Tag: AB Original

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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
London office block
Location
UK
Repair Type
Leaking 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

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 5 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

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 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 towards 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 fountain 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: Environment Agency Repair Crack in Underwater Wall Between River & Trout Farm

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

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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

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Case Study: Fence Spurs Suffering from Concrete Cancer Filler Repair Using Epoxy Putty

Fence spur badly damaged by concrete cancer undergoes filler repair using Sylmasta AB Original Epoxy Putty

On the fence – installing replacement trellis provides the spur for a homeowner to repair posts suffering from concrete cancer

A homeowner installing a replacement trellis fence uses Sylmasta AB Original Epoxy Putty to repair damage to the original fence posts caused by concrete cancer, rather than having to undertake the mammoth task of replacing every spur.

Case Study Data

Site
Domestic property
Location
United Kingdom
Repair Type
Concrete filler repair
Defect
Fence spurs badly damaged by concrete cancer

Products Used

Sylmasta AB Original Epoxy Putty
Hard-wearing epoxy putty which offers excellent corrosion protection and can be used as a permanent repair filler

Case Study PDF

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Case Study Details

Concrete cancer occurs where steel reinforcements inside of concrete begins to corrode. This causes the steel to expand and as a result, the surrounding concrete to fall away and disintegrate.

Having been in place for 30 years, the fence posts were already badly damaged. When disturbed during the replacement of the trellis, they shed several more large chunks of material.

Concrete cancer had caused a fence spur to disintegrate, requiring a filler repair made with Sylmasta AB Original Epoxy Putty
Concrete cancer had caused parts of the fence spur to disintegrate, leaving the inner steel exposed and susceptible to further damage

Replacing every spur would have been a mammoth task and so the homeowner instead sought a means to repair the existing posts. They needed a material which would act as a concrete filler to repair the damage whilst at the same time offering greater protection against corrosion to lessen the impact of concrete cancer in future.

Sylmasta recommended the use of Sylmasta AB Original Epoxy Putty for the application. AB Original is a hard wearing, ceramic-filled putty with high corrosion and chemical resistance. It is suitable for indoor and outdoor use and comes with a two-hour cure for complex repairs.

The longer work time was particularly important for this application. Over 10kg of epoxy putty was needed to repair every concrete spur. Large quantities of putty could be mixed in one go and applied to significant areas of damage without the threat of premature curing.

Sylmasta AB is available in three colours as standard – white, grey and black. Grey was chosen for this repair because of its resemblance to concrete. Part A and Part B were mixed in equal measures. Whilst soft, the putty was pushed into the spur, filling cracks and replacing chunks of concrete which had been destroyed.

Sylmasta AB Original Epoxy Putty used as a filler to repair damage to a concrete fence spur caused by concrete cancer
AB Original Grey was applied to repair all damage and fill the missing concrete

AB Original adhered easily to the existing concrete. Once cured, it formed a rock-hard material to permanently repair the damage caused by concrete cancer. Had the homeowner wanted the putty to blend in more with the existing spurs, then they could have pushed concrete dust into the soft Sylmasta AB before it fully hardened.

This technique is found in the Sylmasta Brick Repair Kit, containing AB Original and brick dust. It is used for the seamless repair of bricks, filling in defects caused during construction work or by processes such as lime blow.

The repair of every concrete fence spur was completed in the homeowner’s spare time over several weekends. They were very pleased with the result. AB Original successfully repaired the damage caused by concrete cancer and improved the appearance of the fence posts, without taking the considerable amount of time replacing every spur would have.

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

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

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Case Study: Repair of Leaking 350mm Effluent Pipe Running out to Sea Underneath Salt Marshes

A leaking effluent pipe under salt marshes undergoes a SylWrap repair in an eight hour window whilst the tide was out

Against the tide – the leaking effluent pipe repair beneath salt marshes that had to be completed in under eight hours

A chemical plant in the UK faced a logistically challenging repair, needing to seal a leaking 350mm effluent pipe running underneath salt marshes and out to sea with only an eight hour timeframe to work whilst the tide was out.

