time for thorough leak sealing without the threat of curing before application is complete

Case Study PDF

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Case Study Details

With the entire office block stripped out as part of the refurbishment, the internal cast iron rainwater stack was accessed for the first time in many years. This revealed that 30-year-old rubber seals used to attach different sections of pipe together had begun to fail and would need replacing.

When these rubber seals were removed, the pipe ends underneath were discovered to be badly corroded where water had become trapped. Because of the uneven pipe surface, pitting and breaches caused by corrosion, it was now impossible to achieve a watertight seal.

Corrosion had left the pipe ends pitted, uneven and breached,, making it impossible to create a watertight joint using seals or clamps

The engineering company carrying out the office refurbishment tried new rubber seals, metal seals, pipe repair clamps and pipe repair clamps with teeth. When the joints continued to leak, it appeared the only option was to replace the entire 250 metres of pipework at considerable cost and with significant delay to the office refurbishment.

Sylmasta were called in to see if there was a better solution to repair the rainwater stack rather than total replacement. It was soon established the newly installed clamps could be removed and Wrap & Seal Pipe Burst Tape used to reconnect the pipe joints together, sealing them much more effectively.

However, the rainwater stack system running close to walls, floors and ceilings made it awkward in some areas to apply Wrap & Seal with the required 300 percent stretch. Removing every clamp would also be a time-consuming task.

It was instead decided to seal each clamp with Sylmasta AB Original Epoxy Putty Stick. Enough putty was cut from the 200g stick and kneaded by hand. Whilst soft, AB Original was forced into both ends of the clamp, filling the gaps between it and the corroded pipe surface.

Pipe repair clamp holding together a corroded joint in a cast iron rainwater stack sealed with AB Original Epoxy Putty
AB Original Epoxy Putty was pushed between the newly installed clamps and the pipe surface, filling all gaps to seal the leaks

Once AB Original had hardened, it permanently sealed any leak paths. The repair was so effective that the engineering company decided to apply AB Original to all 300 joints on the rainwater stack, giving them full confidence the system would have no leaks once it was boxed back in and inaccessible.

The extended two-hour work time of AB Original allowed the engineers to thoroughly seal every joint at a reasonable pace without fear the putty would set before being properly applied.

120kg of AB Original was used for the repair. Supplying the epoxy putty in stick format eliminated the need to measure out separate components of Part A and Part B, making application quicker and more straightforward.

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

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

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Case Study: Luxury Portable Toilet Trailer Leaking Wastewater Holding Tank Repair

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

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

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

Case Study Data

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

Products Used

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

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Case Study: Reassembly & Repair of Composite Stone Water Fountain Cracked into Pieces

A composite stone water fountained cracked into multiple pieces undergoes repair and reassembly

Water fountain repair cracked – putting the pieces of a favourite garden ornament back together

A tiered composite stone water fountain in a Welsh garden undergoes a DIY repair after winter temperatures caused water left inside the upper bowl of the ornament to freeze, cracking it into multiple pieces.

Case Study Data

Site
Garden
Location
Wales
Repair Type
High-strength bonding and stone repair
Defect
Composite stone water fountain cracked into multiple pieces

Products Used

Sylmasta Rapid 5 Minute Epoxy Adhesive
Epoxy adhesive with a five-minute work time which creates high-strength, permanent bonds between all materials

Sylmasta AB Original Epoxy Putty
Hard-wearing epoxy putty used to fill gaps and replace missing sections of damaged stonework

Case Study PDF

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Case Study Details

The water fountain consisted of two tiers and was made from composite stone. When winter temperatures in Wales plummeted below -10°C, the upper bowl cracked into several pieces due to water inside it freezing.

When Spring arrived, the owner of the water fountain decided to try and repair and restore their favourite ornament. Not only did the upper bowl need to be bonded back together, but there were numerous other cracks and missing sections requiring attention.

A badly cracked bowl from a composite stone water fountain before undergoing a Sylmasta repair
Crack lines show the significant damage across the entire upper bowl of the fountain

Sylmasta advised that Rapid 5 Minute Epoxy Adhesive be used first to reassemble the fountain. Rapid 5 Minute creates high-strength, permanent bonds between many materials, including composite stone.

The five-minute cure meanwhile is long enough for parts to be carefully assembled and rearranged if necessary before the adhesive sets, at the same time as requiring minimal holding or clamping.

