Tag: SylWrap HD Pipe Repair Bandage

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Case Study: Cast Iron Waste Pipe U-Bend Crack Repair Above Hospital Corridor

A cast iron pipe U-bend with a hairline crack at a UK hospital is sealed with a SylWrap Drain & Waste Pipe Repair Kit

Ladder-top repair stops leaking cast iron waste pipe driving hospital staff around the U-bend

From the top of a ladder, a maintenance worker makes a repair in under 15 minutes to a hairline crack in a cast iron waste pipe U-bend within a cramped roof space above a hospital corridor

Case Study Data

Site
Hospital
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Hairline crack in cast iron waste pipe U-bend

Products Used

CrackSeal Pipe Sealant
Sealant extruded directly into cracks in cast iron pipework, where it hardens almost instantly to fill the damage

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to create a rock-hard sleeve around pipework

SylWrap Drain & Waste Pipe Repair Kit
Specialist Kit containing products for repairing low-pressure cast iron and plastic waste, sewer and drain pipes

Case Study PDF

Case Study Details

Damp patches were noticed in ceiling tiles above a busy corridor in the hospital. A maintenance worker climbed up a ladder, removed the tiles and accessed the roof space above to investigate.

They found a complex network of cast iron pipework. One of these pipes came down through the ceiling, into a U-bend followed by a 90-degree elbow before connecting with two other waste pipes via a Y-joint.

The Y-joint was heavily corroded and covered in grime. The problem was found to be a hairline crack across the U-bend located directly above the Y-joint.

Wastewater was seeping through this crack, corroding the three pipes at the point they met below and dripping further down to discolour and damage the ceiling tiles.

Hairline crack in a cast iron pipe U-bend through which wastewater was leaking at a UK hospital before undergoing repair
After accessing the roof space, a hairline crack was discovered in a cast iron pipe U-bend

To replace the cracked U-bend, the Y-bend and all pipes connected to it would have needed to be removed to gain enough access. The cash-strapped NHS trust responsible for the hospital could not afford the cost of effectively taking the entire system out of operation.

Research by the maintenance team led them to the SylWrap Drain & Waste Pipe Repair Kit, which is already used by several NHS trusts in England for making fast, straightforward and cost-effective repairs to leaking cast iron and plastic pipework on their estates.

All the products in the Drain & Waste Kit are lightweight enough to be applied from the top of a ladder. The repair started by using CrackSeal Pipe Sealant to fill the crack in the U-bend.

Using a standard sealant gun, CrackSeal was extruded directly into the crack. As a moisture curing sealant, it began to harden almost instantly. Within 10 minutes, it had formed a skin to leave the pipe fully sealed.

CrackSeal was then reinforced using SylWrap HD Pipe Repair Bandage. Although the U-bend was a difficult geometry to wrap the bandage around, the worker managed to apply it effectively.

The resin in SylWrap was activated using water and the bandage wrapped and smoothed around the U-bend. Once the U-bend was covered, wrapping continued vertically to cocoon the entire repair area.

Cast iron pipe U-bend with hairline crack undergoes repair at a UK hospital with SylWrap Pipe Repair Bandage
The crack was sealed with CrackSeal and then reinforced with SylWrap HD, despite the lack of space left by the complex network of pipes in the roof

SylWrap set rock-hard within minutes of application, providing the entire leak area with an impact-resistant layer of protection capable of containing any future leaks should the weakened U-bend become breached in future.

The worker completed the cast iron U-bend repair in under 15 minutes and with little disruption to the hospital, other than the corridor being out of use whilst they were up the ladder.

With the Drain & Waste Pipe Repair Kit containing enough products to seal multiple cracks and holes in different types of pipework, the hospital now have CrackSeal, Superfast Steel Epoxy Putty, SplitFill Epoxy Adhesive and SylWrap HD Bandages on-site in an easy-to-store case for use when future leaks occur.

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: Complex in UAE Approves SylWrap for Chilled Water System ABS Pipe Repair

An ABS pipe leaking at a joint undergoes repair to show SylWrap is effective in chilled water cooling systems

Keeping cool under pressure – SylWrap passes testing for repair of chilled water system ABS pipe joints

Superfast Aqua PW Epoxy Putty and SylWrap HD Pipe Repair Bandage undergo vigorous pressure testing by an engineering company to receive approval for use sealing ABS pipe joints in a chilled water cooling system at a luxury complex in the UAE.

Case Study Data

Site
Luxury complex
Location
United Arab Emirates
Repair Type
No pressure pipe repair
Defect
Leaking ABS pipe flange in chilled water cooling system

Products Used

Superfast Aqua PW Epoxy Putty Stick
Epoxy putty with specialist high underwater adhesion formulation for sealing pipes when the surface is wet

SylWrap HD Pipe Repair Bandage
Composite wrap cures to form a thickened, reinforced layer which restores pipework integrity

Case Study PDF

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Case Study Details

Chilled water and district cooling systems are used throughout the United Arab Emirates to provide an energy efficient method of air conditioning.

Water is stored and cooled in a central plant. It is then pumped around buildings, complexes and even entire districts via vast pipe networks operating at between 5 and 7 bar pressure.