Case Study Data

Site
Chemical plant
Location
United Kingdom
Repair Type
No pressure leak repair
Defect
Corroded steel pipe leaking in numerous areas from a defective clamp

Products Used

Sylmasta AB Original Epoxy Putty
Super-strength, waterproof epoxy putty capable of sealing leaks underwater and in aggressive environments

SylWrap HD Pipe Repair Bandage
Composite repair wrap which sets rock hard in minutes to reinforce leak repairs and strengthen and protect pipelines

Case Study PDF

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Case Study Details

The 350mm steel pipe carried effluent from the chemical plant underneath salt marshes and out to sea. It had undergone a repair just one year earlier, which was now discovered to have failed.

When originally installed in the 1960s, the steel had been coated in cement for reinforcement. The previous repair had consisted of removing part of the cement and covering the heavily corroded and perforated section of steel pipe with a clamp.

The pipe could only be accessed when the tide left the salt marshes, via digging by hand

The line’s location under the salt marshes made any repair logistically challenging. The pipe could only be accessed when the tide went out, after pumping away seawater and then digging by hand through sludge. No heavy tools or machinery could be transported onto the marshes to help dig as it would simply sink.

When nature ran its course and the tide then came back in, the pipe was flooded again and so the process had to begin from scratch. This left only an eight hour window in which the pipe was under dry conditions and could be worked on.

350mm steel effluent pipe located underneath salt marshes prior to undergoing leak repair
Excavation revealed the pipe to be leaking from both ends of a clamp

The chemical plant appointed a specialist marine engineering contractor to formulate a repair method. First, the pipe was excavated for inspection. This revealed it to be leaking from both ends of the pipe repair clamp.

To complicate matters further, the steel had now deteriorated significantly. The wall of the pipe was so thin beneath the clamp that the contractor was concerned removing the original repair could have led to the collapse of the line.

Water was pumped out of the hole to access the pipe for the repair
A wooden framework created a safe working area around the line

The contractor consulted Sylmasta, who recommended encapsulating the clamp with a waterproof material to seal it. Further protection could then be provided with a composite wrap. All products used in the repair had to be applied and functional quickly because of the short timeframe in which the pipe was accessible.

As soon as the tide went out, the process of excavating the pipe began again. Sludge was removed from the hole and water pumped away. A temporary wooden framework was built around the pipe to create a safe working area. Sylmasta AB Original Epoxy Putty was then applied around the entire clamp for the purpose of sealing the leak areas.

The clamp in the centre of the pipe was to be encapsulated with Sylmasta AB Original
Sylmasta AB Original Epoxy Putty is applied to a leaking effluent pipe to seal and repair the line
AB Original was applied around the clamp, creating a watertight seal

AB Original is a waterproof, super-strength epoxy putty with a two hour work time. Once cured, it would easily withstand the harsh environment of the salt marshes. The putty was mixed by hand and pushed onto the clamp, filling all holes and cracks through which effluent had previously escaped.

Two inspection hatches were then cut into the steel pipe either side of where the putty had been applied, so the inside of the line could be accessed. Reaching through these hatches, the contractors were able to coat the interior of the pipe with a liquid metal epoxy coating.

Inspection hatches were cut into the pipe, through which an epoxy coating could be applied to re-line the weakened interior
This left the pipe with two sealed inspection hatches and the entire clamp encapsulated with AB Original

Liquid metal cured inside the pipe to provide a new metallic lining, increasing the sealing security of the repair and restoring wall thickness. The two inspection hatches were then fitted with cover plates and firmly sealed.

A concrete coating was next reapplied over the pipe, and the entire excavated section wrapped with several layers of SylWrap HD Pipe Repair Bandage. SylWrap HD is a water-activated composite wrap which sets rock hard in minutes.

