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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 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: Steel District Heating System Pipe Suspended in Ceiling Live Pinhole Leak Repair

A steel pipe in a district heating system leaking from a pinhole undergoes a live leak repair using a SylWrap Pipe Repair Contractor Case

Saved from substantial district heating damage – the energy company rewarded for equipping all their vans with a SylWrap Pipe Repair Contractor Case

A pinhole leak in a 50mm steel pipe suspended in the ceiling as part of a building’s district heating system required an urgent live leak repair when escaping, pressurised water began causing substantial damage to surrounding surfaces.

Case Study Data


Site
Public building
Location
United Kingdom
Repair Type
Live leak pipe repair
Defect
Pinhole in a 50mm steel district heating system pipe

Products Used


SylWrap Pipe Repair Contractor Case
The energy company responsible for the district heating system equip every van with a Contractor Case

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape used to seal the leak on the pipe despite the difficulty in gaining access to the ceiling

SylWrap HD Pipe Repair Bandage
Composite wrap applied to encapsulate the repaired section with an impact-resistant, protective sleeve

Case Study PDF


Case Study Details


The district heating system was operated by a United Kingdom based company who specialise in installing and maintaining sustainable energy generation systems in public buildings, residential developments, factories and manufacturing sites.

Because of the importance of pipes to these systems, Sylmasta already had an established relationship with the company prior to the repair. Each of the company’s vans are equipped with a SylWrap Pipe Repair Contractor Case in case of emergencies, enabling contractors to make up to four live leak repairs as soon as problems are identified.

A pinhole leak in a 50mm steel pipe in a district heating system prior to being repaired with a SylWrap Pipe Repair Contractor Case
Water jetting from the pipe was causing substantial damage to surfaces and surrounding pipework, both above and below

The repair in question was to a large pinhole leak in a section of 50mm pipe suspended in the ceiling of the building. Pressurised water was jetting out in numerous directions, causing substantial damage to surfaces and surrounding pipework both above and below the leaking pipe.

Flow could not be turned off, as this would have involved shutting down heating across the entire building. A live leak repair to the district heating system was therefore necessary, using lightweight materials which could be easily carried and applied from the top of a ladder used to reach the ceiling.

From the Contractor Case, Wrap & Seal Pipe Burst Tape was used to successfully seal the leak. Despite the difficulty in accessing the pipe caused by the minimal space to work in the ceiling cavity and the surrounding pipes, Wrap & Seal was still stretched by 300 percent, amalgamating to form a solid silicone band over the steel pipe.

Wrap & Seal successfully applied to seal the pinhole

The entire section was then encapsulated with a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets rock hard in minutes. Once cured, it reinforced the pipe from any future breakages.

After seeing the extent of the damage that escaping water managed to cause in the short space of time between the leak being identified and the Contractor Case arriving on site, the company were appreciative of their partnership with Sylmasta.

Had a Contractor Case not been so readily available, then this could easily have turned into a major incident for the district heating system and the building. Instead, the company’s reputation was enhanced for the swift manner in which they reacted to and repaired the problem.

Completed repair of a steel pipe in a district heating system suspended in the ceiling of a building
The repair was completed by encapsulating the entire section with SylWrap HD

The company have since used their Contractor Cases to make live leak repairs to pipes in various systems they operate made from aquatherm, a semi-rigid polypropylene material.

Aquatherm pipe is popular because it does not react with water, preventing leaching, corrosion, scaling and erosion – major causes of water contamination and long-term pipeline failure.

Once thought to be foolproof, it is now known that failures can happen in aquatherm. Reasons for this include excessive clamping, elevated temperatures, extreme vibrations, flow velocity, water pressure and chemistry, or the presence of copper ions.

There is also the danger posed when a section of aquatherm pipeline has been repaired by inserting copper or iron pipe, leading to different coefficients of thermal expansion and severe cracks.

In the event of any failures in aquatherm piping, the presence of Contractor Cases across the company’s fleet of vehicles means that leaks and bursts can be attended to instantly, instead of suffering delays waiting for materials or parts to be delivered.