Some of these systems provide air conditioning to hundreds of different homes and workplaces from a large-scale plant. The Empower Business Bay plant in Dubai for example serves 188 multi-use buildings and skyscrapers. Future expansion is planned to take that number over 300.

Other leisure complexes and skyscrapers have private chilled water systems, supplying air conditioning for their own facilities. This is the case with the Burj Khalifa, which has 34 kilometres of pipework circulating cooled water around the 830-metre tall building.

Sylmasta were contacted by an engineering company responsible for a private chilled water system at a luxurious complex containing over 500 apartments, a leisure centre, shops, restaurants and a 5-star hotel.

They were looking for a quick and straightforward repair method for sealing any leaking joints in the ABS pipe network which pumped cooled water around the complex. Rapid response time was essential to ensure the efficiency of the air conditioning system.

An engineering company in the UAE build an ABS pipe rig to test SylWrap for the repair of chilled water cooling pipes in the UAE
The engineering company built several ABS pipe test rigs with an intentionally weakened flange end for repair using Superfast Aqua PW and SylWrap HD

To evaluate Sylmasta products, the company built several test rigs with 50mm, 100mm and 150mm ABS pipes. Each rig was one-metre long and connected with stub flange sets and MS end flanges.

One side of the flange ends was made intentionally weak so that it would begin leaking when pressure was increased. The pipe was filled with water through a valve. Once it was full, pressure was applied.

At 4 bar, a leak was noticed at the weakened flange end. The area was instantly cleaned and then sealed using Superfast Aqua PW Epoxy Putty. Aqua PW was chosen for its high underwater adhesion properties, enabling it to bond to the ABS even though the pipe surface was wet.

Enough putty was cut from the stick for application all around the weak flange plate. The putty was kneaded by hand and applied to the pipe whilst still soft. Within 20 minutes, it cured to form a rock-hard, waterproof material permanently bonded to the ABS and covering all leak spots to restore pipeline integrity.

SylWrap HD Pipe Repair Bandage applied to an ABS pipe identical to those found in chilled water cooling systems in UAE
SylWrap HD was wrapped over a 250mm section of pipe either side of where the flange was leaking through

SylWrap HD Pipe Repair Bandage was then wrapped over a 250mm section of the pipe either side of the leak. It cured to create a thickened, impact-resistant sleeve around the leak, further enhancing the seal provided by Superfast Aqua PW.

The repair was left for 90 minutes to reach working strength and then pressure tested. Pressure was gradually increased towards 8 bar, reflecting the maximum the chilled water system at the complex reached.

Throughout each of the three pressure tests to the different sized rigs, the gauge was monitored for any significant drops or irregular fluctuations.

Once 8 bar had been exceeded, the repair was left for 18 hours. When the pipe was inspected again, there were no visible cracks, leaks, deformations or signs of damage.

The repair successfully held over 8 bar pressure for 18 hours

Based on the visual inspection and pressure test results, the engineering company concluded the SylWrap repair to have successfully restored the functionality and integrity of the ABS pipe.

In their report compiled after all 50mm, 100mm and 150mm tests had been completed, the company wrote: “The repair material was applied correctly and adhered well to the pipe surface.”

“The pressure test demonstrated the repair’s ability to withstand the specified pressure without any signs of leakage, failure, or abnormal pressure fluctuations.”

“We therefore consider this repair a suitable solution for any leakage on ABS pipes in chilled water cooling systems.”

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 Underground Clay Drainage Pipe Cracked During Building Work

A cracked underground clay drainage pipe undergoes repair using a SylWrap Standard Pipe Repair Kit

An underground clay pipe repair prevents a home drainage system going to pot

Accidental impact and ground movement during building work left an underground 100mm clay drainage pipe with two cracks requiring repair, one of which was severe enough to almost split the pipe into two separate parts.

Case Study Data

Site
Domestic property
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Two cracks in underground 100mm clay drainage pipe

Products Used

Superfast Steel Epoxy Putty Stick
Fast working steel epoxy putty which sets rock hard inside cracks and holes, sealing leaks

SylWrap HD Pipe Repair Bandage
Composite wrap reinforced the repair with a rock hard sleeve which also helped hold the pipe back together

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

Clay was a popular material for drainage pipes in the United Kingdom from the early 20th century until the 1970s, when plastic became more widely used due to being easier and cheaper to fabricate and install.

High resistance to corrosion and chemical degradation gives clay extreme durability and longevity, with an estimated lifespan of anywhere between 60 and 100 years. This means many UK homes built before the 1970s are still serviced by working clay pipes.

One weakness of clay pipes, however, is they are susceptible to damage from root ingress and ground movement – which often only becomes obvious when a patch of ground becomes noticeably waterlogged from an underground leak.

A homeowner was carrying out building works when an area of their garden began suffering from this problem. After digging down, they discovered a dislodged 100mm clay pipe with two areas of significant damage.

The first and most severe was a crack next to a junction almost splitting the pipe into separate parts. The junction and uneven surface meant it would not be possible to reassemble the pipe using a repair clamp.

The clay pipe had a significant crack next to a junction with a smaller hairline crack along its top

Across the top of the pipe was a hairline crack, representing the second damaged area. There was no pressure and the homeowner was keen to avoid the cost and disruption which would come with replacing the pipe.

