Tag: Superfast Steel Stick Pipe

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Case Study: Boat Owner Repairs Pinhole Leak in Rubber Hose Connected to Engine

A rubber hose connecting to a boat engine undergoes repair using a SylWrap Standard Pipe Repair Kit

Plain sailing – a rubber hose connected to a boat engine undergoes repair after developing a pinhole leak

A boat owner keeps their vessel afloat by making a repair to a pinhole leak on a difficult to access section of hardened rubber hose which played an important role in the cooling of the engine.

Case Study Data

Site
Boat
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Pinhole leak in rubber hose connected to boat engine

Products Used

Superfast Steel Epoxy Putty Stick
Fast working steel epoxy putty used to seal the pinhole leak in the hose

SylWrap HD Pipe Repair Bandage
Composite wrap applied over the sealed pinhole leak for reinforcing the repair

SylWrap Standard Pipe Repair Kit
Superfast Epoxy and SylWrap HD are supplied together in the Standard Pipe Repair Kit

Case Study PDF

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Case Study Details

The hose was connected to the engine, carrying water as part of the cooling process. Once the pinhole leak had developed, water was able to spray out at high pressure whenever the engine was in service. This was dangerous and unsustainable.

Repairing the leak was made challenging by the pinhole being located on a bend in the rubber hose. The hose itself was in a confined space below deck, surrounded by other pipes and engine components. A pipe repair clamp could not be fitted because of the constraints.

The hose was in a confined space making a repair difficult

The boat owner contacted Sylmasta seeking a versatile repair method capable of sealing the leak despite the difficulties in accessing the hose. A SylWrap Standard Pipe Repair Kit containing all the products needed to repair a pipe when pressure can be turned off was recommended for the application.

First, the pinhole was sealed using Superfast Steel Epoxy Putty. The putty was kneaded by hand and whilst soft, applied over the pinhole leak. It easily adhered to the rubber. After 5 minutes when the putty had started to harden, it was overwrapped using a SylWrap HD Pipe Repair Bandage.

SylWrap HD is a composite wrap with a water-activated resin, which sets rock hard in five minutes. As the Bandage was wrapped and smoothed around the hose, it forced the Superfast Steel as it cured further into the pinhole, completely sealing the leak. Once SylWrap HD had set, it formed an impact resistant sleeve to increase the repair’s effectiveness.

Superfast Steel Epoxy Putty used to repair a rubber hose in a boat engine system suffering with a pinhole leak
A rubber hose connecting to a boat engine wrapped with SylWrap HD Pipe Repair Bandage
Superfast Steel was used to seal the pinhole. The repair was reinforced with SylWrap HD Pipe Repair Bandage

When used together, Superfast Steel and SylWrap HD create a repair with pressure resistance up to 30 bar and temperature resistance to 200ºC. When the boat engine was started, no water was escaping from the hose. The vessel could return to the sea.

Completing the boat pipe repair took under 30 minutes and cost less than £25, including delivering of the SylWrap Kit. This represented a significant cost saving compared to quotes offered by specialist marine engineering contractors to fix or replace the hose.

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: External Surface Damage Repair to Restore Integrity of 400mm GRP Pipe

A GRP pipe suffering from external surface damage undergoes repair and strengthening with a Superfast Steel Epoxy Putty Stick

Repair damage now, avoid leak later – the oil refinery who reaped the benefits of external pipe surface restoration

When construction work revealed a 400mm GRP pipe suffering from areas of external surface damage, an oil refinery in Saudi Arabia decided to restore the integrity of the line to lessen the chances of a future breach requiring leak repair.

Case Study Data

Site
Oil refinery
Location
Saudi Arabia
Repair Type
Pipe surface profile restoration
Defect
External damage to 400mm GRP pipe

Products Used

Superfast Steel Epoxy Putty
Fast-working epoxy putty smoothed over areas of damage and weakness for restoring pipe strength and integrity

Case Study PDF

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Case Study Details

Ongoing construction work at the oil refinery resulted in the excavation of an underground section of 400mm GRP pipe. The external surface of the line was discovered to be damaged, with two areas suffering from heavy scoring.

Although the pipe was not yet leaking, the refinery were concerned that the weakening of the exterior would lead to a future breach of the line.

The damaged external surface of the GRP pipe

If this happened, they would then be faced with the inconvenient and costly exercise of again excavating the reburied line to fix the problem. Should any future leak prove to be too challenging repair, an even more costly pipe replacement might be required.

