Tag: SylWrap HD Pipe Repair Bandage

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Case Study: Burst Copper Pipe Repair in Portable Horse & Dog Shower Unit

A copper pipe burst during freezing winter weather undergoes repair with a SylWrap Standard Pipe Repair Kit

Replacement? Hold your horses – the repair of a burst copper pipe which had a horse shower running again in no time

When freezing winter weather led a copper pipe in a portable horse and dog shower to burst, it required a quick and simple repair method capable of being effective inside the cramped space of the unit.

Case Study Data

Site
Portable horse and dog shower
Location
United Kingdom
Repair Type
Leak repair
Defect
Split in copper pipe caused by freezing temperatures

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

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Case Study Details

Showerking are a Sussex-based supplier of portable hot shower units designed for horses and dogs. Units are typically stored in unheated outbuildings. Although designed to handle winter weather, copper pipe in the unit which has not been fully drained becomes prone to bursting during periods of exceptionally cold weather.

When temperatures in the United Kingdom dropped as low as -15°C, several Showerking owners reported burst pipes which rendered their units unusable. If they turned the shower on, water would spray out of the large crack created in the copper pipe.

Freezing temperatures had created a split in the copper pipe

Fortunately, Showerking had already contacted Sylmasta about the possibilities of pipe repair for horse showers. The SylWrap Standard Pipe Repair Kit provided the most suitable method as units would be turned off in the event of leaks or bursts, meaning no pressure to the pipe.

It had been established that the smallest Standard Pipe Repair Kit (SYL-106-NP) was ideal for application because of both the cramped space inside the unit and the difficult shape of the pipework. There were many bends which were unrepairable with a clamp.

Through the relationship between Showerking and Sylmasta, users whose horse showers had suffered burst pipes were directed to the exact product they needed to fix the problem, and had the straightforward repair process explained to them.

Superfast Copper Epoxy Putty used to repair a burst in a horse shower copper pipe caused by freezing temperatures
Superfast Copper Epoxy Putty was used to cover the split

Loose material was removed from the burst copper pipe before repair. Superfast Copper Epoxy Putty Stick was then used to seal the crack. Enough putty to cover the crack was cut from the stick and kneaded by hand until it turned a uniform colour.

Whilst soft, the putty was pushed onto the pipe, encompassing the entire crack. This completed the first stage of the repair. The second stage involved applying a SylWrap HD Pipe Repair Bandage over the Superfast Copper.

A burst copper pipe in a portable horse shower unit repaired and reinforced with SylWrap HD Pipe Repair Bandage
The repair was finished with reinforcement via a SylWrap HD Pipe Repair Bandage

SylWrap HD is a composite repair wrap with a water-activated resin which sets rock hard. The bandage was wrapped and smoothed around the pipe as the Superfast Copper began to harden, forcing the putty into the crack to create a permanent, watertight seal.

Within five minutes of SylWrap HD being applied, the bandage had cured to form a rock hard shell reinforcing the pipe, and which also offered protection from expansion in the future. The completed repair was resistant to 30bar, making it more than capable of holding the pressure the horse shower unit operated at.

The repair took less than 30 minutes from start to finish and the SYL-106-NP Standard Pipe Repair Kit cost under £25 including delivery, returning the £180 Showerking unit to service the same day.

For more information about portable horse and dog showers, please see the Showerking website.

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 Repair of 150mm Cement Coated Steel Pipe on Water Network in Mexico

An underground cement coated steel pipe leaking through an 80mm long split is repaired using a SylWrap Pipe Repair Contractor Case

Contractor Case calling – the cement coated steel pipe repair carried out by engineers in Mexico equipped for every leak

An underground cement coated steel pipe on a water network in Mexico undergoes a live leak repair after excavation followed by the removal of the outer coating revealed a 80mm long split in the line.

Case Study Data

Site
Underground water network
Location
Mexico
Repair Type
Live leak pipe repair
Defect
80mm split in a cement coated steel pipe carrying potable water

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating repair tape which seals high pressure live leaks by fusing together to form a solid rubber band

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap which sets rock hard, providing an effective replacement for the removed cement coating

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

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Case Study Details

A potential leak was identified on a section of the water supply network running beneath a street. Excavation took place and revealed a cement coated steel pipe suffering from a crack around 15mm wide across the diameter of its outer coating.