Rapid 5 Minute comes with the two components that make up an epoxy adhesive – resin and hardener – kept separate. The 25ml cartridge extrudes the parts in equal measures, after which they are mixed together for around 30 seconds with a spatula.

The fountain owner extruded the epoxy onto a piece of cardboard for mixing. The mixed adhesive was then applied using the spatula to one of the surfaces to be bonded, and the pieces pushed together and held in place.

A bowl from a composite stone water fountain cracked into two pieces underwent repair with Sylmasta Rapid 5 Minute Epoxy Adhesive
The two largest pieces of upper bowl after the cracks caused it to completely come apart

Any overspill of epoxy was thoroughly cleaned off the stonework. Rapid 5 Minute exposed to sunlight can yellow with age, which would have looked unsightly against the pale coloured fountain.

After five minutes, the stonework no longer needed to be held together as Rapid 5 Minute had begun to set. The fountain was left undisturbed for a further 30 minutes, allowing the epoxy adhesive to reach maximum properties.

Once the upper bowl had been reassembled, any remaining cracks and missing sections were filled in using Sylmasta AB Original Epoxy Putty. AB Original is a hard wearing, waterproof, ceramic-filled putty which bonds to all materials.

It offers a two-hour work time, enabling the putty to be mixed, moulded into shape and applied without any worry about premature curing. It is suitable for use in interior or exterior settings and achieves a full cure in 24 hours.

Cracks in a stone water fountain are barely visible after repair using Sylmasta AB Epoxy Putty
Cracks and missing chunks were filled with AB Original, which can just about be identified as the off-white colour down the centre of the stonework

The putty was kneaded by hand until it turned a uniform colour. It was then shaped and formed to replace missing areas of stonework and pushed into cracks. For shallow cracks, the surface of the curing putty was wetted whilst still pliable to create a type of slurry which could be worked further in.

To help disguise larger sections of AB Original, powdered dust from the stonework was pressed into the putty. This took it from its standard off-white and towards the colour of the fountain, helping the repaired areas blend in.

Once the repair was completed, the water fountain retuned to full working order

The owner even discovered that painting yoghurt onto the fountain helped further disguise the repair by encouraging lichen and moss to grow. The distressed touch this added was in keeping with the original stone.

Once the repair and restoration had been completed, the end result was a robust and fully watertight upper bowl. The fountain could go back into use for the summer with any visitors to the garden none the wiser that just a few months earlier, it had been cracked into multiple pieces.

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: Seawater Storage Tank Floor Repair at Gas Processing Plant in Saudi Arabia

Sylmasta AB Original Epoxy Putty used to repair cracks in the floor of a seawater storage tank

Corrosion could have floored this seawater storage tank – until a repair involving Sylmasta AB Original Epoxy Putty

The floor of a seawater storage tank at a gas processing plant in Saudi Arabia undergoes repair after gaps appeared between rubber sheeting, leaving the concrete which coated the bottom of the tank unprotected and exposed.

Case Study Data

Site
Gas processing plant
Location
Saudi Arabia
Repair Type
Floor repair
Defect
Gaps between rubber sheeting leaving concrete tank floor exposed

Products Used

Sylmasta AB Original Epoxy Putty
Waterproof, hard-wearing epoxy putty with a longer work time used to permanently fill gaps and cracks

Case Study PDF

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Case Study Details

The plant collected gasses produced during the extraction of crude oil – such as propane, butane, methane and ethane – and converted them into a number of different chemicals exported worldwide for industrial and agricultural use.

Seawater was extracted from the Persian Gulf and stored in vast metal tanks for use in cooling and other processes on site. The interior of each tank was concrete coated and then lined with rubber matting for protection against corrosion.

Problems with one tank led to it being drained for inspection. This revealed sections of the rubber matting on the floor of the tank had become loosened, lifted and completely broken apart in some places, leaving the concrete lining exposed.

The rubber matting of the tank floor had become damaged, exposing the concrete coating below

There was a risk that this exposure could lead to seawater finding a way through the concrete and coming into contact with the metal frame beneath. This would put the tank in danger of serious and irreparable damaged caused by corrosion. All gaps in the rubber sheeting therefore had to be sealed before the tank could go back into service.

The engineering team carrying out the seawater tank repair decided to use Sylmasta AB Original Epoxy Putty for the application. AB Original is ceramic-filled, making it stronger and harder wearing than other epoxy putties. It is fully waterproof, adheres to wet surfaces and its high chemical and corrosion resistance mean it is often used as a sacrificial layer.