Keen to avoid that fate, the refinery decided to seek a method to repair the external damage whilst the pipe remained excavated and accessible. This would strengthen the line and restore its integrity.

Superfast Steel was pushed onto the pipe, filling imperfections in the line

Sylmasta supply several products for damage repair. For this particular application, Superfast Steel Epoxy Putty was deemed the best solution due to the relatively small areas requiring repair, and the speed and ease with which it can be worked.

Superfast Steel comes in pre-formatted 114g stick. Multiple sticks were used for the repair. Chunks of putty were cut from the stick and kneaded by hand. Once the putty had turned to a uniform colour and whilst remaining soft, it was pushed down onto the pipe and smoothed over the scored areas.

A GRP pipe in Saudi Arabia suffering from external surface damage undergoes repair with Superfast Steel Epoxy Putty Stick
The putty cured to a material hard as steel over the weakened parts of the pipe

Within 10 minutes of mixing beginning, the putty began to harden. Once fully cured, it permanently imbedded into imperfections in the line. In effect, the putty created a new waterproof layer hard as steel over the weakened parts of the GRP pipe. The entire repair took less than two hours to complete.

Had the area of damage been larger and deeper, then Industrial Metal Epoxy Paste would have been recommended. Industrial Metal is trowel applied and with a longer work time, allowing more to be mixed and spread over significant sections of weakened pipes requiring rebuild.

Superfast Steel Epoxy Putty Stick used to restore external surface profile of a GRP pipe in Saudi Arabia
The completed repair with all damage filled

The GRP line could have been further reinforced using a SylWrap HD Pipe Repair Bandage. However, the trench dug as part of the construction work was not deep enough to effectively wrap a bandage around the bottom of the pipe.

Not wanting to excavate further down, the refinery decided to rely on Superfast Steel to strengthen the line. Several years later and the underground line had still not been breached. Superfast Steel had done its job.

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: Leaking Hydrogen Line Pipe Repair at Power Station in Puerto Rico

A hydrogen line at a power station in Puerto Rico undergoes leak repair and reinforcement after it was discovered to be leaking

Helping hand with hydrogen – The leaking hydrogen pipe repair that put a power station cooling system into service

When a hydrogen line newly installed as part of upgrades to a power station cooling system in Puerto Rico was discovered to be leaking from two joints, repair and reinforcement was needed before the pipe went into full service.

Case Study Data

Site
Power station
Location
Puerto Rico
Repair Type
Leak repair and pipe reinforcement
Defect
Two leaking joints on a 600mm section of hydrogen line

Products Used

Superfast Steel Epoxy Putty Stick
Fast working epoxy putty applied around and over pipe joints where it forms a steel-like material for sealing leaks

SylWrap HD Pipe Repair Bandage
Composite repair wrap with a water activated resin which sets rock hard to encompass pipes with an impact resistant outer sleeve

SylWrap Standard Pipe Repair Kit
Superfast Steel and SylWrap HD can be purchased together as part of the Standard Pipe Repair Kit

Case Study PDF

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Case Study Details

The power plant had previously stored hydrogen used for cooling in an off-site tank. Procuring hydrogen, refilling the tank and then keeping vast amounts of gas was an expensive process.

It was also inefficient. It could take up to four days to deliver refills to the tank, sometimes causing interruptions to power output as turbines at the plant had to be shut down when hydrogen supply ran out.

To overcome this, the plant took the decision to install a new cooling system, including an on-site hydrogen generator capable of supplying gas as and when it was needed.

Pipes would carry hydrogen from the generator to the areas of the plant it was required for cooling purposes, eliminating the need for the plant to buy and then store gas away from the site.

Because gaseous hydrogen consists of such a small molecule, very small leaks are common. These tend not to be dangerous as the tiny amounts of hydrogen being released are not enough to cause a flammable mixture in the air. Problems arise only when the gas can accumulate in a confined area.

Human senses cannot detect small hydrogen leaks as the gas is colourless, odourless and tasteless. To ensure that the newly installed cooling system was in good working order before it was put into full service, the plant therefore used portable hydrogen detectors to analyse the pipes.

It was discovered that a section of the line was leaking, suspected to be from two joints between two valves around 600mm apart. Although the hydrogen leaks posed little threat, the plant decided to repair and reinforce the pipe for efficiency reasons as well as their own peace of mind.

The line was isolated and Superfast Steel Epoxy Putty Stick applied to the joints at either end of the pipe. The required amount of Superfast Steel was cut from the stick and kneaded by hand.

