Tag: AB Original

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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 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 section 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

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. This was problematic for the refinery, who needed the line operational 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 filling 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 its two-hour cure.

Both AB Original 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 Estate in Scotland Against Rot

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 more robust gates were needed 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, offering long enough for the putty to be carefully shaped and formed into the shape of a bevelled edge before curing off.

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

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Case Study: Filler Repair of 50mm Crack Between Toilet Waste Pipe & Bathroom Floor

Cracks left during the installation of a toilet waste pipe undergo repair using Sylmasta AB Epoxy Putty as a filler material

No falling through the cracks – Sylmasta AB Repair Epoxy Putty connects a toilet waste pipe during bathroom renovation work

A hole cut into a bathroom floor during renovation work was made too big for the toilet waste pipe it was housinmg, meaning a waterproof repair material was needed to permanently fill gaps of up to 50mm width between the pipe and the floor.

Case Study Data

Site
Bathroom
Location
United Kingdom
Repair Type
Filler repair
Defect
50mm wide crack between toilet waste pipe and bathroom floor

Products Used

Sylmasta AB Original Epoxy Putty
Waterproof, hard-wearing epoxy putty with a longer work time used to permanently fill all gaps between the pipe and the floor

Case Study PDF

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Case Study Details

Renovations at a property in the United Kingdom involved the toilet being moved to a new location within an improved bathroom. To prepare for the move, the contractors cut a hole out the floor where the toilet waste pipe was to connect with the sewer pipe.

When the toilet waste pipe was fitted in place, it was discovered that the hole which had been cut was too big. This left gapping all the way around between the base of the pipe and the floor. At its largest, the gapping extended to 50mm wide.

Large gapping between the pipe and the floor needed to be filled

The contractors wanted a straightforward method to fill the cracks so that the plumbing in of the toilet waste pipe could be completed. Sylmasta recommended the use of Sylmasta AB Original Epoxy Putty.

AB Original is a ceramic-filled, general purpose, waterproof epoxy putty which is the hardest wearing available. It comes with a two-hour work time for use in larger and more complex repairs.

It was calculated that around 1kg of AB Original would be needed to repair the toilet waste pipe. This was delivered to the property and the putty mixed by hand for around five minutes.

Epoxy putty used to full in cracks between a toilet waste pipe and a bathroom floor in a repair required during renovation work
AB Original was worked and pushed into the crack
The putty was smoothed off using water

Once the putty had turned an off-white colour to indicate successful mixing, it was pushed into the gapping between the waste pipe and the floor whilst it remained soft enough to shape and manipulate.

The longer cure time AB Original meant more of the putty could be mixed at once, shaped and carefully applied without the threat of premature curing. As AB Original was applied, it was smoothed off with a little water and a filling knife and then left to harden.

Completed epoxy putty filler repair of cracks between a toilet waste pipe and the floor
The completed repair with all gapping successfully sealed

A full cure was achieved in 24 hours, leaving the cracks permanently filled with a waterproof material sharing similar properties to the floor. The renovation of the bathroom was able to continue with virtually no disruption to timeframe.

When it came to the installation of a new bathroom floor surface further along the renovation process, AB Original would withstand being tapped, drilled, screwed, sawed, ground, filed, painted and any other treatment needed to complete the improvements.

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: Using Epoxy Putty for Cracked & Damaged Brick Repair & Restoration

Brick repair carried out using epoxy putty to damaged brickwork suffering from lime blow

Another brick in the wall – How epoxy putty can be used to seamlessly repair cracked and damaged brickwork

When lime blow left numerous bricks at a housing estate in the south of England with cracks, holes and missing chunks, a building company in the UK hit upon the idea of using epoxy putty as a brick repair material.

Case Study Data

Site
Housing estate
Location
South of England
Repair Type
Brick face repair
Defect
Chunks of brick missing due to lime blow

Products Used

Sylmasta AB Original Epoxy Putty
Epoxy putty mixed with brick dust seamlessly filled and repaired holes, cracks and areas of damage

Case Study PDF

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Case Study Details

Lime blow occurs when clay bricks contain small amounts of lime. When the bricks are fired, this lime is converted to calcium oxide, also known as quicklime or burnt lime.

When calcium oxide mixes with water, it begins to slake in a highly vigorous process. Bricks which contain quicklime are therefore at risk or suffering from an eruption at their face when they become wet, causing chunks of brick to break away.

In a country like the United Kingdom where it rains a lot, lime blow is a frequent occurrence. Fortunately, it does not impact on the structural integrity of the brick. Some people even like the weathered, old fashioned look of bricks which have exploded.

The effect of lime blow however was not appreciated when the problem began happening frequently on a fairly new housing estate in the south of England. A building company were asked to find a cost effective and straightforward method of brick restoration, involving filling in the damaged areas.

