Tag: Industrial Metal

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Case Study: Dairy Delivery Truck 466 International Engine Cracked Timing Cover Repair

The repair of a crack in a 466 International engine timing cover made using Industrial Metal Epoxy Paste

The delivery truck timing cover repair which meant no crying over spilt milk for a dairy in Puerto Rico

Replacing a delivery truck’s 466 International engine timing cover after it developed a hairline crack was set to cost a milk company in Puerto Rico $1000 until Sylmasta formulated a faster, more cost-effective repair method.

Case Study Data

Repair Type
Timing cover repair
Defect
Crack in 466 International engine timing cover

Products Used

Industrial Metal Epoxy Paste
Epoxy paste used to fill the crack, permanently sealing it to prevent any further oil escaping

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Case Study Details

The delivery truck belonged to a milk company in Puerto Rico. Oil was discovered to be leaking from the timing cover of the vehicle’s 466 International engine. Once opened, a hairline crack was discovered in the casing.

A replacement cover would have cost $1000. Delivery of the part was estimated to take up to a week. The company needed the truck to be back in service as soon as possible and so they sought a faster, more cost-effective repair.

The opened timing cover during inspection
A crack developed in a 466 International Engine timing cover which then underwent repair with Industrial Metal Epoxy Paste
A hairline crack discovered in the centre of the metalwork

Sylmasta technicians were able to formulate a repair method for the timing cover, involving a degree of preparation followed by the use of Industrial Metal Epoxy Paste. Instructions were sent to the engineer, who had been asked to find a solution by the company.

Before the application of the paste began, Sylmasta recommended that the ends of the crack were drilled. This was to relieve stress concentration and prevent the crack from spreading further.

Repair instructions, showing the V-shaped grooves to be cut along the top and bottom of the crack and the overlap of epoxy paste

A coarse 3-square file was used to cut a V-shaped groove along the length of the crack, widening the gap in both the top of the metalwork and underneath. This increased the available surface area to which Industrial Metal could bond. The V-grooves were then degreased to remove contamination.

Part A and part B of Industrial Metal were mixed in the instructed ratio. A spatula was used to force the paste into the crack, completely filling both V-grooves. The paste was also overlapped by 20mm either side of the crack to ensure full adhesion.

Crack in 466 International timing cover undergoes repair using Industrial Metal Epoxy Paste
The crack seamlessly filled in and repaired once Industrial Metal had cured

Industrial Metal has a work time of 60 minutes, allowing it to be carefully applied to the crack without needing to worry about premature curing. A full cure was achieved in 24 hours, after which the paste set to form a solid metallic material which seamlessly filled and repaired the crack.

One day after the application had been completed, the delivery truck was back on the road with the timing cover no longer leaking. The company were very pleased with the technical advice offered by Sylmasta, and the speed and ease with which they had been able to complete the 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: Reinforcement of Weakened Pipe Elbow Joint on 100mm 22 bar Sulphuric Acid Line

A 100mm pipe elbow undergoes reinforcement after the sulphuric acid line it was part of was found to have degraded by 21mm thickness

Chemical romance – the repair and reinforcement of a sulphuric acid line pipe elbow found to have degraded in thickness by 21mm

A pipe elbow on a 100mm sulphuric acid line operating under 22 bar pressure which had degraded from 22mm thickness to just 1mm undergoes urgent repair and reinforcement in Saudi Arabia.

Case Study Data

Site
Petrochemical Refinery
Location
Saudi Arabia
Repair Type
Pipeline reinforcement
Defect
Weakened elbow joint on a 100mm sulphuric acid line

Products Used

Industrial Metal Epoxy Paste
Applied to the elbow joint to strengthen it via the creation of a shell resistant to corrosion and chemical attack

SylWrap HD Pipe Repair Bandage
Applied over Industrial Metal for further reinforcement by encompassing the elbow with a rock hard protective sleeve and increased hoop strength

Case Study PDF

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Case Study Details

The petrochemical refinery produces over 140 million barrels of petroleum products and 5 million tons of petrochemical products every year, including naphtha, kerosene, gasoline, diesel and fuel oil.

During a routine inspection, a 100mm sulphuric acid line operating under 22 bar pressure was found to have degraded to only 1mm thickness from 22mm on an elbow joint. This required urgent attention before the line failed.

The scale of production at the site meant that the petrochemical company were keen not to have to shut down the line to replace the weakened section, as this would severely impacted on output.

They therefore needed a flexible method of reinforcement for making an effective repair to the elbow on the sulphuric acid line which, for example, a pipe repair clamp would not have been capable of.