Whilst soft, it was pushed tightly onto the pipe around both joints. Within 10 minutes, the putty hardened to form a steel-like material to plug any gaps in the pipe through which hydrogen could be leaking.

The line was then further reinforced with a SylWrap HD Pipe Repair Bandage applied along the entire 600mm section. SylWrap HD is a composite repair wrap with a water-activated resin which sets in minutes, curing to form an impact resistant sleeve around pipes and structures.

Despite the pipe being positioned close to a wall, the maintenance team at the plant were able to wrap the pipe effectively with a 50 percent overlay.

The Bandage was smoothed with water as the application continued. Once set, it provided a rock-hard, chemically inert outer shell over the leaking joints strong enough to prevent further hydrogen molecules escaping.

24 hours after the repair and the hydrogen pipe was repressurised. With the hydrogen detector now finding no gas in the air, the application had been a success and the new cooling system could be put into full service.

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: Superfast Steel Epoxy Putty Used to Fix Rust Holes on a Classic Car

Superfast Steel Epoxy Putty used to fix rust holes in the metal frame of a steel car

How to fix rust holes on a classic car in a repair time (nearly) as quick as a lap of Silverstone

When rust holes developed on a classic car, the owner turned to Superfast Steel Epoxy Putty as a cost-effective, quick and easy way to permanently fix the problem.

Case Study Data

Repair Type
Metal filler repair
Defect
Rust holes in classic car

Products Used

Superfast Steel Epoxy Putty Stick
Metal repair putty used to permanently fill rust holes and help prevent further corrosion

Case Study PDF

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Case Study Details

The classic car had developed a rust hole. Corrosion had eaten away at a section of the inside car door where the window mechanism was anchored, causing it to fail.

As a DIY enthusiast, the car owner wanted to find a quick, cost-effective and easy method to permanently fix the rust hole. The owner required a lightweight, metal filler material which would offer resistance to water, temperature extremes and future corrosion.

Heavy corrosion had caused significant rusting to the inside door of the car

They decided to use Superfast Steel Epoxy Putty Stick for the application. Superfast Steel sets in under 10 minutes and makes permanent repairs to damage in steel, iron and other ferrous metals.

Before the repair began, the metalwork was cleaned and prepared as best as it could be. Dirt, grime, and rust were removed. Moisture repellant spray was used to drive moisture and grease out from the crack and leave a fine lubricating film to protect against corrosion.

The area was cleaned prior to repair

Once preparation was completed, the required amount of Superfast Steel Epoxy Putty was cut from the 114g stick and kneaded by hand. Whilst soft, the putty was pushed into the hole in the metalwork, where it was shaped and moulded around the screw.

Within 10 minutes, the putty had begun to harden into a material sharing the look and feel of steel. Maximum properties were reached after an hour, leaving the hole filled and the damage caused by corrosion repaired.

Superfast Steel Epoxy Putty used as a metal filler in the fix of rust holes on a classic car
Superfast Steel filled the hole. Once fully cured, it was painted red to match the car

Once cured, the putty was filed and painted red to appear uniform with the rest of the metal frame. The total cost of the rust hole repair was less than £20, including delivery of the Superfast Steel Stick.

The Superfast and Sylmasta AB ranges of epoxy putties are used frequently across various sections of the motoring industry, including classic car repairs such as this one and in Formula One.

Lightweight yet robust repair materials which are straightforward to use and effective quickly provide the sort of speedy repairs required when it comes to fixing damage on cars.

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 a Leaking 150mm Steel 90 Degree Elbow Bend at a Quarry Wash Plant

A 150mm steel pipe elbow bend leaking at a quarry wash plant undergoes repair with a SylWrap Standard Pipe Repair Kit

When clamps don’t work – the repair of a 90 degree pipe elbow bend at a quarry wash plant

When a quarry in the UK was unable to repair a leaking 150mm steel pipe in their wash plant using a clamp due to the pinhole being located on a 90 degree elbow bend, they instead turned to Sylmasta for an alternative, versatile solution.

Case Study Data

Site
Quarry wash plant
Location
Hampshire, United Kingdom
Repair Type
No pressure pipe repair
Defect
Pinhole leak in a 150mm steel pipe elbow bend

Products Used

Superfast Steel Epoxy Putty Stick
Fast working steel epoxy putty used to seal the pinhole leak in the pipe

SylWrap HD Pipe Repair Bandage
Composite wrap applied over the sealed pinhole leak for reinforcing the repair and further protecting the pipe

SylWrap Standard Pipe Repair Kit
Superfast Epoxy and SylWrap HD are supplied together in the Standard Pipe Repair Kit

Case Study PDF

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Case Study Details

The 150mm steel pipe was located in the wash plant of the quarry, passing across a lake. Wear and tear had caused a pinhole leak to appear in the line around 50mm away from a 90 degree elbow bend, leading foul water to escape into the lake below.