Chuck of brick missing through lime blow prior to repair using epoxy putty
Chunk of brick missing due to lime blow

After consulting Sylmasta, it was decided to use an epoxy putty. Magic Sculp Sculpting Putty was used for a trial repair, after which the company approved Sylmasta AB Original Epoxy Putty for all future brick repair applications.

The putty was mixed by hand and then pushed into the holes and cracks in the brick face, filling in areas of damage. To ensure that the putty seamlessly matched the colour of the brick rather than the standard off-white it cured to, the putty was wetted once it had been applied to the wall and whilst still soft.

Dust was then taken from the brick undergoing repair and pushed into the putty, creating a material the exact same colour as the brick being repaired. To give the putty an identical texture to the existing brickwork, it was then spittled with a wire brush.

A section of brick missing a chunk because of lime blow undergoes a seamless repair and restoration using epoxy putty
Damaged section of brick repaired using epoxy putty mixed with brick dust

AB Original has a work time of two hours, after which it cures to form a solid material. So effective was the application that it is virtually impossible to tell where the area is on each brick that has undergone repair.

Using epoxy putty for brick repair is a practice that is growing in popularity across numerous sectors involved in construction. As well as builders and specialist brick restorers, Sylmasta also supply epoxy putty to facilities management companies, cable installers, DIY enthusiasts, gardeners and many more.

Any tradesperson or individual who may be required to fix a damaged brick – be it through lime blow, accidental damage or having to drill into brickwork – can easily fix holes, cracks and missing pieces using Sylmasta AB.

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: Desalination Plant Partially Buried 3000mm FRP Discharge Return Pipe Repair

A 3 metre diamete FRP desalination plant discharge pipe underoges repair in Saudi Arabia

Pipeline in the sand – how a composite patch repair helped seal a partially buried three metre diameter FRP pipe in Saudi Arabia

Problems during the installation of a three metre diameter FRP discharge pipe at a desalination plant in Saudi Arabia had caused gaps to appear between connecting rings on the line, which had to be sealed in a repair carried out whilst the pipe remained partially buried.

Case Study Data

Site
Desalination plant
Location
Saudi Arabia
Repair Type
Leak repair
Defect
Gaps between rings in a 3000mm FRP discharge return pipe

Products Used

Sylmasta AB Original Epoxy Putty
Epoxy putty used to seal gaps between the ring and the pipe through which water was escaping from a join in the FRP pipe

E190 Brushable Epoxy
Brushable epoxy resin coated onto strips of Fibreglass Tape to create a composite patch repair to reinforce the putty

Fibreglass Tape
Fibreglass Tape soaked with E190, after which it cured to form a rock hard material reinforcing the initial repair

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

Case Study PDF

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Case Study Details

The three metre diameter FRP (fibreglass reinforced plastic) pipe was to play a crucial role at the plant, returning discharge water not turned into fresh water during the desalination process to the Red Sea.

Problems during the installation of the line meant that one section of the pipe was not connected properly. It was only when the system was fully pressurised and water began escaping that the issue was noticed.

The three metre diameter FRP pipe prior to undergoing repair

Even though flow was immediately shut off, the amount of water passing through the pipe meant that the chamber housing the problem section became flooded and had to be drained.

Once drained, a scaffold was erected around the pipe and pressure turned back on with minimal flow rate to properly identify what was causing the leak.

It was discovered that gaps had appeared at both ends of a 310mm wide ring connecting sections of the line together. These gaps had to be sealed before the line could be put into service.

  • Water excaping from a 3 metre FRP pipe in Saudi Arabia before the line underwent a Sylmasta repair
Water escaping between gaps in a join in the pipe

The system was again shut off to enable the repair of the gaps using Sylmasta AB Original Epoxy Putty. After being kneaded by hand, AB Original was pushed into the gaps between the connecting ring and the rest of the pipe and left to harden.

AB Original was chosen as its two hour working time allowed larger quantities of putty to be mixed in one go without the worry of premature curing.

This was a particularly important consideration because of the size of the pipe being repaired and the temperature on-site in Saudi Arabia. Sylmasta recommend AB Original to most clients working in hotter climates.

  • Sylmasta AB Epoxy Putty used to repair and seal gaps in a 3 metre diametre FRP pipe in Saudi Arabia
Sylmasta AB Original was pushed into the gaps to seal the line

The second stage of repair would normally involve reinforcing the AB Original with a SylWrap HD Pipe Repair Bandage to create a rock hard, impact resistant layer of protection.

However, with the bottom of the FRP pipe remaining buried, it was not possible to wrap SylWrap HD around the line in this application. Even if the line had been completely accessible, its size would have made effective wrapping extremely difficult.

Instead, Sylmasta E190 Brushable Epoxy Resin and Fibreglass Tape were used to build a composite patch repair over the ends of the connecting ring which had been earlier sealed with AB Original.