They therefore used a SYL-412-NP SylWrap Standard Pipe Repair Kit to seal the leaks and attach the pipe back together. Before the repair, enough room was dug out underneath the pipe to allow clearance for it to be wrapped.

The two cracks were then filled with Superfast Steel Epoxy Putty. Enough putty was first mixed by hand to cover the hairline crack. It was then pushed firmly down across the top of the pipe, curing within five minutes to form a rock hard material covering the leak.

Superfast Steel Epoxy Putty used to repair cracks in an underground clay drainage pipe
Superfast Steel was used to seal the two cracks in the pipe

For the larger crack, more putty was mixed and forced into the gap between the two sections of pipe. Once it had set, Superfast Steel bridged the crack with a watertight material bonded to both pieces.

The pipe was then overwrapped with SylWrap HD Pipe Repair Bandage. The fast-working resin in SylWrap HD was activated with water and the bandage wrapped along the entire length of the exposed pipe.

SylWrap HD cured to form a rock-hard, impact resistant protective shell. It reinforced the repair and helped hold the two broken pieces of clay pipe back together.

SylWrap HD Pipe Repair Bandage applied to an underground clay drainage pipe to reinforce the line after it cracked
The pipe was overwrapped with a SylWrap HD Bandage to complete the repair

The homeowner said afterwards that the repair worked perfectly and that the product was great. Completing the repair took under 30 minutes and cost less than £50, representing a huge saving compared with removing the pipe and installing a replacement.

With many clay pipes installed before the 1970s now beginning to reach the end of their natural lifespan, repairs such as this are set to become more common in the UK over the coming years.

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: SylWrap Leak Repair Passes ASME PCC-2 402-III Qualification Standard

Superfast Aqua PW Epoxy Putty and SylWrap HD Pipe Repair Bandage are successfully tested to be ASME PCC-2 402-III compliant

Leak repair made using Sylmasta products withstands 30 bar pressure in qualification tests for ASME PCC-2 402-III

Superfast Aqua PW Epoxy Putty and SylWrap HD Pipe Repair Bandage make a leak repair qualified to ASME PCC-2 Appendix 402-III – Validation for Repair of Leaking Component by withstanding 30 bar pressure in multiple tests.

Case Study Data

Site
Sylmasta HQ
Location
United Kingdom
Repair Type
Leak repair
Defect
25mm hole in 110mm diameter carbon steel pipe

Products Used

Superfast Aqua PW Epoxy Putty
Fast working epoxy putty which bonds to wet surfaces with WRAS approval for sealing holes and cracks in pipes

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to reinforce pipework with a thickened, impact resistant sleeve

Case Study PDF

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Case Study Details

ASME PCC-2 Appendix 402-III – Validation for Repair of Leaking Component is a test which assesses the ability of a composite pipe repair system for sealing leaking pipes, tanks and vessels containing non-hazardous fluids operating below 10 bar.

To qualify for ASME PCC-2 402-III, a repair must successfully seal a leaking pipe which has been fully breached, restore pressure-retaining capability to the line and show it will not degrade or be compromised over time under service conditions.

It is a standard widely used across many industries – such as water utilities – to give confidence that repairs on the public supply network will be strong and long-lasting.

ASME PCC-2 402-III is also applicable to other industries where high-pressure water pipes are used – such as desalination plants and cooling systems at oil refineries, power stations and food and beverage production.

Testing took place at Sylmasta HQ in the United Kingdom. A 25mm hole was cut into a 110mm diameter carbon steel pipe. The leak needed to be sealed before being subjected to three separate pressure tests up to 30 bar.

A 25mm hole was cut into a steel pipe for testing

Superfast Aqua PW Epoxy Putty was used to plug the hole in the pipe. To improve adhesion, the pipe was abraded first. This removed any traces of rust, dirt or grime. It also created a textured surface for the repair to grip onto.

The putty was mixed by hand and formed into a disc around 75mm in diameter, ensuring total coverage of the leak. It was placed over the hole and pushed firmly down onto the pipe for maximum contact.

Superfast Aqua PW seals a 25mm hole in a carbon steel pipe to qualify for ASME PCC-2 401-III standard
Superfast Aqua PW Epoxy Putty was formed into a disc and fixed over the hole

At the edges, the putty was smoothed off using a little water to remove any step from the surface. It was allowed to cure for around 10 minutes until gelled but not hardened.

SylWrap HD Pipe Repair Bandage was then used to reinforce Superfast Aqua PW. The composite repair wrap was activated with water and applied over an area approximately 225mm, with the leak at its centre.

As SylWrap HD was wrapped and smoothed over the putty, it helped force Superfast Aqua PW further into the hole for a more effective seal. SylWrap HD set rock hard within minutes, curing to form a thick, rock hard, impact-resistant sleeve around the pipe.

SylWrap HD reinforced the pipe with a rock hard, impact resistant sleeve

The repair was left for 24 hours to achieve maximum properties before pressure testing. This involved increasing pressure through the pipe at a steady rate for more than 30 seconds until 30 bar was reached.

