Tag: Liquid Metal

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Case Study: Repair & Refurbishment of Corroded 20 Metre Long Porth Pipe Bridge

The repair and refurbishment of a pipe bridge crossing the Rhonda River made using the Sylmasta Pipe Refurbishment System

Troubled bridge over water – the repair and refurbishment of a dilapidated steel pipe bridge crossing the Rhonda River

Sylmasta and Arch Services repair and refurbish a dilapidated 20-metre long pipe bridge crossing the Rhonda River in Porth, South Wales, helping to save Dwr Cymru Welsh Water from an expensive replacement of the heavily corroded structure.

Case Study Data

Site
Pipe bridge
Location
Porth, South Wales
Repair Type
300mm steel pipe bridge repair
Defect
Significant cracking and weakening of line caused by corrosion

Products Used

Liquid Metal Epoxy Coating
Brush applied to coat pipes and structures with an ultra-smooth, hard wearing, metallic surface

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

Case Study

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Case Study Details

Sylmasta were contacted by Dwr Cymru Welsh Water for advice on repairing and extending the lifespan of a dilapidated pipe bridge crossing the Rhonda River in Porth, South Wales. The bridge was gravity fed and made up of a 300mm diameter, 20-metre long steel pipe rested inside an angle-iron structure for support and protection.

For such a complex project, it was recommended that the four-stage Sylmasta Pipe Refurbishment System be used as a starting point. A final decision on the repair elements required would be decided once the pipe had been fully inspected.

Dwr Cymru official contractors appointed Arch Services of Porth to carry out the work, and it was agreed that Sylmasta would keep in close communication throughout the project to deal with any questions that might arise.

A heavily corroded pipe bridge prior to undergoing repair by Sylmasta
The steel pipe was covered in corrosion, which had eaten through in places

On inspection, the pipe was discovered to be totally covered in corrosion. This had eaten completely through the steel in several places along the top of the pipe, leaving large holes in the brittle surface.

As these holes were too large or delicate to be repaired with epoxy putty, Arch decided to use fibreglass patches layered over the cracked sections of pipe to seal the leaks. The entire pipe was then coated with Liquid Metal Epoxy Coating.

Liquid Metal is a metal-filled, brushable epoxy. After being coated onto the pipe, it cured to form a smooth, metallic, hard-wearing surface. Several layers of Liquid Metal were used to create an impermeable skin around the original pipe, preventing any further corrosion to the steel and ensuring fluids could no longer escape.

Liquid Metal Epoxy Coating applied to pipe bridge in South Wales to rebuild the corroded outer layer of the pipe
Liquid Metal created an ultra-smooth, hard-wearing metallic surface around the pipe

The 90-minute gel time of Liquid Metal allowed significant amounts of epoxy to be mixed without the threat of premature curing. Arch Services used a roller to apply each coating to a 1mm – 2mm thickness, also painting with Liquid Metal the corroded steel hoops and beams which held the pipe in place.

To further reinforce the pipe and reinstate its integral strength, it was wrapped with four layers of SylWrap CR Corrosion Protection Wrap. SylWrap CR is a composite repair bandage incorporated with highly effective corrosion inhibitors.

SylWrap CR was carefully applied along the length of the pipe, further reinforcing the repair

It has been specially formulated for the prevention of corrosion and the protection and strengthening of pipes, metalwork, and other structures in harsh and aggressive environments.

SylWrap CR was applied to the pipe whilst the final coating of Liquid Metal remained tacky. The resin in SylWrap CR was activated with water and the bandage tightly wrapped and smoothed around the pipe.

SylWrap CR Corrosion Protection Wrap used to reinforce and repair a pipe bridge in Porth, South Wales
The completed repair along the 20 metre length of the pipe

Within minutes, SylWrap CR cured to form a rock-hard, impact resistant shell around the pipe. Arch Services were particularly careful in ensuring that no area of the pipe was left without SylWrap CR. This required precision application close to the steel hoops.

The final result was a very smart pipe bridge now well protected from future corrosion and reinforced against breaches by Liquid Metal and SylWrap CR. Arch Services have subsequently become Sylmasta’s approved contractor for similar projects after their excellent documentation of the process and attention to detail.

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: Liquid Metal Lays Anti Slip Flooring Surfaces at PepsiCo Plant in Chile

An anti slip flooring surface created using Liquid Metal Epoxy Coating and silicone carbide grit at an industrial plant in Chile

Getting a grip in Chile – Liquid Metal combined with silicon carbide grit lay new anti slip flooring at PepsiCo Plant

The PepsiCo production plant in Chile use Liquid Metal Epoxy Coating and silicon carbide grit as a cost effective method for installing new and replacement anti slip flooring in 12 different areas across the site.

Case Study Data

Site
PepsiCo production plant
Location
Chile
Repair Type
Creation of anti slip surfaces on plant flooring

Products Used

Liquid Metal Epoxy Coating
Epoxy coating brush applied across floors to bond silicon carbide grit for the creation of anti slip surfaces

Case Study PDF

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Case Study Details

PepsiCo needed to lay anti slip flooring in 12 different sections across their production plant in Chile, both to replace existing surfaces which had lost their effectiveness and create new safe areas.