Fibreglass Tape wrapped over the pipe which had been coated with E190 Brushable Epoxy
  • Sylmasta E190 Brushable Epoxy is coated onto Fibreglass Tape to reinforce and repair a 3000mm FRP pipe in Saudi Arabia
Coating the Tape with further E190 created a composite patch repair

E190 was painted onto the pipe and strips of Fibreglass Tape of the required length cut off and placed over the epoxy. The E190 soaked through the Tape, attaching it to the pipe.

Another coating of E190 was painted over the top of the Fibreglass Tape, with the open weave of the Tape allowing significant amounts of epoxy to saturate the fabric.

The resin-soaked Fibreglass Tape now constituted a composite wrap similar to a SylWrap Bandage, the crucial difference being that it could be layered over areas requiring repair rather than wrapped.

Multiple layers of Fibreglass Tape were applied over each other and soaked with E190. The repair continued in this manner until the last layer of Fibreglass Tape was covered with a final coating of E190 and left to cure.

  • A composite patch repair made using Fibreglass and E190 Brushable to an FRP pipe in a desalination plant
The completed repair with all cracks sealed and the problematic section of line reinforced

E190 has a work time of 30 minutes and a full cure of 24 hours. The reinforcement of the pipe was completed within 36 hours, after which the line could be returned to service.

Once it had been established that the FRP pipe was no longer leaking and the repair had therefore been a success, the line was buried. It was now ready to serve the desalination plant after construction of the facility was finished.

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: Snapped Nozzle on a 1500mm Seawater Cooling Line Repair & Reinforcement

A 1500mm line in a seawater cooling system undergoes repair after it began leaking from a broken off nozzle

Keeping it cool – the repair and reinforcement of a leaking 1500mm seawater cooling system supply line

A petrochemical plant in Saudi Arabia needed an urgent repair to the 1500mm main supply line in their seawater cooling system after a nozzle snapped off, leaving a 50mm hole discharging water 5 metres vertically at a pressure of 3 bar.

Case Study Data

Site
Petrochemical plant
Location
Saudi Arabia
Repair Type
Leak repair and reinforcement
Defect
Snapped nozzle in a 1500mm seawater cooling pipe

Products Used

Sylmasta AB Original Epoxy Putty
Epoxy putty used alongside a PTFE plug to fill the 50mm hole left by the snapped nozzle

SylWrap HD Pipe Repair Bandage
Composite wrap reinforced the repair and was then applied around the diameter to strengthen the line

Case Study PDF

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Case Study Details

Seawater cooling systems allow water taken from the sea to be used for the cooling of machinery and other processes in industrial plants and factories.

The petrochemical plant were extracting from the Red Sea. A nozzle on the 1500mm diameter main line supplying the cooling system had snapped off from the flange, causing a jet of pressurised water to shoot 5 metres into the air from a 50mm hole.

An engineer fits the PTFE plug to the leaking line

When this seawater returned to ground, it saturated the surface of the pipe, causing external damage, discolouration, mould to form and a suspected weakening of the line.

Losing so much water also had a serious impact on the efficiency of the system. The plant therefore decided to call in a maintenance team to attempt to fix the problem as a matter of urgency.

The supply line was shut off whilst the repair took place. The application began by securing the hole left in the pipe by the snapped nozzle with a plug made from PTFE.

Sylmasta AB Epoxy Putty used to repair a seawater supply line by fixing a PTFE plug in place
Sylmasta AB Original was used to fix the plug in place, creating a watertight seal

To create a watertight seal around the PTFE plug and fix it in place permanently, the nozzle was then encompassed using Sylmasta AB Original Epoxy Putty.

Sylmasta AB is a smooth-setting putty capable of bonding to all materials, including wet surfaces. It has a two hour work time, allowing more of the putty to be mixed, shaped and applied without premature curing that may have otherwise been caused by the hot Saudi climate.

SylWrap HD Pipe Repair Bandage applied to a snapped nozzle in a seawater supply line repair
The plug and AB Original were encompassed with SylWrap HD

Further reinforcement of the plug and the surrounding AB Original was provided by SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets rock in hard in minutes.

Seven layers of SYL412HD were wrapped and smoothed around the nozzle, creating an impact resistant layer of protection. This completely sealed the hole with a repair pressure resistant up to 30 bar.

SylWrap HD Pipe Repair Bandage being applied to a 1500mm seawater supply line
Further SylWrap reinforced the weakened section of pipe around the plug

When the line was put back into operation, the engineers who had carried out the repair noticed during their inspection that the pipe around the nozzle had indeed weakened as suspected.

Although no major leaks were present, the surface could be seen bubbling with air and water. They therefore decided to reinforce the entire area of pipe underneath the nozzle by wrapping the 1500mm diameter with four SYL616HD Pipe Repair Bandages.