After 60 seconds of the pipe being pressurised at 30 bar, the repair was inspected for any visible leakage. This test was carried out on three separate occasions.

With no leak or defect detected during any of the three pressure tests, repairs made using Superfast Epoxy Putty and SylWrap HD are qualified to meet ASME PCC-2 402-III standard.

A SylWrap Pipe Repair withstands 30 bar pressure to be qualified for ASME PCC-2 401-III - Validation for Repair of Leaking Component
The repair was pressure tested three times, withstanding 30 bar on each occasion

In addition to qualifying for ASME PCC-2-402-III, Superfast Aqua PW and SylWrap HD both have WRAS approval – meaning they are certified as safe for use on pipes and fittings carrying drinking water.

For repairs to be fully ASME PCC-2 402-III compliant, installers must undergo training and certification on using Sylmasta products for leaking pipe repair. To find out more, please email sales@sylmasta.com

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: SylWrap Pipe Repair Passes ASME PCC-2 401-III Qualification Standard

Industrial Metal and SylWrap HD Bandage pass PCC-2 401-III qualification testing in a repair on a high temperature steel pipe

Composite pipe repair using Sylmasta products exceeds 309.6 bar pressure resistance to qualify for ASME PCC-2 401-III

SylWrap HD Pipe Repair Bandage and Industrial Metal Epoxy Paste make a repair independently witnessed and verified as passing ASME PCC-2 Appendix 401-III – Short Term Spool Survival standard by exceeding 309.6 bar pressure resistance.

Case Study Data

Site
Test site
Location
United Kingdom
Repair Type
Composite pipe repair pressure test
Defect
Carbon steel pipe machined back to 1mm outer wall thickness

Products Used

Industrial Metal Epoxy Paste
Metal filled epoxy paste used to strengthen pipelines by rebuilding weakened outer walls back towards original thickness

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to reinforce pipework with a thickened, impact resistant sleeve

Case Study PDF

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Case Study Details

ASME PCC-2 Appendix 401-III – Short Term Spool Survival is a test which assesses the ability of a composite pipe repair system to restore the integrity of a weakened pipeline back to the strength of the original pipe.

Industries like oil and gas, chemical processing and power generation where high pressure systems and hazardous pipe content are present require pipe repairs to be ASME PCC-2 401-III compliant.

To qualify Sylmasta HD Pipe Repair Bandage and Industrial Metal for ASME PCC-2 401-III standard repairs, Sylmasta carried out a test independently witnessed and verified by a UKAS registered company.

A steel pipe spool similar to the type of pipe found in high temperature applications was fabricated for the test

The test was performed on an ASTM A106 Grade B pipe spool. This type of carbon steel pipe is often used in high temperature environments such as steam and gas lines.

A defect was machined into the spool to reduce wall thickness down to 1mm, accounting for an 86 percent weakening of the pipe.

An defect was machined into the pipe, reducing wall thickness down to 1mm

Based on the measured yield strength of the pipe, diameter and original wall thickness, the repair needed to withstand 309.6 bar of pressure to pass the test and certify the materials as PCC-2 401-III compliant.

Before the repair, a flap wheel was used to clean the area back to bare metal. The whole area was then thoroughly cleaned using a solvent degreaser to remove any remaining traces of foreign substances.

Industrial Metal Epoxy Paste was used to fill in the defect. It rebuilt the pipe wall back towards original thickness, and acted as a load transfer medium between the pipe spool and SylWrap HD.

Industrial Metal is applied to a pipe during successful testing to make an ASME PCC-2 401-III standard repair
Industrial Metal filled the defect in the pipe, rebuilding the degraded pipe wall back towards original thickness

The two parts were mixed together until turning a uniform grey colour. Industrial Metal was then applied using a putty knife, ensuring maximum contact between the spool and the epoxy paste.

Industrial Metal was allowed to fully set before the flap wheel was used to smooth the cured material and the area around surrounding it, followed by further cleaning with degreaser.

Industrial Metal Epoxy Paste used to successfully repair a pipe to ASME PCC-2 401-III standard
Once Industrial Metal had fully set, the cured material and area surrounding it were smoothed off and cleaned

The Sylmasta Pipe Refurbishment Calculator helped determine the size and number of SylWrap HD Pipe Repair Bandage needed to reinforce the repair so it became strong enough to hold 309.6 bar pressure.

SylWrap HD Pipe Repair Bandage used to successfully repair a pipe to ASME PCC-2 401-III standard
Five SYL633HD Bandages were used over the defect

Five SYL633HD Bandages were used for the repair. The fast working, water activated resin began to cure within minutes to form a rock-hard, impact resistant shell.

Once SylWrap HD had set, the pipe spool was pressure tested by a UK-based specialist using calibrated and certified pressure gauges. The results were recorded using a data logger.

SylWrap HD undergoing pressure testing to qualify for PCC-2 pipe repair
The pipe spool was pressure tested using calibrated and certified pressure gauges with results recorded on a data logger

The repair exceeded the 309.6 bar required to pass PCC-2 401-III, eventually failing when pressure reached 310.29 bar and water began leaking through the edges.