Sylmasta AB Original Epoxy Putty is pushed into cracks to repair a seawater storage tank floor
Sylmasta AB Original Epoxy Putty applied to cracks in the floor of a seawater storage tank to make a repair
Cracks in the coating of a seawater storage tank after repair with Sylmasta AB Original Epoxy Putty
AB Original was used to fill all gaps for the protection of the exposed concrete

AB Original was mixed by hand. Whilst soft enough to shape and manipulate, it was forced into the gaps and cracks between the rubber sheeting and smoothed off with water and a hand tool.

The two hour work time of AB Original allowed large amounts of putty to be mixed and applied without the threat of premature curing. Once hardened, the putty permanently filled every gap with a waterproof material, protecting the concrete lining from seawater exposure.

The repair was completed by coating fibreglass sheets with an epoxy to form a new protective surface over the damaged rubber matting

After the application of AB Original, fibreglass sheets were layered over the rubber matting and coated with an epoxy resin. This created a new reinforced floor surface over the damaged rubber, offering yet another layer between seawater and the metal frame of the tank.

The plant could then put the tank back into operation safe in the knowledge that the metalwork was now far better protected by a combination of concrete, AB Original, rubber matting and an epoxy composite repair.

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: Underwater Wall Between River & Trout Farm Crack Repair

A crack in an underwater wall between a river and a trout farm undergoes repair with Sylmasta AB Original Epoxy Putty

River repair runs smooth – a crack in an underwater wall between a river and a trout farm is permanently sealed

The Environment Agency repair an underwater wall discovered to be cracked when a system monitoring how much water was being taken from a Yorkshire river by a local trout farm began returning inaccurate readings.

Case Study Data

Site
Sluice between river and trout farm
Location
Yorkshire, United Kingdom
Repair Type
Crack repair
Defect
700mm long crack in underwater wall

Products Used

Sylmasta AB Original Epoxy Putty
Super-strength epoxy putty effective underwater used to permanently seal holes and cracks

Case Study PDF

Download


Case Study Details

Trout farms in North Yorkshire are allowed to draw a limited amount of water from local rivers and streams. Extraction is normally controlled by a sluice connecting a farm to a river, which also enables the Environment Agency to monitor water levels to ensure no more than the permitted amount is taken.

Anomalies with data from one farm alerted the Environment Agency to a potential issue, initially believed to be with the sluice or the monitoring equipment. An inspection revealed that the problem was actually a 700mm long crack in a wall next to the sluice. The crack widened into a sizable hole as it reached the riverbed.

The sluice controlling the extraction of water from the river to the trout farm

Water from the river was now escaping through the crack and into the trout farm, making readings of the flow through the sluice completely inaccurate. The wall needed to be sealed to prevent water loss and ensure that the true level of water being taken by the farm could be recorded.

Sylmasta AB Original Epoxy Putty provided the ideal solution. AB Original is a ceramic-filled, high strength epoxy putty which cures underwater. It comes with a two hour work time, meaning that significant amounts of putty could be mixed to fill the crack without the threat of premature curing.

A 700mm long crack in an underwater wall prior to undergoing repair with Sylmasta AB Original Epoxy Putty
Significant levels of water were escaping from the river through the crack in the wall, seen here both above and below the waterline

An engineer from the Environment Agency attended the site with a large quantity of AB Original. Part A and Part B were kneaded in dry conditions. Once the putty had turned a uniform white colour and whilst it still remained soft, it was pushed into the crack.

The application began above the waterline, proceeding below it and then right the way down to where the crack met the waterbed. High-strength adhesion was achieved between the putty and the wall. Once cured, AB Original formed a rock-hard material to permanently fill the crack.

Sylmasta AB Original Epoxy Putty used to repair a crack in an underwater wall located alongside a river
AB Original was pushed into crack, curing to permanently seal the gap in the wall

After the repair was completed, water levels were carefully monitored. A very small leak remained, identified as being at the crack’s widest point near the riverbed. During the initial repair, it had been impossible to tell if all underwater areas in the wall had been sealed.

Further AB Original was applied at the base of the wall on a return visit. This brought the amount of water being drawn by the farm from the river back to expected levels, indicating that the crack had been successfully repaired.

Given the challenging nature of underwater repairs, the Environment Agency were delighted to have discovered such a versatile material capable of being effective underwater. They have since begun using AB Original for other applications and projects.

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