The floor surfaces requiring treatment included the tiled floor of a warehouse, concrete corridors, a metal ramp, stainless steel ladders and staircases, and an open lift used to transport goods between floors.

Exisiting anti slip flooring at the PepsiCo industrial plant had become worn and in effective prior to being repaired using Liquid Metal and silicone carbide grit
Existing anti slip surfaces had become worn and needed replacing

Because of the large scale of the application, the maintenance team wanted to find the most cost-effective and convenient method for laying anti slip surfaces possible.

The way they decided to do this was by using an epoxy coating capable of bonding silicon carbide grit to each of the different surface materials requiring anti slip treatment.

A stainless steel floor prior to having a new anti slip flooring surface applied using an epoxy coating
Stainless steel floor with worn anti slip surface

Sylmasta recommended the use of Liquid Metal Epoxy Coating. Liquid Metal would adhere to all the surfaces throughout the plant, offering high bond strength between the floor and the silicon carbide grit.

A long gel time allows for more Liquid Metal to be mixed at once and carefully painted onto a substrate without worry of the coating curing off before application is completed.

Masking tape was used to mark out where the anti slip strips were required and the exposed surface painted with Liquid Metal. Whist the epoxy coating remained tacky, silicon carbide grit was sprinkled over the top. The masking tape was then removed.

Liquid Metal and silicone carbide grit are used to create anti slip flooring at the PepsiCo industrial plant in Chile
Completed refurbishment of the anti slip surface on the stainless steel floor using Liquid Metal and silicon carbide grit

Once the Liquid Metal had fully cured, it permanently bonded the grit with the floor to leave behind a new anti slip surface.

This method was used across all 12 areas of the plant and was successful no matter whether the surface was metal, concrete or tile. The application was completed within 24 hours of the final area being coated with Liquid Metal.

The ease and speed of the installation has since led PepsiCo to use Liquid Metal and silicon carbide grit for laying anti slip surfaces at other plants and even inside their delivery vans.

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 22 Degree Cast Iron Pipe Elbows

Reinforcement of 22 degree elbows on cast iron water mains carried out by Sylmasta

Ending a potentially explosive situation – Sylmasta provide reinforcement for pipe elbows following a blowout in a valve chamber

A blowout in a valve chamber in Grimsby, United Kingdom, alerted a water company to the fact that numerous 22 degree 450mm cast iron pipe elbows were below specification and required urgent reinforcement to prevent further incidents occurring.

Case Study Data

Site
Valve Chamber
Location
Grimsby, United Kingdom
Repair Type
Elbow joint reinforcement
Defect
Below specification 22 degree elbow joints on 450mm cast iron water mains

Products Used

Liquid Metal Epoxy Coating
Offered protection to the pipework from factors such as corrosion and created a PCC-2 compliant load transfer layer with SylWrap HD.

SylWrap HD Pipe Repair Bandage
10 layer application reinforced each elbow joint by providing an impact-resistant protective sleeve.

Case Study PDF

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Case Study Details

Numerous large diameter water mains made from cast iron were operated by the water company with most of these approximately 50 years old.

After an incident in a valve chamber in Grimsby where a 22 degree bend on a 450mm main blew apart, analysis of the cast iron showed that the original castings were below specification.

The incident was believed to have occurred when the water main pump from the reservoir to the treatment works stopped and the non-return valve closed, causing a pressure surge which peaked at 10 bar from zero.

Analysis of the cast iron pieces showed no corrosion along the crack lines. The blowout was therefore most likely caused by the low strength of the original casting which had a hardness of only 107.

To prevent similar incidents occurring again, the water company needed to carry out reinforcement of all remaining pipe elbows of the same specification.

  • Pipework in a valve chamber where Sylmasta carried out the reinforcement of 22 degree cast iron pipe elbows
Pipework in the Grimsby valve chamber

The length of the repair area was 350mm between flanges and the application needed to withstand 8 bar operating pressure with fluctuations up to the 10 bar which had caused the original blowout.

Sylmasta advised using Liquid Metal Epoxy Coating and SylWrap HD Pipe Repair Bandage to strengthen the elbow joints against future pressure surges and other factors including corrosion.

Each pipe was cleaned prior to being coated with Liquid Metal, a metal-filled brushable epoxy which sets to a smooth, metallic, hard-wearing surface over pipework.

Coating the elbow joints with Liquid Metal provided corrosion protection and improved adhesion between the pipework and the SylWrap HD Bandage, creating a PCC-2 compliant load-transfer layer.

10 layers of SylWrap HD were then applied over the Liquid Metal. SylWrap HD is a composite repair wrap with a water-activated resin which sets rock hard in minutes, providing reinforcement to pipework pressure resistant to 30bar.

  • Reinforcement of elbow joints in a valve chamber made using Liquid Metal Epoxy Coating and SylWrap HD Pipe Repair Bandage

Each elbow joint could be reinforced in two to three hours and there was no need to turn off the water supply to complete an application. Sylmasta’s repair saved the water company considerable money compared to replacing the below specification pipework and the necessary shutdown of equipment.

After the repair, the strategic water operations manager told Sylmasta: “The wrapping materials have proved central to our project in securing the structural condition of some 22 degree bends found to be in weak condition.”

“The early success of the project in Grimsby has seen it already adopted by other sites in our network, with Hartlepool also happy with it as a preventative measure and more to follow.”

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