Normally when pipework failed on site, the quarry would fit a pipe repair clamp over the problem area. This was not possible in this case because of the location of the leak area being so close to the elbow.

Seeking a more versatile repair method capable of being effective on the bend, the quarry contacted Sylmasta. Once it was established that pressure could be easily shut off, a SylWrap Standard Pipe Repair Kit was delivered to the site.

A leaking elbow bend on a 150mm steel pipe at a quarry wash plant before undergoing repair with a SylWrap Standard Pipe Repair Kit
The steel pipe was leaking close to an elbow bend

The pipe was cleaned as best it could be before the repair began. Superfast Steel Epoxy Putty Stick was used to seal the pinhole. The required amount of putty was cut from the stick and kneaded by hand.

After around two minutes of mixing and whilst still soft, the putty was pushed into the hole in the pipe. Within 10 minutes it had hardened, forming a material as hard as steel which now filled the pinhole.

To further reinforce the repair, a SylWrap HD Pipe Repair Bandage was applied around the leaking section. SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes.

Completed repair of a 150mm steel pipe on an elbow bend
Completed repair finished with a SylWrap HD Pipe Repair Bandage

SylWrap was wrapped and smoothed around the pipe, curing to form an impact resistant sleeve. This would help protect the pipe from future breakages, a common occurrence due to the abrasive nature of operations at the quarry.

The entire application was completed in under 30 minutes by a member of the operations team at the quarry. No training was required; they simply followed the instructions provided with the Kit to make a permanent pipe elbow bend repair.

Since the repair, the quarry group have taken further stock of SylWrap Pipe Kits, knowing them to be capable of making more versatile repairs than heavy, bulky pipe repair clamps.

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 a Cracked 90-year-old 70mm Malleable Iron Water Supply Pipe

A SylWrap Pipe Repair Kit is used to seal a crack on a 90-year-old malleable iron water supply pipe

Helping towards a century – the malleable iron pipe repair that kept a 90-year-old water supply line in operation

With replacement fittings of the required size and type no longer manufactured because of the age of a 90-year-old malleable iron water supply pipe, when the pipe became cracked a repair solution was needed to avoid digging out and replacing the entire line.

Case Study Data

Site
Domestic property
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Cracked 90-year-old malleable iron water supply pipe

Products Used

Superfast Steel Epoxy Putty Stick
Fast working epoxy putty used to seal all holes in the pipe

SylWrap HD Pipe Repair Bandage
Repair area was overwrapped with a SylWrap HD Bandage for reinforcement and protection

SylWrap Standard Pipe Repair Kit
Superfast Steel and SylWrap HD were provided together in the Standard Pipe Repair Kit

Case Study PDF

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Case Study Details

The 70mm malleable iron pipe connected a property with the public supply network. When the property owner was alerted to a potential leak, excavation revealed that an awkward-shaped large crack and several smaller holes had developed, through which water was now escaping.

Because the pipe was 90 years old, replacement fittings of the correct size and type were no longer manufactured. The crack and holes therefore had to either be repaired, or the entire section would need to be dug out and replaced with a new line at considerable expense.

Sylmasta recommended a SylWrap Standard Pipe Repair Kit for the application. All products in the Standard Kit have WRAS approval, meaning they are certified as safe to use for the repair and maintenance of pipes carrying drinking water.

Pressure was turned off and the malleable iron pipe cleaned and dried as best it could be prior to the two-stage repair.

A large crack and several holes in a 70mm malleable iron water supply pipe prior to being repaired with a SylWrap Pipe Repair Kit
Holes in the pipe included a large, awkward shaped crack

First, Superfast Steel Epoxy Putty Stick was used to seal the pipe. Superfast Steel is a fast working putty in an easy-to-use stick format which makes permanent repairs to steel, iron and other ferrous metals.

For the smaller holes, the required amount of epoxy was cut from the stick and kneaded by hand. It was pushed into all visible holes in the pipe, where it hardened within five minutes to plug all leaks.

To seal the large crack, Superfast Steel was formed into a disc bigger than the area of the pipe the crack covered. This guaranteed that no part would be missed when sealing.

This disc was then stretched over the entire crack area. Once in position, the edges of the disc were pushed tightly down onto the pipe, forming a good seal with the surface.