There was no sign that any water had escaped through this crack. To inspect the condition of the pipe inside, engineers removed the cement using a hammer and chisel. As the coating was chipped away, water began spraying out from a 80mm long split in the steel pipe.

A cement coated steel pipe suffering from a 15mm crack before undergoing repair with a SylWrap Pipe Repair Contractor Case
A 15mm wide crack had appeared in the cement coating around the steel pipe
As the coating was removed, water began spraying out from a split in the steel pipe

By the time the cement coating had been fully removed from around the leak area, enough water had escaped into the excavation hole to half-submerge the pipe. There was no means of isolating this section of the network and so the only option was to make a live leak repair.

The specialist company involved in the identification of the leak and excavation of the pipe equip all their engineering teams with SylWrap Pipe Repair Contractor Cases, meaning everything needed to seal the pipe was already on-site.

Contractor Cases contain enough WRAS approved products to make up to six permanent live leak repairs to pipes of all diameters and materials. WRAS approval was necessary for this application because the pipe carried potable water.

A split discovered in cement coated steel pipe before undergoing repair with a SylWrap Pipe Repair Contractor Case
Engineers were equipped with a SylWrap Pipe Repair Contractor Case which they used to seal the split once the cement coating had been fully removed

A bucket was used to remove enough water from the hole to enable the repair to take place. Wrap & Seal Pipe Burst Tape was used to seal the leak in the line, with several Tapes applied to cover the entire length of the split in the steel.

When stretched and wrapped around a pipe, Wrap & Seal fuses to itself to form a solid rubber band. Multiple Tapes can be applied over each other to build pressure resistance up to 30bar. For this repair, the requirement was around 3bar.

Enough Wrap & Seal Tapes were applied until the leak had been fully arrested. A SylWrap HD Pipe Repair Bandage was then wrapped over the top for the purpose of reinforcing and protecting the initial repair.

The completed repair of a leaking cement coated steel pipe in Mexico using a SylWrap Pipe Repair Contractor Case
The pipe was successfully sealed in under an hour

SylWrap HD is a composite wrap with a water-activated resin. After being wrapped and smoothed around the pipe, the bandage set rock hard in minutes. The impact resistant sleeve formed by SylWrap provided an effective replacement for the removed cement coating.

The application was completed in under an hour. Having all the products required to repair the cement coated pipe ready and available via the Contractor Case made a significant difference to response time and how quickly the leak could be sealed, reducing the amount of water lost and disruption to supplies.

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 Leaking Stainless Steel Pipe Inside Farm Biodigester Tank

A stainless steel pipe in a biodigester tank at a pig farm undergoes repair using a SylWrap Universal Pipe Repair Kit

Rescuing a pig’s ear of a repair – SylWrap seals a leaking pipe in a farm biodigester tank after patch welding failed

A leaking stainless steel heating pipe inside a biodigester tank at a pig farm undergoes repair after an initial attempt to arrest the damage via patch welding was found to have failed.

Case Study Data

Site
Pig farm
Location
United Kingdom
Repair Type
Leak Repair
Defect
Damaged stainless steel pipe in biodigester tank

Products Used

Wrap & Seal Pipe Burst Tape
Repair tape with high pressure and temperature resistance to seal the leak

SylWrap HD Pipe Repair Bandage
Provided an impact-resistant layer to protect against possible future damage

SylWrap Universal Pipe Repair Kit
The products were supplied to the farm in a SylWrap Universal Pipe Repair Kit

Case Study PDF

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Case Study Details

Biodigester systems are installed on farms for the purpose of turning waste into fertiliser and gas. The process involves organic material such as plant matter and animal manure being diluted with water and mixed in an airtight tank. Microorganisms present in the waste ferment the mix, creating a liquid called digestate.

During fermentation, the bacteria responsible for decomposition produce methane. Also known as biogas, this methane is captured and used to help power the farm. Digestate meanwhile is either kept in its liquid form and sprayed back onto the farm as fertiliser, or it can be dried out to a solid material which is used for animal bedding.

The biodigester system at the pig farm consisted of a wide circular tank 20 metres in diameter and around five metres tall. Inside the tank were a number of stainless steel heating pipes which warmed the digestate to aid fermentation. The digestate itself was mixed by a large propeller blade attached to a metal pillar.

