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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: 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: 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: 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

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Case Study: Emergency Repair of Hospital 300mm Air Conditioning Pipe on Hottest Day of June

A water return pipe in a Lonndon hospital air conditioning unit undergoes a SylWrap repar to ensure that the system could remain in operation

Keep cool and carry on – a SylWrap repair gets a hospital air conditioning system back in operation on the hottest day of June

On a day when temperatures in London reached 27ºC, a burst 300mm water return pipe forced the shutdown of a hospital air conditioning system until a SylWrap emergency leak repair was made

Case Study Data


Site
Hospital
Location
London, United Kingdom
Repair Type
No pressure leak repair
Defect
Two deep cavities in a 300mm air conditioning water return pipe operating under 12 bar pressure

Products Used


Superfast Steel Epoxy Putty Stick
Fast setting epoxy putty used to fill in the deep cavities in the water return pipe

Wrap & Seal Pipe Burst Tape
Multiple self-fusing silicone repair tapes provided additional leak sealing security

SylWrap HD Pipe Repair Bandage
Two layer application completed the repair with an impact resistant protective sleeve

Case Study PDF


Case Study Details


The 300mm water return pipe was located in a cabinet alongside other service pipes. It burst through a previous repair attempt, requiring an immediate shutdown of the air conditioning system as water escaping the pipe at 12 bar pressure would have caused internal flooding.

This shutdown left the hospital building without any temperature control on the hottest day of the year. The burst was initially discovered in the middle of Sunday night, at which point the hospital immediately contacted their maintenance team.

The maintenance team arrived at Sylmasta HQ first thing on Monday morning to collect the products needed to carry out a repair. Sylmasta technicians were also able to offer technical assistance based on photos of the burst air conditioning pipe.

Coarse fibreglass strands remained on the pipe from the previous repair. It was decided to cut these away to enable the maintenance team to locate the actual leak site and have a better chance of sealing it.

Two distinct leak areas were stripped back, revealing two deep cavities in the pipe. These were filled with Superfast Steel Epoxy Putty, a fast curing putty supplied in stick format.

Superfast Steel is kneaded by hand and pushed into areas of damage whilst soft. Within 5 to 10 minutes, the putty had hardened to seal the cavities in the pipe.

Because of the inconsistent substrates in this case, it was decided to take a ‘belt and braces’ approach to the repair and use Wrap & Seal Pipe Burst Tape to provide additional leak sealing security.

The entire leak area was wrapped with multiple layers of Wrap & Seal, a self-amalgamating silicone repair tape which fuses to form a solid rubber band for high-pressure resistant repairs.

Combining Superfast Steel and multiple Wrap & Seals created a repair with resistance to the required 12 bar and ensured that there was no chance of seepage of water around the epoxy putty.

Once it had been established that the leak had been completely sealed, the application was finished with the wrapping of two SYL866HD SylWrap HD Pipe Repair Bandages over the repair.

SylWrap HD is a water activated composite wrap which sets rock hard in minutes. It provided a protective sleeve around the pipe, reinforcing the repair even further.

As the temperature began to heat up during Monday morning when the pipe remained out of operation, numerous alarms in the hospital building were triggered as equipment and machinery began to overheat without any air conditioning.

A 300mm water return pipe in a London hospital's air conditioning system is repaired using a SylWrap HD Pipe Repair Bandage
Repair completed with SylWrap HD

The ease and speed with which the products in the SylWrap Pipe Repair range can be applied meant that by Monday afternoon, the pipe was fixed and the air conditioning system back in operation.

Without the repair method and the technical assistance provided by Sylmasta, the hospital could have gone days without any air conditioning – a clearly unsustainable situation when temperatures in London were peaking at 27ºC.

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: Buried 600mm Asbestos Cement Pipe Leaking Sleeve Repair in Mexico

A leaking asbestos cement pipe with water escaping from a sleeve undergoes repair in Mexico using a SylWrap Pipe Repair Kit

The 600mm asbestos cement pipe repair which showed Sylmasta have all kinds of tricks up their sleeve

When a water utility company in Mexico discovered that a 600mm asbestos cement pipe was leaking from both ends of a sleeve, they needed to access the buried line and seal the gaps with a repair method flexible enough to be effective when applied in a trench.

Case Study Data


Site
Pipeline
Location
Mexico
Repair Type
No pressure leak repair
Defect
Leaking sleeve on a 600mm asbestos cement pipe

Products Used


Superfast Copper Epoxy Putty Stick
Fast-working epoxy putty pushed into gaps between the sleeve and the pipe to seal the leaks

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape used to force Superfast Copper further into the gaps, strengthening the repair

SylWrap HD Pipe Repair Bandage
Applied over the sleeve to provide an impact resistant layer of protection

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


The water utility company had been carrying out maintenance work on a 500mm buried pipeline outside the city of Morelia, around a four hour drive from Mexico City.

Whilst undertaking this work, it was discovered that there was a failure in a 600mm asbestos cement parallel line. Water was escaping from both ends of a sleeve on the 600mm pipe.

To replace this damaged section would have been difficult; the pipeline passed under a building less than 10 metres away from the location of the leaking sleeve. Excavation of the pipe would also have been challenging.

A trench was dug to access the asbestos cement pipe, affording 500mm of space on one side, 1.7 metres on the other and minimal space between the line and the ground. Any repair method therefore needed to be effective in tight spaces.

Superfast Copper Epoxy Putty was used to plug the gaps between the sleeve and the surface of the pipe, through which water was escaping.

The Putty was kneaded by hand and pushed firmly into the gaps at both ends of the sleeve. Within 10 minutes, the Putty had begun to harden to seal the space.