SylWrap HD Pipe Repair Bandage is applied to a 350mm effluent pipe in a complex leak repair application
The line was covered in rapid concrete and wrapped with SylWrap HD across its entire length
SylWrap HD restored integrity to the entire pipe, protecting it from the sludge and seawater which would return with the tide

Numerous bandages were smoothed and wrapped around the pipe, curing to form a reinforced protective sleeve. This restored the integrity of the line, uniting and strengthening both the weak and solid areas of the repair.

The speed and ease with which AB Original and SylWrap HD could be applied enabled the application to be completed within the eight hour window. By the time the tide returned to the salt marshes, the pipe had been successfully sealed ahead of being covered with mud and seawater again.

Following the completion of the effluent pipe repair, the contractors told Sylmasta that they were very impressed with the products and the technical assistance provided. They are intending to use AB Original again on a similarly complex application for another client in the near-future.

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

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

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Case Study: Reinforcement of Heavily Corroded Steel Pipe to Avoid Future Leak Repair

A heavily corroded pipe in Saudi Arabia undergoes repair and reinforcement using epoxy putty

Rebuild after rust – a heavily corroded steel pipe undergoes repair and reinforcement before the line was breached

An industrial site in Saudi Arabia use two stages of the Sylmasta Pipe Refurbishment System to reinforce a 2 metre long section of heavily corroded steel pipe before the line was breached and required a complex leak repair.

Case Study Data

Site
Industrial site
Location
Saudi Arabia
Repair Type
Pipeline reinforcement and protection
Defect
Heavy corrosion to a 600mm patch causing a serious weakening of the line

Products Used

Sylmasta AB Original Epoxy Putty
Two part epoxy putty offering excellent protection against corrosion and chemical attack used to rebuild the weakened area

SylWrap CR Pipe Repair Bandage
Composite repair wrap specially formulated to prevent corrosion and strengthen pipes in aggressive environments

Case Study PDF

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Case Study Details

The steel pipe was suffering from a 600mm patch of very heavy corrosion to its external surface. It was only a matter of time until the pipe was breached, at which point the site would have been forced to shut off the line whilst either the leak was sealed or a new section was installed.

To avoid this, it was decided to rebuild and strengthen the line before corrosion could eat all the way through the metalwork. The first stage of repair involved rebuilding the area weakened by corrosion, bringing it back up to full specification.

Heavily corroded section of pipe before undergoing repair using the Sylmasta Pipe Refurbishment System
Heavy corrosion to the pipe looked like to breach the line in the near future

Because the corrosion was impacting only a relatively small area of pipe, it was decided to use Sylmasta AB Original Epoxy Putty to fill in the damage and restore the integrity of the line. Had the damage been on a much larger scale, an epoxy paste like Industrial Metal would have been applied using a hand tool.

Sylmasta AB is a super strength putty filled with ceramic to make it harder wearing. A two hour work time means it is more suitable for warmer climates like Saudi Arabia, where the cure is often accelerated by the natural temperature.

AB Original offers excellent protection against corrosion and chemical attack. In chemically aggressive environments, it can be used as a sacrificial layer to protect pipes and metalwork.

Heavily corroded section of steel pipe having undergone repair with Sylmasta AB Original Epoxy Putty
Sylmasta AB was applied across the entire corroded section, restoring the integrity of the line

The two parts of the putty were mixed by hand in equal measures. It was then pushed down onto the pipe, where it cured to strengthen the heavily corroded areas by increasing the thickness of the pipe back towards its original specification.

Once the putty had cured, SylWrap CR Corrosion Protection Wrap was applied over the top to further protect the repair. SylWrap CR is a black-coloured composite repair bandage incorporated with highly effective corrosion inhibitors.