Repair of a 90-year-old cracked malleable iron water supply pipe made using a SylWrap Standard Pipe Repair Kit
The completed repair prior to the pipe being re-burried

Once the putty had become firmer but not completely cured, the entire repaired section was tightly wrapped with a SylWrap HD Pipe Repair Bandage to compress the putty into any remaining gaps.

SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes, providing an impact resistant protective layer around the pipe.

Once the application was completed, pressure was turned back on. The pipe had ceased leaking and could therefore be re-buried. The repair had cost less than £25 to complete, including delivery of the SylWrap Kit and the property owner described it as going “fantastically well.”

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

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

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Case Study: ‘Impossible’ Repair of a 900mm Water Main Flange Leak in an Underground Chamber

A 900mm steel water main leaking in an undeground chamber undergoes repair using Superfast Steel Epoxy Putty

Mission impossible – the repair of a leaking 900mm steel water main flooding an underground chamber in Malaysia

Water escaping from cracks caused by corrosion around a flange on a 900mm steel water main had flooded an underground chamber, leaving a pipe repair to be considered impossible until a determined Malaysia engineering team spent two days on the scene

Case Study Data

Site
Underground water main
Location
Malaysia
Repair Type
Leak repair
Defect
Cracks caused by corrosion on a 900mm steel pipe flange

Products Used

Superfast Steel Epoxy Putty Stick
Fast working epoxy putty for sealing holes and cracks in pipework, filling gaps between joints and high-strength adhesion

Case Study PDF

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Case Study Details

Heavy corrosion had caused numerous cracks to appear on the 900mm steel pipe around a stub flange. The leak point was located in an underground chamber, which had subsequently filled with water escaping the pipe at high pressure.

Accessing the pipe was difficult even before the flooding of the chamber. A repair clamp could not be fitted because of the flange, and the main was so close to the ground that there was insufficient room for pipe repair tapes or bandages to be wrapped around the pipe.

There was no visible means of isolating the main either, meaning that pressure could not be turned off or reduced. Replacing the damaged section would have involved excavating the chamber and shutting down the main for a prolonged period, something not considered an option by the water company operating the system.

The flooded chamber prior to water being pumped out
As water was removed from the chamber, the scale of the leaks on the main became evident

As a result, repairing the main had been considered impossible. It had been allowed to leak unabated since the problem was discovered, save for a few cursory checks and the pumping out of water when flood levels became dangerously high.

That was until an engineering team arrived on site, accompanied by a technician from Sylmasta, who were determined to formulate either a method for repairing the main or a means of substantially reducing the amount of water being lost.

Before any repair could be attempted, water had to be pumped out of the chamber. Once this had been done, an engineer accessed the pipe and hammered a series of plastic plugs into the larger cracks along the flange.

Water escaping a 900mm underground water main in Malaysia prior to undergoing a Sylmasta repair
An engineer hammered plastic plugs into the significant cracks, reducing the amount of water being lost so that an inspection could take place

The plugs reduced the amount of water escaping from the pipe enough for a proper inspection to take place. The engineer in the chamber then spotted a stopcock a little further along the pipe.

They were able to reach the stopcock, preventing flow into the leak area. With pressure now turned off, it meant that Superfast Steel Epoxy Putty could be used to attempt to permanently seal the cracks in the main.

Numerous Superfast Steel Epoxy Sticks were used for the repair

Superfast Steel has a fast, 10 minute work time and comes in an easy-to-use 114g stick format. A large number of sticks had to be used in the application because of the size of the repair.

Each stick was kneaded by hand. Whilst soft, the putty was pushed into visible holes in the pipe where it hardened, filling the crack. Superfast Steel was also used to seal the flange and as a means of permanently fixing the rubber plugs in place.

An engineer applies Superfast Steel Epoxy Putty Stick to a cracked 900mm steel water main during a repair in Malaysia
Superfast Steel plugged the visible cracks in the pipe and permanently fixed the rubber plugs in place

Because of the diameter of the pipe and the size of the damage area, it took over an hour to apply the necessary Superfast Steel. With flow isolated, it was difficult to tell whether all the leaks in the pipe had been found and sealed.

Even after pressure was restored, it was still hard to identify remaining problem areas. As a result, the maintenance team decided to return 24 hours later to check the effectiveness of the repair.

With the main continuing to leak the following day, further Superfast Steel was used to plug remaining cracks and a valve fitted

Unfortunately, this inspection revealed that the main was again leaking, although nowhere near as seriously as before. There were several small leak areas which had not been suitably arrested the previous day, alongside a larger jet of water escaping from a gap between the flange and the pipe.