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: 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


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: Snapped Nozzle on a 1500mm Seawater Cooling Line Repair & Reinforcement

A 1500mm line in a seawater cooling system undergoes repair after it began leaking from a broken off nozzle

Keeping it cool – the repair and reinforcement of a leaking 1500mm seawater cooling system supply line

A petrochemical plant in Saudi Arabia needed an urgent repair to the 1500mm main supply line in their seawater cooling system after a nozzle snapped off, leaving a 50mm hole discharging water 5 metres vertically at a pressure of 3 bar.

Case Study Data


Site
Petrochemical plant
Location
Saudi Arabia
Repair Type
Leak repair and reinforcement
Defect
Snapped nozzle in a 1500mm seawater cooling pipe

Products Used


Sylmasta AB Original Epoxy Putty
Epoxy putty used alongside a PTFE plug to fill the 50mm hole left by the snapped nozzle

SylWrap HD Pipe Repair Bandage
Composite wrap reinforced the repair and was then applied around the diameter to strengthen the line

Case Study PDF


Case Study Details


Seawater cooling systems allow water taken from the sea to be used for the cooling of machinery and other processes in industrial plants and factories.

The petrochemical plant were extracting from the Red Sea. A nozzle on the 1500mm diameter main line supplying the cooling system had snapped off from the flange, causing a jet of pressurised water to shoot 5 metres into the air from a 50mm hole.

An engineer fits the PTFE plug to the leaking line

When this seawater returned to ground, it saturated the surface of the pipe, causing external damage, discolouration, mould to form and a suspected weakening of the line.

Losing so much water also had a serious impact on the efficiency of the system. The plant therefore decided to call in a maintenance team to attempt to fix the problem as a matter of urgency.

The supply line was shut off whilst the repair took place. The application began by securing the hole left in the pipe by the snapped nozzle with a plug made from PTFE.

Sylmasta AB Epoxy Putty used to repair a seawater supply line by fixing a PTFE plug in place
Sylmasta AB Original was used to fix the plug in place, creating a watertight seal

To create a watertight seal around the PTFE plug and fix it in place permanently, the nozzle was then encompassed using Sylmasta AB Original Epoxy Putty.

Sylmasta AB is a smooth-setting putty capable of bonding to all materials, including wet surfaces. It has a two hour work time, allowing more of the putty to be mixed, shaped and applied without premature curing that may have otherwise been caused by the hot Saudi climate.

SylWrap HD Pipe Repair Bandage applied to a snapped nozzle in a seawater supply line repair
The plug and AB Original were encompassed with SylWrap HD

Further reinforcement of the plug and the surrounding AB Original was provided by SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets rock in hard in minutes.

Seven layers of SYL412HD were wrapped and smoothed around the nozzle, creating an impact resistant layer of protection. This completely sealed the hole with a repair pressure resistant up to 30 bar.

SylWrap HD Pipe Repair Bandage being applied to a 1500mm seawater supply line
Further SylWrap reinforced the weakened section of pipe around the plug

When the line was put back into operation, the engineers who had carried out the repair noticed during their inspection that the pipe around the nozzle had indeed weakened as suspected.

Although no major leaks were present, the surface could be seen bubbling with air and water. They therefore decided to reinforce the entire area of pipe underneath the nozzle by wrapping the 1500mm diameter with four SYL616HD Pipe Repair Bandages.

Repair and reinforcement of a 1500mm seawater supply line after a nozzle snapped off
The repair was completed in two hours, leaving the line sealed and strengthened

This provided a protective sleeve around the weakened section of the line, strengthening it against potential future breaches and thus extending the lifespan of the pipe.

Completing the repair of the nozzle and the reinforcement of the line took less than two hours, after which the seawater cooling system was able to operate at full capacity once again.

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: Live Leak Pinhole Repair on 150mm Elbow at Pumping House in Malaysia

A SylWrap Live Leak repair made to a pinhole leak on a 6 bar 150mm elbow joint with a pinhole leak

Fixing an elbow – a pumping house in Malaysia stays operational thanks to a SylWrap live leak repair

When a 150mm steel pipe elbow in a Malaysia pumping house developed a pinhole leak through which water was spraying out at 6 bar pressure, the company responsible for the facility turned to Sylmasta for a rapid live leak repair.