Repair and reinforcement of a 1500mm seawater supply line after a nozzle snapped off
The repair was completed in two hours, leaving the line sealed and strengthened

This provided a protective sleeve around the weakened section of the line, strengthening it against potential future breaches and thus extending the lifespan of the pipe.

Completing the repair of the nozzle and the reinforcement of the line took less than two hours, after which the seawater cooling system was able to operate at full capacity once again.

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 & Refurbishment of a 19th Century Pit Wheel at Mordiford Mill

A 19th century cast iron pit wheel in Mordiford Mill, Herefordshire undergoes repair and refburbishment with Sylmasta AB Epoxy Putty

Big wheel keeps on turning – the repair and refurbishment of a 19th century pit wheel using Sylmasta AB Epoxy Putty

When the repair and refurbishment of a 19th century pit wheel required a waterproof, corrosion resistant material to protect the cast iron wheel from water and help bond two protective steel hoops for reinforcement, Sylmasta had the ideal solution.

Case Study Data

Site
Mordiford Mill
Location
Herefordshire, United Kingdom
Repair Type
Corrosion protection, water ingress prevention & high strength bonding
Defect
Cracked & weakened 19th century cast iron pit wheel

Products Used

Sylmasta AB Original Epoxy Putty
Water resistant epoxy putty with high strength adhesion and a long work time for complex and larger applications

Case Study PDF

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Case Study Details

Mordiford Mill is a 19th century tall stone corn mill in Herefordshire. A water wheel connects to a three metre diameter cast iron pit wheel which drives iron machinery and two pairs of stones.

The Mill ceased grinding flour in 1935. Over 80 years later and the Mill’s latest owner was undertaking a long-term refurbishment project to make it turnable again. One of the most challenging aspects of this was the repair of the pit wheel.

Pit Wheel at Mordiford Mill suffering from numerous cracks and breaks before refurbishment and repair with Sylmasta AB Epoxy Putty
The pit wheel was suffering from cracks and breaks in several places

Corrosion and the passage of time had weakened the castings of the wheel. Both the inner and outer castings had been unusually thin for a pit wheel when they were originally installed in the 1800s, and two generations of previous repair attempts had been unable to suitably reinforce them.

The wheel was cracked and broken in various places. Calculations indicated sudden impacts such as a cog breaking would cause the casting to break apart again – possibly irreparably.

Sylmasta AB Epoxy Putty applied to a 19th century cast iron pit wheel in Mordiford Mill, Herefordshire
Sylmasta AB being applied to the outer casting of the wheel

Replacement was not a viable option because the cost of doing so exceeded the budget of the project. The only way to get Mordiford Mill operating again was by finding a repair and refurbishment method for the pit wheel.

It was decided to strap both the inside and the outside of the wheel with steel hoops to encompass the 19th century ironwork. This would reinforce the pit wheel, ensuring it had adequate protection from future impacts.

Repair and refurbishment of a pit wheel at Mordiford Mill
Steel reinforcement hoop applied over Sylmasta AB and held in place with clamps

These steel hoops could not be welded to the pit wheel because of the dangers associated with welding old cast iron, which tends to explode due to air pockets within the iron. No welder would guarantee a result as success of such a process is less than 50 percent.

Welding would also have left gaps between the steel hoops and the uneven, damaged casting of the wheel. Water entering these gaps would potentially collect inside them, leading to further corrosion of the original cast iron.

Once the putty had cured, the steel hoop was screwed into place

As a water-resistant material capable of high-strength bonding, Sylmasta AB Original Epoxy Putty provided the ideal solution for encompassing the cast iron to prevent water ingress at the same time as aiding the adhesion of the steel hoops to the wheel.

Prior to the application of Sylmasta AB, the casting was cleaned with a needle gun and a wire brush on an angle grinder. This removed rust, grime and dirt from the surface.

The long work time of Sylmasta AB meant that large quantities could be mixed in one go without the worry of premature curing. The putty was applied to the outside casting of the wheel first, after which large sections of the steel hoop were fitted over the putty and held in place using clamps.

Steel hoop screwed into place on the outside casting

The steel hoop was then screwed in place and the clamps removed. The entire process was repeated to the inside casting, although this was slightly more challenge because of the spokes of the pit wheel connecting with the casting.

To overcome this, the application was broken down into smaller sections between each spoke. Sylmasta AB was applied and a small section of steel hoop added, clamped and screwed, before moving onto the next section on the inner wheel.

Clamps fitted to hold a smaller section of steel hoop to the inside of the pit wheel in-between spokes

Once completed, the original pit wheel was successfully reinforced with a steel casing that would last for many years and the presence of Sylmasta AB meant that no corrosion caused by trapped water could attack the ironwork.

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