Further Superfast Steel was used to seal the smaller leak areas. The epoxy putty was worked into a sausage shape and pushed into the remaining cracks in the pipe.

Superfast Steel Epoxy Putty Stick used to plug holes in a cracked 900mm water main repair
With most of the leaks arrested, the valve funnelled any water still attempting to escape into one area

For the larger leak, the engineering team manager hit upon the idea of fixing a valve in place using more Superfast Steel. The water trying to escape the main would be channelled towards this valve. A tap would be fitted and closed, sealing the pipe shut.

A tap was then fitted, shutting off the valve
Successful repair of a leaking 900mm water main in an underground chamber carried out by Sylmasta
The successful repair

Tapping off the main ended up being a success, much to the delight of the water company and the engineering team. Normally, Sylmasta would recommended reinforcing the epoxy putty with SylWrap HD Pipe Repair Bandage, but that was just not possible in this application.

It may have taken two days, but the ‘impossible’ water main repair had been completed, reducing the levels of water being lost and preventing any further flooding of the chamber.

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: Magic Corner Kitchen Unit Repair Saves a Client Over £200 in Replacement Costs

A magic corner kitchen unit undergoes repair using Superfast Steel Epoxy Putty after a pin snapped off

Magic repair of a magic corner – Superfast Steel prevents a broken kitchen unit needing a £290 replacement

When a magic corner unit in a Sylmasta client’s kitchen collapsed, they were left facing the prospect of paying £290 for a replacement – until it was decided to attempt a repair using the high-strength bonding properties of Superfast Steel Epoxy Putty.

Case Study Data

Repair Type
High-strength bonding
Defect
Collapsed magic corner kitchen unit

Products Used

Superfast Steel Epoxy Putty Stick
Epoxy putty used for super-strength adhesion between broken pin and unit which had previously been welded in place

Case Study PDF

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Case Study Details

A magic corner kitchen unit makes use of dead space in corner cupboards which are otherwise hard to access. A slide out mechanism attached to a cabinet door allows items to be easily stored and retrieved from blind corners.

There are several reasons why magic corners can break. Wear and tear is one. Frequent opening and closing of the cupboard and stress on the sliding mechanism will take its toll after many years.

Magic corners will often be overloaded in excess of the weight that the manufacturer recommends they carry. Because they are attached to a cupboard door rather than being a part of the actual unit, overloading can lead to units collapsing and subsequent damage to the door itself.

In this case, the magic corner unit was very old. The client also admitted that they may have overloaded it. Eventually, this led to the magic corner collapsing, detaching it from the kitchen cupboard door.

Upon inspecting the broken corner, the problem was discovered to have been caused by a vital pin on which the mechanism pivoted, breaking away from the frame and causing the detachment.

  • A broken magic corner kitchen unit before undergoing repair using Superfast Steel Epoxy Putty Stick
Photo on the left shows another pin welded to the magic corner for an idea of how it was attached. On the right, the broken section of the unit after the damaged pin snapped off

A replacement magic corner would have cost £290 and required some advanced DIY skills to fit. After consulting Sylmasta to see if a repair was possible, it was decided to attempt to fix the magic corner kitchen unit using Superfast Steel Epoxy Putty.

Superfast Steel is used for filling holes and cracks, restoring surface profile, fabricating new parts and for high-strength bonding between materials. For this particular application, it was Superfast Steel’s adhesive properties that were required.

To use Superfast Steel, the required amount is cut from the 114g stick and kneaded by hand. This causes a chemical reaction to take place between the resin and hardener contained within the stick, and within 10 minute the soft material will have cured into one as hard as steel.

The damaged pin was around 100mm in length and had been welded to the magic corner prior to the collapse. The pin was to be reattached to the unit using Superfast Steel, which would provide a bond as strong as the previous welding.

  • A broken pin on a magic corner kitchen unit is repaired using Superfast Steel Epoxy Putty Stick
The pin prior to being reattached to the magic corner using Superfast Steel

Completing the reattachment took less than 30 minutes. Within an hour, the putty had fully hardened. The magic corner could be filled with kitchen items again – although the client was careful not to overload it this time.

One Superfast Steel Stick was all that was required for the application . At an outlay of only £10.08 plus postage, the repair represented a huge saving compared to the cost of replacing the magic corner.