Case Study Data


Site
Pumping house
Location
Malaysia
Repair Type
Live leak repair
Defect
Pinhole leak in 150mm steel pipe elbow joint

Products Used


Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape used to seal the live leak on the elbow joint

SylWrap HD Pipe Repair Bandage
Composite repair wrap applied to reinforce the initial repair via an impact resistant protective layer

SylWrap Pipe Repair Contractor Case
Contains enough products to make up to six live leak repairs, now approved for use on Kuala Lumpur’s vast network

Case Study PDF


Case Study Details


The steel pipe was an important part of the system at the pumping house, operated by a water company. A pinhole leak had appeared on an elbow joint weakened by corrosion where two sections of metalwork joined together.

Because the leak was on an elbow, a repair clamp could not be fitted. The pipe could not be taken out of operation for repair or replacement due to its importance to operations at the pumping house.

A pinhole leak on an elbow joint in a Malaysia pumping station prior to undergoing a live leak repair
The pinhole was located on an elbow
A pressurised jet of water escaping from a 150mm pipe elbow in a Malaysia pumping station
Pressurised jet of water spraying from the pinhole leak

The water company’s maintenance team therefore used a SylWrap Universal Pipe Repair Kit to carry out a live leak repair which would be effective on the 150mm elbow operating under 6 bar pressure.

Wrap & Seal Pipe Burst Tape was used to seal the pinhole leak in the pipe. Wrap & Seal is made from self-amalgamating silicone. It stretches by 300 percent and fuses to form a solid rubber band over holes and cracks in pipework.

Wrap & Seal Pioe Burst Tape used to repair a pinhole leak on a 150mm pipe elbow in Malaysia
Wrap & Seal Pipe Burst Tape was stretched by its maximum 300 percent
Wrap & Seal successfully sealed the pinhole leak

Once the Tape had successfully sealed the hole in the pipe, it was overwrapped with a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets rock hard in minutes.

The Bandage was wrapped around the elbow and smoothed down whilst water from a bucket was poured over it at sporadic intervals. Once cured, SylWrap HD provided an impact resistant shell around the elbow, preventing it from any future leaks or bursts.

Within 30 minutes of the start of the application, the maintenance team had successfully repaired the elbow with no interruption to operations at the pumping house.

SylWrap HD Pipe Repair Bandage used to reinforce a repair on a 150mm elbow joint in a Malaysia pumping station
SylWrap HD Bandage was used to reinforce the repair
The repair was completed in less than 30 minutes

Both Wrap & Seal and SylWrap HD are WRAS approved, meaning that they are certified as safe to use on pipes and fittings carrying drinking water according to British Standards.

Numerous other successful pipe repair applications have since been made in Malaysia using Wrap & Seal and SylWrap HD supplied in a SylWrap Pipe Repair Contractor Case.

This has led the Case to be approved by the national supplier in Malaysia for carrying out leak repairs across Kuala Lumpur’s vast pipe network.

Each Contractor Case contains enough products to make up to six live leak repairs on pipes of all diameters and types without the need for any training.

The Case can be easily stored on-the-van, providing a lightweight and more versatile alternative to carrying around heavy, bulky pipe repair clamps.

When leaks and bursts on the water network are identified, a contractor simply has to reach for the Case on their van to repair the problem in under 30 minutes.

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 200mm Fuel Oil Line Pressure Resistant to 44 bar in Libya

Sylmasta repair a 200mm underground oil fuel line in Brega, Libya suffering from a crack caused by heavy corrosion

Fuel for thought – a high pressure, high temperature pipe repair keeps an oil line in Libya operating

Heavy corrosion caused a small crack to appear in a 200mm fuel oil line buried underground in Libya, leaving the pipe requiring a repair that could withstand pressure up to 44 bar and temperatures up to 70°C

Case Study Data


Site
Underground fuel oil line
Location
Brega, Libya
Repair Type
Leak repair
Defect
Small crack in 200mm pipe

Products Used


Wrap & Seal Pipe Burst Tape
Multiple self-fusing silicone repair tapes used for creating a high pressure seal over the crack

SylWrap HD Pipe Repair Bandage
Provided an impact resistant protective shell over the initial repair, reinforcing the line

SylWrap Pipe Repair Contractor Case
Contains multiple Wrap & Seals and SylWrap HD Bandages to carry out up to six live leak repairs

Case Study PDF


Case Study Details


The town of Brega serves as a major export hub for Libyan oil, being home to one of the five oil terminals operating in the eastern half of Libya. It is also the starting point of the 670 km Brega-Khoms Intisar gas pipeline.