A pipe elbow in a line carrying sulphuric acid undergoes repair using Sylmasta Industrial Metal Epoxy Paste
The elbow joint was reinforced using Industrial Metal Epoxy Paste

The petrochemical refinery consulted an engineering company with whom Sylmasta work with in the region, and they decided to apply Industrial Metal Epoxy Paste to the elbow to strengthen it.

Industrial Metal is reinforced with corrosion-resistant metal platelets which provide excellent protection against corrosion and chemical attack, creating a tough outer shell around pipes and structures.

Industrial Metal Epoxy Paste is applied to a pipe elbow joint in Saudi Arabia to reinforce a weakened 100mm sulphuric acid line
Industrial Metal applied to the elbow using a putty knife

The epoxy paste was spread over the area requiring reinforcement using a putty knife. The 60 minute work time allowed for a large quantity of paste to be mixed and applied without the threat of premature curing, an especially important consideration given the hot climate.

If the remaining 1mm degraded further and the original line was breached, its contents would now be contained by a casing with high chemical and corrosion resistance surrounding the elbow provided by the cured Industrial Metal.

To further reinforce the elbow, SylWrap HD Pipe Repair Bandage was applied over the Industrial Metal. SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in 30 minutes.

It provided an impact resistant layer of protection over the elbow, increasing the hoop strength of the line until such time as a replacement could be conveniently carried out.

Repair completed with SylWrap HD for increased hoop strength

Whilst the reinforcement took place, the pressure was reduced to 8 bar with only a minor amount of disruption to operations at the site. 24 hours after the repair had been completed, the line was restored to its normal 22 bar pressure..

The petrochemical refinery were delighted with the ease and speed of repair made possible by Sylmasta. Regular inspections of the line showed that there had been little to no decrease in the strength of the repair over two years later.

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: Industrial Metal Repairs a Large Gouge to Refurbish a Drill Base Stand

Industrial Metal used to repair a severely damaged drill base stand

Drill and fill – the repair and refurbishment of a badly damaged second-hand drill base stand

An engineer refurbished a second-hand drill base stand at a fraction of the cost of buying new, using Industrial Metal Epoxy Paste to repair a large gouge caused by the previous owner’s misuse.

Case Study Data

Repair Type
Metal repair and refurbishment
Defect
Large gouge in a drill base stand

Products Used

Industrial Metal Epoxy Paste
Epoxy paste used to fill the significant gouge suffered by the drill base

Case Study PDF

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Case Study Review

The stand was suffering from a significant gouge where the drill had frequently been allowed to penetrate the base by the previous owner, who as a result had subsequently decided to sell the stand.

It was otherwise in good condition, meaning that if the engineer who bought the stand could refurbish it, then he would have a working second-hand drill base at a fraction of the cost of purchasing new stock.

After consulting Sylmasta, it was decided that Industrial Metal Epoxy Paste would be the most suitable material for filling in the gouge and returning the base to close to its original state.

A large crack in a drill base stand which required a repair to refurbish the stand to its original state
The large gouge in the drill base stand requiring repair

Industrial Metal is thixotropic, meaning it will not sag. It is virtually odourless, with no unpleasant smell compared to other epoxy pastes.

It is temperature resistant to 130°C and reinforced with corrosion-resistant metal platelets, giving it a smoother finish than regular epoxy repair pastes when machined.

The gouge in the stand requiring repair had penetrated right through the base. To prevent the Industrial Metal falling onto the floor as it was applied, a wooden plate was placed underneath the gouge.

Wooden plates fashioned to assist the application of Industrial Metal

Further wood was used to ensure that the necessary gaps included as part of the base’s design did not inadvertently become filled by the epoxy paste.

Before using Industrial Metal, the drill base had to undergo a degree of preparation. All traces of rust and grime were removed from the surface, which was then roughed up using abrasives.

Industrial Metal was applied as soon as the preparation stage was complete. The epoxy paste was pushed into the gouge using a hand tool, with the work time of 60 minutes allowing more of the paste to be mixed and applied without the threat of premature curing.

Industrial Metal Epoxy Paste applied to fill in a large crack in a drill base stand repair and refurbishment
Industrial Metal applied to fill the gouge
Completed repair of a drill base stand using Industrial Metal Epoxy Paste
The completed repair was sanded down to an ultra-smooth finish

A full cure was achieved in 24 hours, after which the surface of the drill stand was sanded down to provide an ultra-smooth finish which was seamless with the rest of the base. The rebuild using epoxy paste had been a complete success.

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