It has been specially formulated to protect pipes, metalwork and other structures in harsh and aggressive environments against corrosion. SylWrap CR was activated with water and then wrapped and smoothed along a 2 metre section of the pipeline.

The pipe was reinforced with SylWrap CR to complete the repair

Within minutes, it began to cure rock hard. Once set, SylWrap CR formed an impact resistant shell around the pipe to further strengthen it from future attack and remove the prospect of a breach in the line.

Completing the repair from the first kneading of Sylmasta AB to the finished application of SylWrap CR took half a day. The line remained in operation throughout, meaning there was no disruption to the site and the reinforcement cost a fraction of a future leak repair or replacement of an entire section of the line.

The site were therefore very pleased that they opted for strengthening the steel pipe before their corrosion problem could develop into a much bigger issue.

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: Oil Refinery Repair of a Leaking Underground GRP Seawater Return Pipe

An underground seawater cooling system return line undergoes repair using epoxy putty

Sealing in seawater – the rapid repair of a cooling system return pipe that had an oil refinery back online in no time

A rapid epoxy putty repair made to an underground 3000mm FRP return pipe in a seawater cooling system cut downtime at an oil refinery to just two days of reduced production, compared to several weeks for a replacement section to be fitted.

Case Study Data

Site
Oil refinery
Location
Saudi Arabia
Repair Type
No pressure leak repair
Defect
Cracks in an underground 3000mm GRP seawater cooling system return pipe

Products Used

Superfast Copper Epoxy Putty
Fast-working epoxy putty with a cure time of under five minutes used to permanently seal small holes and cracks on pipes of all diameters

Sylmasta AB Original Epoxy Putty
Epoxy putty with a longer work time, allowing more to be mixed and applied to larger cracks without the threat of premature curing

Case Study PDF

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Case Study Details

The oil refinery was one of the biggest in the Middle East, processing approximately 400,000 barrels per day. Various processes at the site relied upon the seawater cooling system, which extracted water from the Red Sea and transported to and from the refinery.

This was done via a network of underground 3000mm GRP (glass reinforced plastic) lines. Whilst such large pipes enabled vast quantities of seawater to be moved around, any failure would have a hugely detrimental impact on the efficiency of the system and cause massive water loss unless attended to as a matter of urgency.

A potential problem with the return line was first flagged when the ground above a section of buried pipe was noticed to be wet. The line was taken out of service and excavation organised, leading to a hole being dug to access the top 50 percent of the vast pipe.

The earth surrounding the pipe was thoroughly saturated, indicating a significant leak. When pressure was then turned back on, so much water escaped from several areas that the hole was instantly flooded. This water had to be pumped out to regain access to the line.

So much water escaped the line when pressure was restored that the hole dug to access the pipe became heavily flooded

Clearly, the pipe could not go back into service leaking so much water until it had been sealed. This was problematic for the refinery, who needed the line in operation for oil to be produced at full capacity. For this reason, replacement of the damaged section was not considered an option as it would have left the line out of action for up to three weeks.

With a rapid repair required, it was decided to use two epoxy putties to seal the seawater cooling system return pipe. For the smaller cracks on the line, Superfast Copper Epoxy Putty Stick was chosen. Although designed for copper pipe repair, it adheres to all materials and comes with a fast work time.

Epoxy putty applied to repair a seawater cooling system return line at an oil refinery in Saudi Arabia
Superfast Copper applied to seal the smaller cracks in the pipe

Superfast Copper is supplied in a 114g stick containing pre-measured resin and hardener. The required amount of putty was cut from the stick, kneaded by hand, and then pushed into the cracks on the GRP line whilst soft.

The heat of Saudi Arabia accelerated the five minute cure time of Superfast Copper so that within a couple of minutes, the putty began to set to a material as hard as steel, permanently fillin the cracks and starting to seal the line.