A 200mm fuel oil line required repair after it was found to be leaking underground
Excavation revealed that the pipe was in poor condition

Heavy corrosion had caused a small crack to appear in a 200mm fuel oil line buried underground. Once the pipe had been excavated for inspection, it became clear that it was in terrible condition, badly pitted and covered in escaped oil.

To add to the complexity of the application, the line operated under 44 bar and at temperatures of up to 70°C. Any repair had to be able to withstand these pressure and heat extremes.

Oil leaking from a damaged 200mm fuel pipe line in Brega, Libya
The leak area was a small crack caused by corrosion

Prior to the application, the pipe was cleaned as best as it could be. Oil and dirt was removed and the surface smoothed off to enable a good connection between the line and Wrap & Seal Pipe Burst Tape, which made up the first stage of the repair.

Wrap & Seal is a self-amalgamating silicone repair tape which stretches by 300 percent and fuses to form a solid rubber band over holes and cracks. Multiple tapes can be applied over each other, where they will also fuse together, building repairs with high pressure resistance.

Multiple Wrap & Seal Tapes were used to seal the crack

Once several Wrap & Seals had been used and the team carrying out the repair was satisfied that the leak was suitably sealed, the repair was reinforced using SylWrap HD Pipe Repair Bandage.

SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes. It provides an impact resistant protective shell to pipes and structures, increasing life span and hoop strength.

200mm fuel oil line in Brega, Libya undergoes leak repair using a Sylmasta Pipe Repair Kit
The line was reinforced using SylWrap HD

Four SylWrap HD Bandages were used to cover the repair area, reinforcing the fuel oil line before it was reburied. Each Bandage cured within 2 to 5 minutes of application.

Both Wrap & Seal and SylWrap HD have a maximum service temperature of 250°C and using multiple products created a repair capable of withstanding the pressure that the line operated under.

Completed repair prior to the line being reburied

It took less than two hours to complete the application, notwithstanding the time to excavate and inspect the pipe. The repair was a cost-effective and less time-consuming alternative to replacing the damaged section, which could have left the line out of operation for a prolonged period.

The maintenance team who carried out the job in Brega have since gone onto use Sylmasta products to make numerous repairs to other oil lines in the region, taking advantage of the ease and convenience offer by the SylWrap range.

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 Copper Pipe in a Camper Van Boiler System

A copper pipe in a camper van boiler system undergoes repair using Superfast Copper Epoxy Putty and a SylWrap HD Pipe Repair Bandage

Carry on camping – a difficult-to-access copper pipe in a camper van boiler system undergoes repair

A camper van owner manages to repair a crack in a copper pipe located within the van’s boiler system, despite the leak area being extremely difficult to access

Case Study Data


Site
Camper van boiler
Location
United Kingdom
Repair Type
Leak repair
Defect
Crack in a copper pipe

Products Used


Superfast Copper Epoxy Putty Stick
Fast-working epoxy putty pushed into the crack in the copper pipe to seal it

SylWrap HD Pipe Repair Bandage
Composite repair wrap applied over Superfast Copper to reinforce the initial repair

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

Case Study PDF


Case Study Details


The boiler system provided heat and hot water to the camper van. A deep crack appeared in a copper pipe located underneath the cover of the boiler, causing a pressurised jet of water to spray out whenever the boiler was turned on.

Problematically, the crack was located at a point where the pipe angled towards the back casing of the boiler. It faced towards the side of the casing with access extremely limited.

The confined space meant that there was no room to fit a pipe repair clamp, nor apply Wrap & Seal Pipe Burst Tape with enough stretch for it to self-amalgamate effectively.

Because the boiler could be turned off, Sylmasta recommended to the camper van owner that they use Superfast Copper Epoxy Putty Stick to plug the crack in the pipe.