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 and Reconnection of a Ruptured 20bar Cast Iron Water Supply Pipe

A ruptured cast iron water supply pipe is removed, repaired and then reconnected to the water network in a Sylmasta pipe repair

The Only Way is Sylmasta – A complex pipe repair in Essex reconnects a block of flats to their water supply

After removing a damaged section of water supply pipe connected to a block of flats, a contractor discovered new fittings were not available – they now needed a repair for the initial rupture which could hold up to 20bar and to reconnect the pipe with the rest of the line.

Case Study Data

Site
Block of Flats
Location
Essex, United Kingdom
Repair Type
No pressure repair and pipeline reconnection
Defect
Ruptured 70mm cast iron water supply pipe

Products Used

SylWrap Pipe Repair Contractor Case
The complexity of the application required the multiple pipe repair products available in a Contractor Case

Superfast Steel Epoxy Putty Stick
Epoxy putty sealed the holes in the pipe which caused the rupture

Wrap & Seal Pipe Burst Tape
Increased pressure resistance of repair and provided watertight seal for reconnecting the damaged section to the supply line

SylWrap HD Pipe Repair Bandage
Provided an impact resistant protective layer over the damaged section and the entire length of pipe once reconnected

Case Study PDF

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Case Study Review

Corrosion had caused the 100-year-old 70mm cast iron water supply pipe to rupture, resulting in a high-pressure leak that was losing a considerable amount of water.

Upon inspecting the pipe, the contractor in charge decided that it was too badly damaged to be repaired and so they removed the effected section with the intention of carrying out a replacement.

It was only once the pipe had been cut away that the contractor discovered replacement fittings of the size and type required were no longer manufactured because of the age of the pipe.

Whilst the damaged section remained unrepaired and disconnected from the supply line, the block of flats was disconnected from the public network and therefore had no water.

  • The leaking pipe was losing considerable amounts of water
  • Contractors cut away the damaged section from the supply line

The contractor needed to find a rapid repair method for the rupture capable of withstanding the 20bar pressure which the pipe was normally under and a way to reattach the removed section to the supply line so that service could be restored to the flats.

The seriousness of the problem was such that the contractor drove from Essex to Sylmasta HQ in West Sussex first thing in the morning to collect a SylWrap Pipe Repair Contractor Case. Sylmasta recommended the use of the Case rather than a Universal Pipe Repair Kit because of the complexity of the repair.

A 100-year-old cast iron water supply pipe which was badly ruptured prior to having a Sylmasta repair carried out
Corrosion had led to the cast iron pipe rupturing

A Sylmasta Contractor Case contains enough products for up to six live leak pipe repairs but on this occasion, the additional Wrap & Seal Pipe Burst Tape and SylWrap HD Pipe Repair Bandage were to be used for reconnecting the pipe after the initial repair had been made to the ruptured section. It was in effect two repairs in one.

Superfast Steel Epoxy Putty Stick was used to seal the rupture in the cast iron pipe. The putty was kneaded by hand and pushed into the cracks where it hardened, plugging the leaks. Because of the high pressure that the water supply pipe comes under, it was decided to reinforce the putty with an overwrapping of Wrap & Seal Pipe Burst Tape.

Superfast Steel Epoxy Putty used to seal a ruptured cast iron water supply pipe as part of a Sylmasta repair
Superfast Steel sealed the rupture in the pipe
Wrap & Seal Pipe Burst Tape provides a high-pressure repair to a ruptured cast iron water supply pipe
The epoxy putty was reinforced with Wrap & Seal, increasing pressure resistance
A SylWrap HD Pipe Repair Bandage provides a protective layer to the repair of a leaking cast iron water supply pipe
Initial repair is overwrapped with a SylWrap HD Bandage

Wrap & Seal is made from self-fusing silicone and stretches by three times its length, fusing into a solid rubber band. Layers of Tape can be built up to provide a repair which is pressure resistant up to 30bar.

Using Wrap & Seal and Superfast Steel in conjunction increased the pressure resistance of the application in a similar manner. The initial damage repair was completed with a SylWrap HD Pipe Repair Bandage, providing a rock-hard, impact-resistant protective layer to the Superfast Steel and the Wrap & Seal.

Wrap & Seal Pipe Burst Tape used to reconnect a section of cast iron water supply pipe to the rest of the line following removal
Wrap & Seal applied at the joints to reconnect the cut-out section to the supply line
SylWrap Pipe Repair Bandage used to reconnect a section of cast iron water supply pipe with the rest of the line
Additional SylWrap HD used to encompass the entire pipe

For stage two of the repair, further Wrap & Seal was used to reconnect the damaged section of pipe to the supply line. The Tape provided a high-strength, watertight seal between the joints. To further protect the connections between joints and the initial damage repair, another SylWrap HD Bandage was applied.