The propeller mixer blade and metal pillar had caused damage to a steel pipe behind

Over time, the propeller mixer had pushed the metal pillar backwards to the point where it came into contact with one of the heating pipes. This in turn led to a breach of the steel and a leak developing.

The farm were alerted to the problem through a noticeable drop-off in the efficiency of the biodigester. They accessed the inside of the tank, discovered the damage and attempted to try and seal the pipe via patch welding.

Patch welding failed to seal the leak with numerous pinhole leaks appearing through the weld, after which it was ground down for a SylWrap repair

Not long after the repair and again the biodigester began underperforming. A second inspection revealed that the patch welding had failed, with water sprouting out of numerous pinhole leaks through the weld.

The farm opted for a SylWrap Universal Pipe Repair Kit for their second repair attempt. The pipe was cleaned and the patch weld ground down prior to Wrap & Seal Pipe Burst Tape being applied as the first stage of the SylWrap repair.

Wrap & Seal Pipe Burst Tape used to seal a leaking stainless steel heating pipe in a biodigester tank and a pig farm
Wrap & Seal Pipe Burst Tape applied along a 600mm long repair area

There being multiple leak areas across a 600mm area of pipe made it easier to wrap along the length of the line using Wrap & Seal than trying to encapsulate or plug each individual hole with Superfast Epoxy Putty.

When applied to the pipe, Wrap & Seal amalgamated to form a solid rubber band over every pinhole leak present. The tape was easily capable of withstanding both the pressure and temperature which the heating pipe operated at.

SylWrap HD Pipe Repair Bandage used to seal a leaking stainless steel heating pipe in a biodigester tank and a pig farm
SylWrap HD provided an impact resistant sleeve to protect the pipe from future contact with the pillar

To reinforce and protect the repair should the mixer blade and pillar come into contact with the pipe again in future, a SylWrap HD Pipe Repair Bandage was applied over the top of the Wrap & Seal.

The resin within SylWrap HD was activated with water and the bandage wrapped and smoothed around the pipe. It cured in minutes, encompassing the entire repair with a rock hard sleeve capable of protecting the pipe from impact by the pillar.

Applying Wrap & Seal and SylWrap HD took less than one hour. The biodigester tank was put back into service the following day and with no issues regarding the efficiency or performance of the system noticed, the pipe repair was deemed a success.

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: Reinforced Welded Corners in Chromic Acid Tank Sealed Using SylWrap HD

A chromic acid tank at a factory in Argentina undergoes repair to heavily corroded corners using SylWrap HD Pipe Repair Bandage

Preventing a chromic acid attack – SylWrap HD seals welded corners in a corroded tank repair

After new corners were welded in place during the repair and reinforcement of a badly corroded chromic acid tank at a factory in Argentina, SylWrap HD provided sealing security against any leaks in the welding.

Case Study Data

Site
Chroming factory
Location
Argentina
Repair Type
Tank repair
Defect
Reinforcement and sealing of corroded tank corners

Products Used

SylWrap HD Pipe Repair Bandage
Composite wrap used to encompass parts and structures which sets rock-hard for ultimate protection

Case Study PDF

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Case Study Details

The iron tank was at a chroming factory in Argentina. It held chromic acid and was used during the re-chroming process of piston parts for oil extraction pumps. It was 10 metres long, 1.5 deep and 1.5 metres wide.

After a long time in service, the tank was suffering from corrosion. The damage was particularly heavy in the corners. The factory decided to repair the chromic acid tank, which involved installing welded reinforcements to each inside corner.

Not wanting to risk the possibility of there being leaks in the welding which could cause a future escape of chromic acid, the factory used SylWrap HD Pipe Repair Bandage to provide additional sealing security to the corners of the tank.

New metal corners were welded to reinforce the corners of the tank. These were then covered in SylWrap HD

The normal method of application for SylWrap HD is to activate the resin, then wrap around the pipe or structure requiring repair whilst the bandage cures to form a rock hard material.

Wrapping was obviously not possible to the inside of the tank. Instead, the factory unwound their SylWrap HD and cut it into patches, making sure not to contaminate the bandage with dirt or grime.