The repair exceeded the 309.6 bar required to meet PCC-2 401-III, failing when pressure reached 310.29 bar

With the test signed off as a success, composite pipe repairs using SylWrap HD and Industrial Metal are qualified to meet ASME PCC-2 401-III standard.

To determine the quantity of Sylmasta materials needed to make a composite pipe repair conforming to PCC-2 401-III standard, please use the ASME PCC-2 Compliant Repair Calculator below.

The calculator serves only as a guide. Judgement should be made on the exact repair based upon all conditions. Please contact Sylmasta for more information or if you need help with a specific application.

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: Aluminium Conduit Pipe Carrying Cables Underneath Train Repair

All aboard for the SylWrap HD conduit pipe repair which helped keep a train on the tracks

Aluminium conduit pipe carrying cables underneath a train undergoes repair and reinforcement using SylWrap HD Pipe Repair Bandage after stones, ballast and other debris flying up from the railway track bed caused impact damage.

Case Study Data

Site
Railway network
Location
United Kingdom
Repair Type
Conduit pipe repair
Defect
Damaged aluminium conduit pipe carrying electrical cables underneath train

Products Used

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin encompasses pipes with a rock-hard, impact resistant outer sleeve

Case Study PDF

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Case Study Details

The railway network in some areas of the United Kingdom operates a third rail system. Rather than electricity coming from overhead cables, it is supplied to the train from a powered conductor rail on the track bed.

Metal blocks – known as shoegears – underneath the train make contact with the third rail. They take electricity from it, which then flows into the power system of the train through a series of cables also attached underneath.

Sylmasta were approached by a rail operator whose under-train cables were housed in aluminium conduit pipe. When the train hit high speeds on sections of the railway where the ballast track bed was loose, stones were becoming airborne and damaging the pipe.

Over time, this repeated impact caused tears to appear in the aluminium conduit. The cables inside were subsequently left dangerously exposed and at risk of being damaged themselves.

Impact caused by stones becoming airborne from the track bed had left the aluminium conduit pipe underneath the train damaged

The rail operator was looking to repair the holes in the aluminium and provide better protection from future damage, without having to take the train out of service for a long period of time to replace the entire conduit pipe.

Sylmasta recommended wrapping SylWrap HD Pipe Repair Bandage along the conduit pipe to seal the tears and provide the aluminium with a robust outer casing.

Unlike other suppliers of moisture cured composite wraps who import from Asia or North America, Sylmasta manufacture the SylWrap range of pipe repair bandages at their site in the UK.

It was therefore possible to produce a customised SylWrap HD based on the rail operator’s requirements. Black dye was used, colouring the bandages black instead of the standard white to better disguise the repair.

SylWrap HD Pipe Repair Bandage used to reinforce and protect aluminium conduit pipe attached underneath a train
SylWrap HD Pipe Repair Bandage was wrapped along the pipe, providing the aluminium with an impact-resistant outer protective shell

Additional inhibitors were also added to make the bandages more fire retardant, enabling them to comply with stringent regulations governing materials used on the railway.

Rail workers accessed the bottom of the train and applied eight layers of SylWrap HD to all areas of the conduit pipe requiring repair and protection. The fast-working resin set within minutes, curing to form a rock-hard shell offering total resistance to impact damage.

When stones, ballast and other materials now flew up from the track bed, they would be repelled by SylWrap HD rather than coming into contact with the aluminium conduit pipe.

The repair was completed inside a day and with a huge cost saving compared to replacing the conduit pipe. The train returned to service with the rail operator confident there would be no further damage.

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 Domestic Water Main Pipe Leaking Due to Stone Damage and Corrosion

A heavily corroded and leaking domestic water main supply pipe undergoes repair and refurbishment

Stone the crows – underground domestic water main pipe damaged by corrosion and imbedded stones kept in service thanks to a homeowner DIY repair

A homeowner undertakes a DIY repair and refurbishment of a 2-metre section of domestic water main supply pipe leaking underneath their driveway because of heavy corrosion and surface damage caused by stones.

Case Study Data

Site
Domestic property
Location
Devon, UK
Repair Type
Leak repair and pipe reinforcement
Defect
Water main supply pipe damaged by heavy corrosion and imbedded stones

Products Used

Superfast Aqua PW Epoxy Putty Stick
WRAS approved epoxy putty with excellent wet surface adhesion, used to seal leaks and fill other imperfections in pipework

Liquid Metal Epoxy Coating
Brush applied coating painted onto pipework to form a new, hard wearing, metallic outer surface with high corrosion resistance

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin encompasses pipes with a rock-hard, impact resistant outer sleeve

Case Study PDF

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Case Study Details

Abnormal levels of water use alerted the homeowner to a potential leak somewhere in their supply system. The problem was soon identified to be underneath the front driveway.

Because the leak was in the pipe between the property and the external stop tap connected to the public supply, repair was the responsibility of the homeowner and not their water supplier.

The homeowner excavated the pipe and discovered it to be heavily corroded. Stones were imbedded deeply at various points across the entire 2-metre line, and the metal had been breached and was leaking in multiple places.