This final Bandage encompassed the entire pipe; the section which had been removed and the rest of the water supply line which had remained in place either side. Once cured, the bandage was painted black to make it a uniform colour with the rest of the pipe.

The completed repair and reconnection of a ruptured cast iron water supply pipe using a Sylmasta Pipe Repair Contractor Case
SylWrap HD is painted black to appear uniform with the pipe and complete the repair

The entire repair was completed in under two hours, after which water supply to the block of flats was restored. The contractor estimated that replacing the damaged section with specially fabricated new parts would have cost £12,000. Thanks to Sylmasta, the repair was completed for under £300.

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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: Leaking Cast Iron Wastewater Pipe Repair at a London Hotel

Pipe repair carried out to a wastewater pipe made of cast iron in a central London hotel

Getting a room – Sylmasta solve the problem of a leaking cast iron wastewater pipe in an iconic London hotel

An iconic central London hotel faced having to shut one of its most prestigious rooms after a cast iron wastewater pipe located in the ceiling above developed a large circular crack which initially proved impossible to repair.

Case Study Data

Site
Hotel
Location
London, United Kingdom
Repair Type
No pressure pipe repair
Defect
50 x 25mm hole in a cast iron wastewater pipe

Products Used

Superfast Steel Epoxy Putty Stick
Superfast Steel was formed into a disc shape and used to seal the crack

SylWrap HD Pipe Repair Bandage
The Superfast Steel was overwrapped with a SylWrap HD Bandage, reinforcing the initial seal

SylWrap Standard Pipe Repair Kit
Superfast Steel and SylWrap HD can be purchased together as part of the Standard Pipe Repair Kit

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Several attempts had been made to repair the leaking cast iron wastewater pipe, but its location within the hotel made it particularly troublesome. The pipe was crammed into a gap between the floor of one level and the ceiling of another, leaving virtually no room to work.

The hotel’s initial repair attempt had seen them try and wrap the pipe with a repair bandage. Although the crack was successfully covered, it was not successfully sealed and so began leaking again once pressure was turned back on.

A cracked cast iron wastewater pipe repair which had failed at a hotel in the United Kingdom
The failed first repair of the pipe
A 50 x 25mm crack in a cast iron wastewater pipe which required repair
The 50 x 25mm crack was located on an elbow joint

The 50 x 25mm hole therefore required an alternative repair method. To complicate the repair further, the crack in the cast iron wastewater pipe was on an elbow joint.

Sylmasta decided that the most effective pipe repair product to seal the hole would be Superfast Steel Epoxy Repair Stick. The size and the position of the crack still possessed some challenges, which were eventually overcome by some out-of-the-box thinking by the Sylmasta technicians.

The Superfast Steel Stick was hand kneaded as normal, but rather than being pushed immediately into the crack it was instead formed into a disc larger than the hole in order to completely cover it. This disc of epoxy putty was then attached to a strip of polythene sheeting.

Steel epoxy putty used to seal a crack in a leaking cast iron wastewater pipe
Superfast Steel formed into a disc and applied over the crack

The sheeting would support the epoxy putty whilst it was stretched over the crack in the pipe. Once in position, the edges of the disc were pushed tightly down onto the cast iron pipe to form a good seal with the surface of the pipe.

Once the epoxy putty was in place, the whole repair was overwrapped with a SylWrap HD Pipe Repair Bandage. SylWrap is water activated and sets rock-hard to provide an impact resistant layer over the initial repair. It does not need to be stretched for an effective application, meaning that it could easily be applied to the cast iron pipe despite the space constraints.

A SylWrap Pipe Repair Bandage applied over a cracked cast iron wastewater pipe in a London hotel
The Superfast Steel was overwrapped with a SylWrap HD Pipe Repair Bandage

After the repair was completed, the hotel was able to reopen to the public the popular room which had been affected by the leaking wastewater pipe. The solution is permanent and was carried out at a fraction of the cost of hiring a plumber or replacing the damaged pipe.

It also saved time with the repair being effective in less than an hour. Sylmasta have since recommended that the hotel take stock of the SylWrap Pipe Repair Contractor Case, a kit which contains enough products to carry out up to six pipe repairs.

A Contractor Case can be easily stored on site, enabling an emergency pipe repair to be carried out as soon a pipe related problem arises for the hotel in the future. All the products included in the Contractor Case are WRAS approved, making them safe to use with drinking water.

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