Sylmasta AB Original was used for the larger cracks because of its extended cure time

For the bigger cracks, a putty with a longer work time was needed so that greater quantities could be mixed and then applied over larger areas without the threat of premature curing. Sylmasta AB Original Epoxy Putty was used for both its two-hour cure and its availability in bulk sizes far beyond the 114g per stick offered by Superfast Copper.

Both Sylmasta AB and Superfast Copper achieved maximum properties after 24 hours. Applying the epoxy putties to all leak areas took less than four hours. A day later and the system was turned back on.

Completed repair of a leaking 3000mm FRP seawater cooling system return pipe using epoxy putty at an oil refinery in Saudi Arabia
The line was successfully sealed using epoxy putty

Once it had been established that no water was now leaking from the pipe, the line was reburied. Whilst the repair was carried out, the refinery had to operate below full capacity for only two days with all the required materials costing under £100 – a far cry from the disruption and expense which would have come with replacing the damaged pipe.

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: Protection of Wooden Entrance Gates at an Estate in Scotland Against Rotting

An entrance gate at an estate in Scotland where wood slats were protected from rot using Sylmasta AB Original Epoxy Putty

Stopping the rot – the ingenious solution an estate in Scotland found for the protection of wood slats on an entrance gate

When upgrades to an entrance gate at an estate in Scotland left an area where rainwater could pool and potentially rot wooden slats, protection was provided for the wood through a clever piece of engineering involving epoxy putty.

Case Study Data

Site
Country estate
Location
Scotland
Repair Type
Rot protection
Defect
Wooden slats on an entrance gate with the potential to be damaged by static water

Products Used

Sylmasta AB Original Epoxy Putty
Versatile epoxy putty with a longer work time which cures to create an ultra-smooth, waterproof material

Case Study PDF

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Case Study Details

The estate was located in beautiful open countryside. When Storm Arwen brought wind gusts in excess of 90mph to Scotland in November 2021, the wooden gates were an easy victim to the violent weather and subsequently became damaged.

In response, the estate decided that more robust gates would need to be installed to withstand future storms. A heavy steel frame was constructed for each gate with wooden slats attached to the frame via stainless steel self-tapping screws, providing a much stronger structure.

A new, robust steel frame constructed for the gates

One problem was identified during the construction of the new gates – the potential for rainwater to gather in a groove at the base of the frame. Static water left here would have no means of escape other than evaporation. Where this water came into contact with the wooden slats, it would eventually lead to rotting of the bottom of the slats.

To overcome this, the estate had the ingenious idea of creating a bevelled edge using a waterproof epoxy putty between the base and the frame behind it. Water would be diverted onto the ground instead of pooling at the bottom of the frame.

Sylmasta AB Original Epoxy Putty was chosen for the application because of its waterproof qualities and two-hour work time, enabling the putty to be shaped and formed without the threat of premature curing.

Sylmasta AB Original Epoxy Putty used as a means of protection against rot for wood slats on an entrance gate at a Scottish estate
AB Original formed into a bevelled edge to prevent water pooling at the bottom of the frame
Epoxy putty used to create a bevelled edge, diverting rainwater away from wood slats as a means of rot protection
Putty was applied along the entire length of the base of the frame

AB Original was mixed by hand. The putty was pushed onto the frame, easily adhering to the steel before being moulded into the required bevel. The bottom of each slat had been similarly bevelled, leaving a 5mm gap separating the wood and the putty.

Once set, AB Original provided an ultra-smooth run off. Rainwater would now drip down this run off, through the gap between putty and slats and onto the driveway below.

The bevel created with putty hidden behind the bottom of each slat
The gates were painted a uniform colour before being installed

The steel frame, wooden slats and epoxy putty were then coated in a protective paint. The paint was a beige colour, disguising the steel frame and the epoxy putty to make the entire structure appear uniformly made of wood.

Since being installed, the new gates have proven to be far more robust against the extreme Scottish weather. The application constituted a fine piece of engineering involving some out-of-the-box thinking which should last a very long time.

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