Heavily corroded domestic water main supply pipe also imbedded with stones before a Sylmasta repair sealed and refurbished the line
Excavation revealed the pipe to be heavily corroded with stones also deeply imbedded into the metal

Sealing the leaks would therefore not be enough; the homeowner needed to strengthen the pipe to prevent further damage in the future, before it was reburied under the drive.

Water supply was turned off at the external stop tap and the system drained before the domestic water main pipe repair began. The homeowner then set about thoroughly cleaning the pipe as much as possible.

Stones imbedded in a domestic water main pipe before the line underwent a Sylmasta repair and refurbishment
The pipe exterior was so damaged that simply sealing the leaks would not be enough

This involved removing dirt, followed by surface corrosion. Next came the challenge of the stones, some of which were imbedded so deep into the pipe as to effectively be welded to the metal.

Many of the stones therefore left craters and severe surface damage in the pipe following their removal. These and the other leak areas identified after excavation were repaired with Superfast Aqua PW Epoxy Putty.

Superfast Aqua PW was chosen for its excellent wet surface adhesion; compensating for the possibility some water may have been left behind when the pipe was drained and could seep from the pipe during repair.

It also has WRAS Approval, meaning it is safe to use on pipes and fittings carrying drinking water. This was an important consideration with the main bringing supplies from the public network into the property.

The putty was kneaded by hand until it turned a uniform white colour. Whilst still soft, it was pushed into all leak holes and craters in the pipe. Within 20 minutes, Superfast Aqua PW had cured to a solid material, filling all damage.

Liquid Metal Epoxy Coating was then used to reinforce and refurbish the brittle steel. The homeowner painted 1kg of Liquid Metal in two coatings over the entire pipe and all joints. It set to form a new smooth, metallic, hard-wearing outer surface as a shield against corrosion.

Liquid Metal Epoxy Coating painted onto a pipe to refurbish after heavy corrosion in a domestic water main pipe repair
After surface damage was repaired with Superfast Aqua PW, Liquid Metal was coated across the entire pipe and all joints

Further reinforcement was provided by SylWrap HD Pipe Repair Bandage. SylWrap is a composite wrap with a water-activated resin which sets rock-hard in minutes.

Three SYL309HD Bandages were wrapped across the entire 2-metre section, including around a 90-degree elbow and another difficult geometry where the pipe began to climb up a wall.

SylWrap HD Pipe Repair Bandage used as a final layer of rock hard protection in a domestic water main pipe repair damaged by corrosion and imbedded stones
SylWrap HD provided the pipe with a rock-hard, impact resistant final layer of protection before it was reburied

The application of SylWrap began whilst the final coating of Liquid Metal remained slightly tacky, improving adhesion between the bandage and the pipe surface.

Once cured, SylWrap provided an impact-resistant sleeve around the pipe – preventing any stones from imbedding themselves and penetrating the water main in future.

The homeowner completed the repair over a weekend; one day for cleaning the pipe, removing debris and sealing holes. The second day for the application of Liquid Metal and SylWrap HD Bandage.

Water supply was turned back on to test the main. The combination of Superfast Aqua PW, Liquid Metal and SylWrap HD easily contained pipe content, as well as offering robust protection and a fully refurbished line. The pipe was then reburied.

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 Dishwasher 50mm Plastic Pipe Repair in Golf Clubhouse Kitchen

A leaking 50mm plastic pipe connected to a dishwasher undergoes live leak repair at a golf club

SylWrap Universal Pipe Repair Kit seals hole in one with leaking dishwasher pipe repair at golf clubhouse

A dishwasher pipe discovered to be leaking at a golf clubhouse on Sunday morning undergoes repair in under 30 minutes using a SylWrap Universal Pipe Repair Kit, ensuring no disruption to the busy lunchtime service just a few hours away.

Case Study Data

Site
Golf club
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Split in 50mm plastic pipe connected to dishwasher

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating repair tape which fuses to form a solid rubber band, containing pipe content

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to reinforce and protect repairs

SylWrap Universal Pipe Repair Kit
Kit containing products needed to make a single permanent live leak repair in under 30 minutes

Case Study PDF

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Case Study Details

Staff arrived at the golf club on Sunday morning to discover a significant amount of water all over the kitchen floor, surrounding the dishwasher which was always left to run overnight.

After emptying the appliance and pulling it out from its position against the wall, they noticed a 50mm plastic drainpipe at the back of the dishwasher had a split around its diameter.

Staff arrived at the golf course on Sunday morning to discover a split in a 50mm plastic drainpipe connected to the dishwasher

Sunday is the busiest day of the week for the golf club; not just with members playing but also guests drinking in the bar and the restaurant serving brunch and Sunday lunch.

Washing everything by hand until the dishwasher pipe could be fixed by a plumber or replaced would therefore have been almost a full-time job for one member of staff.

The split went around the diameter of the plastic pipe

Worried about the disruption this would cause, the golf club initially considered calling someone in on their day off to try and help manage the load. But before doing that, they contacted the contractor who serviced their drains in the hope he might have a solution.

The contractor kept a stock of Sylmasta products on his van for fixing leaking pipes at hospitals and other facilities. After arriving at the clubhouse, the contractor opted to use a SylWrap Universal Pipe Repair Kit.

