Tag: Pipe Repair Contractor Case

Case Study Data

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Site
Underground Water Main
Location
United Kingdom
Repair Type
Live leak pipe repair
Defect
Split 400mm carbon steel water main

Products Used

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Wrap & Seal Pipe Burst Tape
Multiple Wrap & Seal Pipe Burst Tapes were used to provide a pressure resistant repair to the live leak

SylWrap HD Pipe Repair Bandage
SylWrap HD was overwrapped to offer an impact resistant layer over the Wrap & Seal

SylWrap Universal Pipe Repair Kit
All the products used in the repair are available as part of the SylWrap Universal Pipe Repair Kit for fixing live leaks

SylWrap Pipe Repair Contractor Case
A Contractor Case containing enough products to make up to six live leak pipe repairs was recommended to the contractor for conveniently fixing future bursts and leaks

Case Study PDF

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Case Study Review

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The large split across the diameter of the 400mm underground carbon steel water main had been considered unrepairable for 15 years for several reasons. The normal method for fixing a pipe on the underground water network would be to use a hefty pipe repair clamp, but that was not possible due to the severely confined space the main was located in.

Only a single contractor could access the water main at any one time and there was no room for any heavy equipment, including a clamp. This also made replacement impossible without digging up the area surrounding the water main.

The importance of the water main to the network meant that shutting off flow to carry out work was impractical. The only solution therefore was to find a way to carry out a live leak repair in a restricted space which could be effective even when water pressure could not be turned off – something which had proven elusive until Sylmasta were consulted.

Because of the complexity of the repair and the lack of space in which the contractor attempting to fix the burst water main had to work, Sylmasta recommended the use of multiple Wrap & Seal Pipe Burst Tape and SylWrap HD Pipe Repair Bandage.

It was decided to double wrap 400mm from the flange up the tapered pipe. Double wrapping compensated for the fact that the waterproof repair tape could not be stretched by its full 300%, which could have resulted in less effective fusion.

Applying more than the required number of tapes increased the pressure resistance of the repair. These additional rolls of Wrap & Seal bond to each other in the same way that a single tape fuses to form a solid rubber band. This repair method sealed the leak on the water main.

The Wrap & Seal was then overwrapped using several SylWrap HD 416 Pipe Repair Bandages. On a pipe 400mm in diameter, Sylmasta would normally have advised the use of an 866 Bandage but at 200mm wide by 20m long, there would have been no room to apply such a large wrap to the pipe.

Multiple 416 Bandages were used to cover the same repair area as an 866 Bandage, providing an impact resistant, protective layer to the Wrap & Seal, turning the repair permanent. Once cured, it was evident that the job had worked. Sylmasta had done in an hour what nobody else had managed in a decade-and-a-half by finding a method to repair the burst water main.

Wrap & Seal and SylWrap HD both have WRAS approval, meaning that they are safe to use on drinking water. With the water main in question connected to the public supply network, any repair materials had to meet the stringent criteria set out by WRAS so as not to pose a threat by contaminating water which could be consumed by humans.

The contractor carrying out the repair was delighted that after such a long period of time, they had finally been able to offer a solution. They said afterwards: “The repair was a complete success, as we knew it would be. The information that Sylmasta provided greatly supported the project and more importantly, future projects.”

Sylmasta have since recommended that the contractor take stock of the SylWrap Pipe Repair Contractor Case. The Case contains enough products to enable a user to carry out up to six live leak pipe repairs, allowing the contractor to fix burst and leaking pipes in under 30 minutes as soon as problems are reported.

They will never have to wait 15 years to repair a leak again.

Case Study Data

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Site
Wastewater treatment works
Location
Sussex, UK
Repair Type
Live leak pipe repair
Defect
Highly pressurised leak on a 450mm steel contaminated water pipe

Products Used

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Wrap & Seal Pipe Burst Tape
Multiple Wrap & Seal Pipe Burst Tapes were used to increase the pressure resistance of the repair

SylWrap HD Pipe Repair Bandage
SylWrap HD was wrapped and smoothed around the pipe to provide a protective layer over the initial repair

SylWrap Universal Pipe Repair Kit
Both Wrap & Seal and SylWrap HD are available as part of the Universal Pipe Repair Kit

SylWrap Pipe Repair Contractor Case
The site was recommended to stock a Contractor Case to enable instant response to future leaks and bursts

Case Study PDF

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Case Study Review

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The contractors working at the wastewater treatment works in the United Kingdom mistakenly believed the pipe in question had been decommissioned and was due for removal.

In actual fact, it was one of the most important live pipes on site, linked to all the waste treatment ponds. As a result, there was no feasible way to stop the flow once the pipe had been breached.

From the moment the pipe was damaged, the severity of the cuts inflicted to such a highly pressurised pipe resulted in a significant amount of contaminated water escaping.

A rapid, live leak repair to the wastewater pipe was therefore required to prevent a catastrophic situation from occurring.

The contractor contacted Sylmasta for urgent assistance. Luckily, the site was located less than one hour from Sylmasta HQ, so our technical team were able to rush all the products needed and offer assistance throughout the repair.

Several Wrap & Seal Pipe Burst Tape were first applied to the pipe. Wrap & Seal is a waterproof self-amalgamating repair rape which fuses to form a solid rubber band over the hole or crack, sealing the leak.

The 450mm diameter of the pipe combined with the high pressure meant that multiple tapes were needed to hold the leak.

This initial repair was then overwrapped using a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite repair wrap with a water-activated resin.

It was wrapped and smoothed around the pipe, setting rock hard in 30 minutes to provide an impact resistant layer over the Wrap & Seal to protect the repair from further damage.

Within an hour of Sylmasta being on site, the contaminated water pipe had been permanently repaired at a cost of less than £300 to the contractor.

This included additional SylWrap HD should there be any further mishaps or any existing pipes require strengthening or reinforcing during the construction works.

Had a live leak repair not been possible, the wastewater treatment works would have needed to shut down the entire site to isolate the damaged pipe whilst a replacement was sourced and fitted. The cost of such a procedure would have been astronomical.

The speed of the SylWrap repair also prevented a serious environmental incident from unfolding. This could have been damaging in monetary terms through the cost of a clean-up operation and possible fines, and for the reputations of both the wastewater treatment works and the contractor involved.

Understandably, the project manager was extremely happy with the speed and ease with which the contaminated water pipe had been repaired. They emailed Sylmasta a few days after the repair, saying: “Thank you so much, the pipe repair worked a treat.”

Sylmasta have since recommended that the wastewater treatment works takes stock of a SylWrap Pipe Repair Contractor Case. The Case contains enough equipment to carry out up to six live leak pipe repairs.

By keeping one on site, the wastewater treatment works will have everything they need to fix any future leaks as soon as a problem arises.