Superfast Copper comes in a 114 gram stick format and has a work time of 5 to 10 minutes, enabling rapid repairs to be made to copper and other non-ferrous metals.

Before the application began, the pipe was cleaned and dried to aid the adhesion of the putty to the metalwork. The required amount of putty was cut from the stick and kneaded by hand.

Whilst soft, the putty was pushed into the crack in the copper pipe where it hardened, sealing the hole. Enough putty was used to cover the section of pipe both above and below the crack to improve the chances of success.

To reinforce the putty, the entire section of pipe was then covered with a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes to provide an impact resistant layer of protection.

Typically, SylWrap HD would be wrapped around the pipe. The space constraints meant that this could not be done effectively in this particular application, and so the bandage was cable tied to the pipe whilst it cured.

Once the copper pipe repair was completed, the boiler was turned back on. Water was no longer escaping from the crack, denoting a successful boiler pipe repair and saving a considerable amount of money for the camper van owner compared to the cost of fitting a replacement pipe.

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: Bahrain International Airport Repair of Leaking Step Joint on 100mm UPVC Pipe

A leaking 100mm UPVC pipe at Bahrain International Airport undergoes a live leak repair using a SylWrap Pipe Repair Contractor Case

Flying high – the live leak repair of a 100mm UPVC pipe step joint which kept a system operational at Bahrain International Airport

When a 100mm UPVC pipe which was part of an important system at Bahrain International Airport began leaking from a step joint, a quick-and-easy live leak repair method was required as shutting down the line was not an option.

Case Study Data


Site
Airport
Location
Bahrain
Repair Type
Live leak repair
Defect
Leaking step joint on a 100mm UPVC plastic pipe

Products Used


Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape which sealed up and over the leaking step joint

SylWrap HD Pipe Repair Bandage
Applied over the sealed step joint to reinforce the repair by providing a rock hard, impact resistant layer

SylWrap Pipe Repair Contractor Case
Products were supplied as part of a Contractor Case, capable of making up to six live leak repairs

Case Study PDF


Case Study Details


UPVC is a strong and versatile pipe material which is assembled using a solvent cement to bond pieces together. Sometimes, these bonds can loosen and begin leaking, which is what happened to the 100mm pipe at Bahrain Airport.

The leak in question was through a step joint connecting two sections of pipe together. The pipe could not be shut off for a repair because of the importance of the airport system it supported.

This meant that the normal method Sylmasta recommend to clients for sealing a leaking step – by using a Superfast Epoxy Putty Stick to plug the gaps between the joint and the pipe – would not be effective because the pipe was wet.

The airport therefore had to use Wrap & Seal Pipe Burst Tape as their sealing material. Wrap & Seal is a self-amalgamating silicone repair tape which stretches by 300 percent, fusing to form a solid rubber band over leak areas.

Using Wrap & Seal on a step is not as straightforward as wrapping a straight section of pipe. To create a repair capable of sealing the step between the 100mm UPVC pipe and the sleeve, the maintenance team carrying out the application began wrapping approximately 100mm away from the joint.

After approaching the sleeve by overlapping the Tape by 50 percent, they then built up layers of Wrap & Seal immediately next to the joint. This created a ridge. When this ridge reached near-level height with the step, the application of the Tape continued for a further 50mm across the step joint to fully encompass it.

Two 50mm x 4m Wrap & Seals were required before it was established that water had stopped escaping the joint and the leak was fully sealed. The repair was then completed by applying a SylWrap HD Pipe Repair Bandage over the Tape.

SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes. The Bandage was wrapped around the pipe and smoothed down using water poured onto the pipe from a bottle. It cured to provide an impact resistant, protective shell.

The entire repair was carried out in less than 30 minutes whilst the pipe remained in operation. The two Wrap & Seal Tapes and SylWrap HD Bandage were supplied to the maintenance team as part of a SYL-PRO-633 Pipe Repair Contractor Case.

A Contractor Case contains enough products to make up to six live leak repairs on pipes of all types and diameters. The Case is easy-to-store on site and transport, ensuring that everything needed to fix a leaking pipe is close to hand and enabling repairs to be made as soon as problems are identified.