SylWrap Universal Pipe Repair Kit used to seal a leaking 50mm plastic pipe attached to a dishwasher at a golf club
A SylWrap Universal Pipe Repair Kit was used to seal the leak

Because the split covered the diameter of the pipe, the contractor applied Wrap & Seal Pipe Burst Tape for the first stage of repair. It was easier to wrap tape over the split than mixing and forming epoxy putty into a sausage before applying it all around the pipe.

Wrap & Seal was stretched by three times its length and as it was wrapped, fused together to form a solid rubber band exerting enough force over the leak to withstand 25 bar pressure.

This easily contained the leak in the dishwasher drain pipe, which operated at no more than 2 bar. The repair was then reinforced with SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water-activated resin.

SylWrap HD Pipe Repair Bandage applied around a leaking dishwasher pipe at a golf club
The repair was completed in under 30 minutes

It was wrapped and smoothed over the Wrap & Seal, where it cured within minutes to form a rock-hard, impact resistant layer of protection.

The contractor completed the repair in under 30 minutes before the lunchtime rush began. Thanks to the ease and speed with which the leak was sealed, the dishwasher was back in operation for staff to clear the minimal backlog of dirty dishes from breakfast without needing to clean any by hand.

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: Bilge Pipe Leaking Through Corroded Welded Joint Repair On Board Superyacht

SylWrap Pipe Repair Kit used to seal a pinhole leak in a steel bilge pipe onboard a superyacht

The seventy pound bilge pipe repair which kept a multimillion dollar superyacht sailing safely

A leaking bilge pipe on board a multimillion dollar superyacht undergoes repair after corrosion at a welded joint caused a hole to appear in an area of the steel line where it was impossible to fit a clamp.

Case Study Data

Site
Superyacht
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Hole in a steel bilge pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape fuses to form a solid rubber band, sealing high pressure leaks

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to reinforce and protect repairs

SylWrap Pipe Repair Contractor Case
Products supplied in a Contractor Case, enabling up to six live leak repairs to be made to pipes of different diameters

Case Study PDF

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Case Study Details

Bilge pumps are one of the most important systems on any boat for keeping the vessel dry and safe. Water naturally collects at the lowest point on board a boat from everyday sources like rainwater, waves when sailing rough seas and spray.

The bilge pump removes this excess water and other fluids which may have found their way to the bottom of the vessel – such as engine oil – by pumping it through a series of pipes and out via an exit hole in the hull.

This prevents flooding impacting the balance of the boat and causing overflow into other areas. Oily water coming into contact with machinery or electrics in the engine room for example can cause serious problems, potentially destroying a boat’s system.

In the event of a hull breach, a bilge pump removing water as it is being taken onboard buys time to slow or repair the leak. If major damage is obtained, the bilge pump allows for safe evacuation by helping keep the vessel afloat for longer than would otherwise be possible.

Corrosion had caused the leak in the superyacht bilge pipe by attacking the steel at a welded joint. The subsequent hole was close to a 90-degree elbow and the hull of the boat.

It was also surrounded by other pipes and equipment, making it impossible to repair with a clamp. With water jetting out the pipe whenever the bilge pump went into operation, the hole needed to be urgently sealed until a new pipe could be fabricated and installed.

Hole caused by corrosion in a bilge pipe onboard a superyacht leaking before a SylWrap repair
Corrosion attacking a welded joint had caused a hole to appear in the steel bilge pipe

The superyacht were sent a SylWrap Pipe Repair Contractor Case, from which Wrap & Seal Pipe Burst Tape was used to seal the leak. Wrap & Seal is a self-amalgamating repair tape with a unique tapered profile which stretches by three times its length.

As it was wrapped around the pipe, it fused to form a solid rubber band capable of containing the water sent through the line by the bilge pump at around 2 bar pressure.

The repair was then reinforced using a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin. It was wrapped and smoothed around the pipe, curing in minutes to form a rock hard, impact resistant sleeve.

SylWrap HD Pipe Repair Bandage used to seal a leaking bilge pipe onboard a superyacht
The pipe was repaired using Wrap & Seal Pipe Burst Tape before overwrapping with SylWrap HD Pipe Repair Bandage

Completing the bilge pipe repair took under 30 minutes at a material cost of a little less than £70. And having discovered how quick and easy a SylWrap repair is, the superyacht now permanently carries a Pipe Repair Contractor Case on board.

The Case contains enough products to make up to six live leak repairs to pipes of different diameters. It is easily stored onboard and means repairs can be made to any boat pipes on the superyacht as soon as leaks develop – even when sailing the high seas.

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: Corroded 30-Metre Section of Sewer Force Main In Underground Vault Repair

A severely corroded sewer force main pipe in Hawaii undergoes repair and refurbishment using the Sylmasta Pipe Refurbishment System

Say aloha to a sewer force main in Hawaii restored from a corroded state by a repair made using the Sylmasta Pipe Refurbishment System

An engineering company in Hawaii refurbish a severely corroded 30-metre section of 450mm ductile iron sewer force main inside an underground vault, rectifying a previous repair attempt which ended up sandblasting a 75mm round hole in the pipe.