These patches of SylWrap HD were then activated and smoothed as tightly as possible up the entire 1.5 metre length of the welded reinforcement, creating a watertight seal between the weld and the existing frame of the tank.

The corner of a chromic acid tank having undergone repair and reinforcement using SylWrap HD Pipe Repair Bandage
Complete repair with patches of SylWrap HD encompassing the welded corner, sealing any potential holes or cracks

SylWrap HD was applied to all four corners of the tank in this way. Within 10 minutes of application, it had completely set to encompass each welded corner and cover any gaps or holes which may have otherwise been left exposed.

The final stage of the tank repair saw an acid-resistant PVC covering added. Whilst SylWrap HD offers good resistance against chemicals including sulphuric acid (which is a stronger concentration than chromic acid), this additional step was taken with the aim of further protecting the entire tank from future corrosion and attack.

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

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

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

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

Case Study Data

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

Products Used

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

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

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

Case Study PDF

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Case Study Details

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

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

The hose was in a confined space making a repair difficult

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

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

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

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

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

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

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

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

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Case Study: Wastewater Treatment Plant Seal Pipe Flange Against Tree Root Ingress

A pipe flange which had suffered tree root ingress is protected using SylWrap HD Pipe Repair Bandage

Putting down roots – preventing tree ingress from blocking an important pipe in the process of wastewater treatment

When a tree penetrated an underground 1800mm pipe between flange plates connecting to a chlorine contact tank, a wastewater treatment plant needed to seal the line and protect it against future root ingress.

Case Study Data

Site
Wastewater treatment plant
Location
South East England
Repair Type
Flange repair and reinforcement
Defect
Tree root ingress between flange plates on 1800mm underground pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape which fuses to form a solid rubber band for the sealing of live leaks

SylWrap HD Pipe Repair Bandage
Composite repair wrap with a water activated resin which sets in minutes to form a rock hard protective shell

Case Study PDF

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Case Study Details

The 1800mm underground steel pipe brought wastewater to the chlorine contact tank for the final stage of the treatment process. Known as tertiary treatment, it involves introducing chlorine to remove harmful pathogens which can cause diseases including cholera, polio, and typhoid.

After a significant reduction in performance was noticed, the ground around the pipe was excavated to identify the problem. It was discovered that a tree root had penetrated between two flange plates. This had caused a blockage of the pipe and potential recontamination of water which had undergone the majority of the wastewater treatment process.

A small amount of water was seeping through the gap caused by the tree ingress. Once the root was removed from the pipe, the plant needed a method to seal the leak and protect the flange against ingress occurring again.

The water company operating the plant sought technical advice from Sylmasta. Because the flange was 100mm thick, there was enough surface area for it to be repaired and reinforced using the normal SylWrap method for a live leak repair.

Wrap & Seal Pipe Burst Tape was wrapped over the point where the two flange plates connected. Wrap & Seal is a self-amalgamating repair tape which stretches by 300 percent, fusing to form a solid rubber band over leak areas.

Several Wrap & Seal Tapes were applied on top of each other, bonding together to build pressure resistance. The application of tapes continued until no more water was seeping from the pipe. Once the flange had been successfully sealed, attention turned to preventing future tree root ingress of the pipe.

A pipe flange suffering from tree root ingress is protected using SylWrap HD Pipe Repair Bandage
SylWrap HD was applied over the 100mm thickness of the flange which had been sealed with Wrap & Seal

The flange was next wrapped in SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water-activated resin. It sets in minutes, curing to form an impact resistant sleeve around pipes and structures.

A SYL412HD Bandage was used as its 100mm width meant it fitted perfectly over the flange plates. With SylWrap HD providing a rock hard shell around the flange, future tree roots growing in the direction of the pipe once it was reburied would be unable to penetrate the weak spot between the plates.

SylWrap HD Pipe Repair Bandage applied over the top of a flange to protect as steel pipe at a wastewater treatment plant from tree root ingress
A SYL412HD Bandage was used as its 100mm width perfectly covered the width of the flange

Wrapping the flange with both Wrap & Seal and SylWrap HD took less than an hour. The water company were delighted with the speed of the application and the lack of disruption carrying out the repair caused.