Following the success of the 100mm UPVC pipe repair, the maintenance team have since gone onto use Contractor Cases at the Airport to fix 150mm and 200mm pipes suffering from similar problems.

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

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

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Case Study: Reinforcement of Weakened Pipe Elbow Joint on 100mm 22 bar Sulphuric Acid Line

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

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

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

Case Study Data


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

Products Used


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

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

Case Study PDF


Case Study Details


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

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

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

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

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

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

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

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

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

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

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

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

Repair completed with SylWrap HD for increased hoop strength

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

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

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

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

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Case Study: 650mm Ductile Iron Pipe Located in Pit Undergoes Live Leak Coupling Joint Repair

A 2 metre section of 650mm pipe buried in an inspection chamber was discovered to be leaking, excavated and then sealed using SylWrap pipe repair products

Coupling goals – the challenging repair of an iron water pipe discovered to be leaking from coupling joints in a disused pipe inspection chamber

A 2 metre section of 650mm ductile iron pipe buried in a former underground inspection pit is excavated by a UK water company to undergo repair after it was found to be leaking from two coupling joints.

Case Study Data


Site
Inspection Pit
Location
United Kingdom
Repair Type
Live leak repair
Defect
650mm ductile iron pipe leaking from coupling joints

Products Used


Wrap & Seal Pipe Burst Tape
Multiple self-fusing silicone repair tapes used for building up a repair to seal the coupling joints

SylWrap HD Pipe Repair Bandage
Reinforced the coupling repair and fortified the pipe from further deterioration before it was reburied

SylWrap Pipe Repair Contractor Case
Contains multiple Wrap & Seals and SylWrap HD to carry out up to six live leak repairs

Case Study PDF


Case Study Details


The pit had originally been an inspection chamber housing a valve. Many years ago, the valve had been replaced with a two metre section of straight ductile iron pipe attached to the existing pipe carrying mains water via two coupling joints.

After the straight section was fitted, the whole chamber had been filled in with earth and covered over, where it remained forgotten. That was until the water company responsible for the pipe rediscovered it during maintenance work.

Contractors discovered a 2 metre long section of 650mm ductile iron pipe buried in what used to be a valve chamber was leaking
The 2 metre section of pipe with raised couplings at either end

Soil within the pit was found to be extremely muddy, suggesting that the pipe was leaking in the chamber. After excavating the entire pit to investigate further, the water company discovered that the pipe was in poor condition with slight seepage from both couplings.

The water company decided to seal the couplings to prevent further leakage. Each coupling was 80mm wide but 100mm higher than the 650mm pipe, presenting contractors with an awkward ridge that the repair needed to wrap over.

There were also challenges with the clearance in the pit. The two couplings gave only 35mm underneath in which to work. Conditions within the chamber meant that any repair material wrapped around the pipe would be in danger of picking up mud and dirt off the floor.

Coupling joints on a 650mm ductile iron pipe were leaking before undergoing a leak repair using SylWrap Pipe Repair products
Raised couplings were 100mm higher than the pipe

To overcome this, a polythene sheet was squeezed underneath the pipe. For sealing the couplings, multiple Wrap & Seal Pipe Burst Tape were used to build a repair over and around the couplings.

Wrap & Seal is made from self-amalgamating silicone which fuses to form a solid rubber band for live leak repairs. Separate Tapes will also fuse to each other, this being how the repair was built up and the difficult ridge shape of the coupling sealed.

Each coupling and the surrounding area was then encompassed with a SYL1266HD SylWrap Pipe Repair Bandage. SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes to provide an impact resistant layer of protection.

SYL1266HD Bandages are 300mm wide, giving them more than enough coverage to be moulded around the raised coupling. With the reinforcement provided by SylWrap, the water company could rebury the pipe safe in the knowledge that the leaks were sealed and the pipe had been suitably fortified to prevent further deterioration.

Both Wrap & Seal and SylWrap HD have WRAS approval, meaning that they are certified to British standards as safe to use on pipes carrying drinking water. Because the pipe carried mains water, it was a legal requirement that any repair materials used had to be WRAS approved.

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