Case Study Data

Site
Sewer force main
Location
Hawaii
Repair Type
Pipe repair and refurbishment
Defect
Severely corroded 450mm ductile iron pipe, including 75mm round hole

Products Used

Industrial Metal Epoxy Paste
Metal-filled epoxy paste used to bridge large holes, rebuild weakened pipes and restore surface profile

Liquid Metal Epoxy Coating
Brush applied coating which cures to a hard wearing, metallic surface for protecting pipes against corrosion

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

Case Study PDF

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Case Study Details

The 450mm ductile iron pipe inside the vault was the final section of the sewer force main before it discharged into a manhole housing a gravity collection system. Its operating pressure was around 3 bar.

It was installed in the 1970s. Conditions inside the often-flooded vault over a period of nearly 50 years had led to severe exterior corrosion and a significantly weakened pipe.

Water was pumped out of the flooded vault before repair

A recent attempt to add structural strength and protect against further corrosion involved sandblasting the line prior to coating with epoxy. Unfortunately, the contractor failed to realise just how weakened the ductile iron had become.

Sandblasting to clean the pipe subsequently put a 75mm round hole in the top of the sewer between a flange and the concrete wall where the main entered the adjacent manhole. Wastewater could escape through this hole when the line was pressurised.

To seal the leak in the pipe, the contractors ordered a pipe repair clamp specifically fabricated for the line. But because the surface was so badly deformed by corrosion, it was impossible for the clamp to achieve a watertight seal. There were also concerns that tightening the clamp fully would further breach the brittle metalwork.

The pipe surface was severely corroded, leaving it weakened and brittle

The contractors contacted Sylmasta for assistance with the corroded sewer main repair. They needed to improve the surface profile of the pipe to make the clamp effective, before refurbishing the entire 30-metre section inside the vault to keep the line operational and protect against further degrading.

Any repair method had to take into account the weakness of the line and the damage already done by sandblasting. Sylmasta therefore recommended using Stages 2, 3 and 4 of their Pipe Refurbishment System.

The hole was attended to first. Wire mesh was used to bridge the gap. Industrial Metal Epoxy Paste was then applied around the entire diameter of the pipe between the flange and the wall, including over the hole. The wire mesh prevented any epoxy paste entering the pipe.

Sandblasting to clean the pipe during a previous repair attempt left a hole in the pipe, through which water could escape when the sewer main was pressurised

Industrial Metal is a two-part epoxy paste used to rebuild weakened metalwork and improve surface condition of pipes. In this application, 5kg of Industrial Metal filled in all imperfections caused by pitting and increased pipe thickness surrounding the hole.

Once cured, Industrial Metal sealed the hole and rebuilt the pipe, leaving it strong enough to withstand the clamp being fitted and smooth enough to ensure a watertight seal could now be achieved.

Industrial Metal Epoxy Paste used to repair a hole in a corroded sewer main line
Industrial Metal was applied to seal the hole and rebuild the area of pipe around it, enabling a repair clamp to be fitted

Industrial Metal could have held the leak of its own accord. The contractors though decided to take a belt and braces approach by also fitting the clamp, seeing as it had been specifically made for this sewer line.

Attention next turned to refurbishing the rest of the corroded sewer main. Loose material was carefully cleaned off using wire brushes before the sewer main was painted with Liquid Metal Epoxy Coating.

10kg of Liquid Metal was used to apply two coatings across the entire 30-metre pipe, the two flanges at either end and the coupling in the middle. Re-coat time was four hours, meaning the application of Liquid Metal took one day.

Corroded sewer main pipe in Hawaii before undergoing repair and refurbishment with Liquid Metal
Liquid Metal used to repair a heavily corroded sewer main ductile iron pipe
Liquid Metal refurbished the sewer main by creating a metallic external shield around the entire pipe

Liquid Metal cured to create a new, metallic, hard-wearing pipe exterior for the sewer main, providing a shield against corrosion and a waterproof barrier against future leaks.

The final stage of the repair saw the sewer main given further reinforcement using 20 x SYL866HD SylWrap Pipe Repair Bandage. SylWrap Bandage is a composite repair wrap with a water-activated resin.

It was wrapped and smoothed around the whole pipe, curing within minutes to form a rock-hard, impact resistant layer of further protection. Six layers of SylWrap Bandage were used based on the 3 bar operating pressure of the sewer main.

Application of SylWrap Pipe Repair Bandage to a heavily corroded sewer main pipe in Hawaii
SylWrap Pipe Repair Bandage forms a rock hard, impact resistant layer of protection for a sewer main ductile iron pipe in Hawaii
The repair was completed by wrapping the entire 30-metre pipe with SylWrap Bandage for a rock-hard, reinforced final layer of protection

From sealing the hole to reinforcement with SylWrap Bandage, the repair was completed over the course of one week. The contractors were impressed with how easy all three Sylmasta products were to apply given the cramped, wet and dirty conditions inside the vault.

They had originally planned to encase the sewer main in concrete after refurbishment as an additional means of protection. This was no longer deemed necessary once they saw the strength and effectiveness of the repair.

At a total cost of just under $5000 including delivery to Hawaii, refurbishing the corroded sewer force main provided a significant financial saving compared to ripping out the pipe and replacing it.

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