The plant remained fully operational throughout the repair, compared to the significant downtime it would have faced in isolating both the pipe and the chlorine contact tank had the flange needed replacing.

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: Pipe Capping of Decommissioned Underground Drainage System at Landfill Site

A pipe stub undergoes encapsulation at a landfill site in Cardiff after capping

Limiting leachate from landfill – a pipe stub undergoes encapsulation to further reinforce it after capping

A landfill site in Wales encapsulates a pipe stub and flange plate after capping to protect it against corrosion and a potential future failure, ensuring a decommissioned drainage system could not release toxic leachate into the environment.

Case Study Data

Site
Landfill site
Location
South Wales
Repair Type
Encapsulation of pipe stub
Defect
Reinforcement of stub and flange plate after pipe capping

Products Used

Liquid Metal Epoxy Coating
Brushable epoxy coated onto pipes and structures to create a metallic surface which protects the original metalwork from corrosion

SylWrap HD Pipe Repair Bandage
Composite repair wrap with a water activated resin which sets in minutes to form a rock hard protective shell

Case Study PDF

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Case Study Details

A series of underground drainage pumps were found to not be working at the landfill site in South Wales. Drainage is vital on landfill as it is important that rainwater does not flood, gather or pool on the site unchecked to mix with other fluids, which will often be toxic.

Rainwater that does mix with landfill to dissolve environmentally harmful substances is known as leachate. Leachate must be collected and managed properly. If it is allowed to escape into soil, groundwater or surface water, it can have an acute and chronic impact on the environment, causing serious pollution.

Rather than carrying out a complicated and expensive repair of the pumps, it was decided to decommission and replace them with an entirely new drainage system. The old system needed all pipes to be capped off at the start of the network as part of the decommissioning process.

To further reinforce after capping, the landfill site wanted to protect and encapsulate the main pipe stub and its flange plate. This would save it from corrosion and a possible failure in the future, which could lead to the release of leachate.

Despite the pipe stub’s location in a difficult to access area, Liquid Metal was successfully applied

The stub was protruding around 300mm from a concrete wall, located towards the bottom of a chamber. There was very little space to manoeuvre within the chamber and various metal structures above the stub made access more difficult still. The flange plate itself had seven bolts and a tap which needed to be tightly sealed around.

Arch Services were appointed by the site to find a solution. Arch are a Sylmasta approved contractor for major projects and after consultation with Sylmasta technicians, a method for reinforcing the pipe stub after capping was formulated.

Liquid Metal Epoxy Coating used to encapsulate a pipe which had undergone capping to prevent the escape of leachate
Liquid Metal created a new corrosion resistant shield for the flange plate and stub

Liquid Metal Epoxy Coating was first used to protect the pipe stub and flange plate. Liquid Metal is a brushable epoxy which cures to form a new metallic surface when painted over pipework and other structures. It offers excellent protection against corrosion and chemicals by acting as an external shield.

Several coatings of Liquid Metal were painted all over the pipe stub and flange plate. Whilst the final coating had gelled but remained a little tacky, the stub was then encapsulated with SylWrap HD Pipe Repair Bandage.

SylWrap applied to a pipe stub for encapsulation after a pipe undergoes capping
The entire stub was encapsulated with SylWrap HD Pipe Repair Bandage to complete the repair

A SYL633HD bandage was used. The resin was activated with water and the bandage wrapped around the stub and smothered over the plate. More water was applied to smooth the wrap, which cured to form a rock-hard, impact resistant covering of the stub.

Arch said after the successful completion of the application: “Given the protruding bolts and cramped application position, this was not a ‘pretty’ repair. But it absolutely did the job!” The site now had full confidence that the capped pipe would not fail in future.

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 Leaking Effluent Pipe Running out to Sea Underneath Salt Marshes

A leaking effluent pipe under salt marshes undergoes a SylWrap repair in an eight hour window whilst the tide was out

Against the tide – the leaking effluent pipe repair beneath salt marshes that had to be completed in under eight hours

A chemical plant in the UK faced a logistically challenging repair, needing to seal a leaking 350mm effluent pipe running underneath salt marshes and out to sea with only an eight hour timeframe to work whilst the tide was out.

Case Study Data

Site
Chemical plant
Location
United Kingdom
Repair Type
No pressure leak repair
Defect
Corroded steel pipe leaking in numerous areas from a defective clamp

Products Used

Sylmasta AB Original Epoxy Putty
Super-strength, waterproof epoxy putty capable of sealing leaks underwater and in aggressive environments

SylWrap HD Pipe Repair Bandage
Composite repair wrap which sets rock hard in minutes to reinforce leak repairs and strengthen and protect pipelines

Case Study PDF

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Case Study Details

The 350mm steel pipe carried effluent from the chemical plant underneath salt marshes and out to sea. It had undergone a repair just one year earlier, which was now discovered to have failed.

When originally installed in the 1960s, the steel had been coated in cement for reinforcement. The previous repair had consisted of removing part of the cement and covering the heavily corroded and perforated section of steel pipe with a clamp.

The pipe could only be accessed when the tide left the salt marshes, via digging by hand

The line’s location under the salt marshes made any repair logistically challenging. The pipe could only be accessed when the tide went out, after pumping away seawater and then digging by hand through sludge. No heavy tools or machinery could be transported onto the marshes to help dig as it would simply sink.

When nature ran its course and the tide then came back in, the pipe was flooded again and so the process had to begin from scratch. This left only an eight hour window in which the pipe was under dry conditions and could be worked on.

350mm steel effluent pipe located underneath salt marshes prior to undergoing leak repair
Excavation revealed the pipe to be leaking from both ends of a clamp

The chemical plant appointed a specialist marine engineering contractor to formulate a repair method. First, the pipe was excavated for inspection. This revealed it to be leaking from both ends of the pipe repair clamp.

To complicate matters further, the steel had now deteriorated significantly. The wall of the pipe was so thin beneath the clamp that the contractor was concerned removing the original repair could have led to the collapse of the line.

Water was pumped out of the hole to access the pipe for the repair
A wooden framework created a safe working area around the line

The contractor consulted Sylmasta, who recommended encapsulating the clamp with a waterproof material to seal it. Further protection could then be provided with a composite wrap. All products used in the repair had to be applied and functional quickly because of the short timeframe in which the pipe was accessible.

As soon as the tide went out, the process of excavating the pipe began again. Sludge was removed from the hole and water pumped away. A temporary wooden framework was built around the pipe to create a safe working area. Sylmasta AB Original Epoxy Putty was then applied around the entire clamp for the purpose of sealing the leak areas.

The clamp in the centre of the pipe was to be encapsulated with Sylmasta AB Original
Sylmasta AB Original Epoxy Putty is applied to a leaking effluent pipe to seal and repair the line
AB Original was applied around the clamp, creating a watertight seal

AB Original is a waterproof, super-strength epoxy putty with a two hour work time. Once cured, it would easily withstand the harsh environment of the salt marshes. The putty was mixed by hand and pushed onto the clamp, filling all holes and cracks through which effluent had previously escaped.

Two inspection hatches were then cut into the steel pipe either side of where the putty had been applied, so the inside of the line could be accessed. Reaching through these hatches, the contractors were able to coat the interior of the pipe with a liquid metal epoxy coating.

Inspection hatches were cut into the pipe, through which an epoxy coating could be applied to re-line the weakened interior
This left the pipe with two sealed inspection hatches and the entire clamp encapsulated with AB Original

Liquid metal cured inside the pipe to provide a new metallic lining, increasing the sealing security of the repair and restoring wall thickness. The two inspection hatches were then fitted with cover plates and firmly sealed.

A concrete coating was next reapplied over the pipe, and the entire excavated section wrapped with several layers of SylWrap HD Pipe Repair Bandage. SylWrap HD is a water-activated composite wrap which sets rock hard in minutes.

SylWrap HD Pipe Repair Bandage is applied to a 350mm effluent pipe in a complex leak repair application
The line was covered in rapid concrete and wrapped with SylWrap HD across its entire length
SylWrap HD restored integrity to the entire pipe, protecting it from the sludge and seawater which would return with the tide

Numerous bandages were smoothed and wrapped around the pipe, curing to form a reinforced protective sleeve. This restored the integrity of the line, uniting and strengthening both the weak and solid areas of the repair.

The speed and ease with which AB Original and SylWrap HD could be applied enabled the application to be completed within the eight hour window. By the time the tide returned to the salt marshes, the pipe had been successfully sealed ahead of being covered with mud and seawater again.

Following the completion of the effluent pipe repair, the contractors told Sylmasta that they were very impressed with the products and the technical assistance provided. They are intending to use AB Original again on a similarly complex application for another client in the near-future.

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 Pipe Repair of Above and Below Ground Water Supply Pipelines

A cracked water supply pipe in Libya having undergone a completed repair with a SylWrap Universal Pipe Repair Kit

Two for the price of one – Underground and overground live leak repair to a water supply pipe network in Libya

One above-ground water pipe and one below-ground water pipe servicing a town in Libya as part of a supply network required live leak repair to seal cracks through which significant levels of water were escaping.

Case Study Data

Site
Water supply network
Location
Brega, Libya
Repair Type
Live leak pipe repair
Defect
Cracks in two sections of 100mm steel pipe operating at 5 bar pressure

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating repair tape used to seal high pressure leaks on both sections of pipe

SylWrap HD Pipe Repair Bandage
Composite wrap applied to reinforce the repaired areas with a rock hard, impact resistant sleeve

SylWrap Universal Pipe Repair Kit
Kit containing Wrap & Seal and SylWrap HD Pipe Repair Bandage for making fast, live leak pipe repairs

SylWrap Pipe Repair Contractor Case
Case with enough products to make multiple pipe repairs, which could have been used here if available rather than 2 x Universal Kits

Case Study PDF

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Case Study Details

Around 80 percent of the population of Libya live along or near the northern Mediterranean coast. With freshwater scarce, they rely on supplies being pumped via pipelines from aquifers in the south – known as the Great Man Made River of Libya.

The town of Brega in the north east is serviced by a network of 100mm steel water pipes running both above and below ground, connecting to the Great Man Made River. At least one underground leak was known about through visible signs in the earth surrounding the pipe.

Attending to the problem had never been a priority because of the complexity and cost involved in excavating the pipe, shutting down the line and then either repairing or replacing the leaking section.

The leak was not visible and so it could be ignored. This school of thought was changed when a section of above ground pipe developed a longitudinal split, through which significant amounts of water were escaping at around 5 bar pressure.

Water pouring from the split in the above ground pipe

A blind eye could not be turned to such a substantial leak causing flooding to the area underneath the pipe. The importance of the line meant it could not be isolated whilst the line was fixed or replacement took place.

It was decided to use a SylWrap Universal Pipe Repair Kit to make a live leak repair. All the products contained within the Kit are WRAS approved, meaning they are safe to use with drinking water.

First, Wrap & Seal Pipe Burst Tape was applied to seal the pipe. Wrap & Seal stretches by 300 percent and self-amalgamates to form a solid rubber band capable of sealing high pressure leaks.

The tape was anchored to the side of the split and then wrapped towards and over it. Once the split had been covered, layers of Wrap & Seal were built up until no more water was detected leaking from the pipe. This indicated a successful repair.

A SylWrap HD Pipe Repair Bandage applied to an above ground water supply line as part of a live leak repair
The above ground pipe successfully repaired with SylWrap HD

To reinforce the line, a SylWrap HD Pipe Repair Bandage was then applied. SylWrap is a composite wrap with a water activated resin which sets rock hard in minutes. It was wrapped and smoothed across the entire repair area, creating an impact resistant protective shell around the pipe.

Completing the repair took less than 30 minutes. Having seen how quick and easy the SylWrap Universal Kit was to use, the decision was taken to proceed with the repair of the leaking underground section of water supply pipe.

An underground water supply pipe is excavated and leak sealed using a SylWrap Pipe Repair Kit
The below ground pipe having been excavated and repaired

A trench was dug to reach the line with enough clearance underneath so that both Wrap & Seal and SylWrap HD could be applied. The defect in this pipe was a smaller crack easily arrested using the same repair method as with the above ground pipe.

Two leaking sections of water supply pipe had now been successfully repaired without disruption to homes and businesses in Brega. More importantly, there was now an awareness of how quick and easy pipe repair can be.

Future leaks are now set to be tackled with SylWrap Pipe Repair Kits as soon as they are identified, something which can help make a huge difference in an arid country like Libya.

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

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

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

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

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

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

Case Study Data

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

Products Used

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

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

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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