To further reinforce the putty and add another leak sealing layer, each joint was wrapped with a Wrap & Seal Pipe Burst Tape. Despite the space constraints, the Tape was stretched by the maximum 300 percent to form a solid silicone band.

Completing the application, a SylWrap HD Pipe Repair Bandage was used to encompass the entire sleeve. SylWrap HD provided one final, impact resistant layer of protection to the pipe before it was re-buried.

All the products required for the repair were supplied as part of a SYL-PRO-50-150 SylWrap Pipe Repair Contractor Case, containing enough products to make up to six live leak repairs.

In this instance, the Case was the most suitable product as multiple Wrap & Seal and SylWrap HD were required due to the size of the asbestos cement pipe requiring repair.

The purpose of the Contractor Case normally though is to allow regular users to carry out several repairs. It is designed to be kept on-site or on the van, enabling rapid response to leaks when they are identified.

With the water utility company currently investing in leak detection technology, Sylmasta are providing assistance as to how the problems that the new technology identifies can be repaired as quickly as possible.

The Contractor Case works hand-in-hand with leak detection, equipping contractors with everything they need to fix leaks and burst as soon as they are discovered.

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 an 80mm Split to a Plastic Hose Supplying Water to a Pond

A longitudinal split in a plastic hose supplying water to a bond undergoes repair with a SylWrap Universal Pipe Repair Kit

Not sleeping with the fishes – a lengthy split in a plastic hose supplying water to a pond undergoes repair

During landscaping work, a pruning saw caused serious damage across a 300mm area of an unnoticed plastic hose supplying water to a pond, including a 80mm longitudinal split requiring repair.

Case Study Data


Site
Domestic Property
Location
United Kingdom
Repair Type
Leak repair
Defect
80mm longitudinal split and 300mm of damage to a plastic supply hose

Products Used


Wrap & Seal Pipe Burst Tape
Self-fusing silicone repair tape used to seal the split and other leaks

SylWrap HD Pipe Repair Bandage
Composite repair wrap provided an impact resistant layer to protect the repair and the hose

SylWrap Universal Pipe Repair Kit
The property owner was supplied with a Universal Pipe Repair Kit containing both products

Case Study PDF


Case Study Details


The pond was on a property cut into the side of a hill with a retaining wall behind it. The roots of shrubs, ivy, and other plants and weeds above the wall were beginning to cause damage to the structure and so the property owner decided to cut some of them away with a pruning saw.

Unfortunately, the owner did not realise that buried just beneath the soil was a hose made from industrial grade plastic supplying water to the pond. As they attempted to remove the shrubs using the saw, they inadvertently cut into the hose.

A plastic hose inadvertently cut into with a pruning saw prior to undergoing a SylWrap repair
Water spraying from the 80mm split in the plastic hose

The damage to the hose was severe with a 80mm longitudinal split from which pressurised water was spraying out. There were several smaller leaks either side of the main split, leaving a 300mm area of hose requiring repair.

Gaining access to make a hose repair was extremely difficult because of the roots, the shrubs and the proximity of the retaining wall. To repair the split in the plastic hose, a versatile solution was therefore needed.

The split in the hose once water pressure had been turned off

Sylmasta supplied the property owner with a SylWrap Universal Pipe Repair Kit for sealing live leaks, containing SylWrap HD Pipe Repair Bandage and Wrap & Seal Pipe Burst Tape. An additional roll of Wrap & Seal was included due to the 300mm coverage of the repair area.

Water supply was turned off and the hose was cleaned to remove all traces of soil. A plastic sheet was then placed underneath the hose to prevent any further soil or grit being picked up during the application of the Wrap & Seal, which was wrapped across the entire damaged section.

Despite the space constraints around the hose, the Wrap & Seal was successfully stretched by the maximum 300 percent. It fused to form a solid rubber band which sealed the 80mm split and the other smaller leaks present.

The repair was finished by wrapping SylWrap HD over the Tape. The water-activated composite repair wrap provided a rock hard, impact resistant layer in minutes to protect the hose prior to it being reburied in the ground.

Completed repair of a leaking plastic hose suffering from a 30mm longitudinal split
Completed repair of the split plastic hose

Completing the repair took less than 30 minutes and cost under £40. Afterwards, the property owner contacted Sylmasta to say: “There are no longer any leaks in the hose, so I am very happy with the repair.”

“SylWrap is an excellent piece of kit which I wish I had come across years ago and the technical assistance I received from Sylmasta was very much appreciated.”

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: Leak Repair & Encapsulation of a Steel & Iron Welded Pipe Joint

Pipe repair of a central heating system in a church which had begun to leak around a welded joint suffering from corrosion

Good deed done – Sylmasta answer a church’s prayers with a welded pipe leak repair and encapsulation

A church central heating system had suffered heavy damage caused by corrosion and begun leaking at the point where a 100mm cast iron pipe met a 50mm steel pipe via a welded steel plate, leading to a challenging leak repair and encapsulation application.

Case Study Data


Site
Church
Location
United Kingdom
Repair Type
Leak Repair
Defect
Leaking welded joint between a 100mm cast iron pipe, a 50mm steel pipe, and a 6mm steel plate

Products Used


Sylmasta AB Original Epoxy Putty
Epoxy putty with two-hour work time allowing for careful application and watertight encapsulation of the leaking joint

Wrap & Seal Pipe Burst Tape
Self-fusing silicone repair tape used initially to seal leaks on the 100mm cast iron pipe

SylWrap HD Pipe Repair Bandage
Applied over Wrap & Seal to provide a rock hard, impact-resistant layer to the initial repair.

Case Study PDF


Case Study Details


Several years previously, the central heating system in the church had undergone renovations when a 100mm cast iron pipe had been stepped down to a 50mm steel pipe.

To facilitate this, a 6mm thick steel plate had been attached to the end of the larger cast iron pipe with a hole cut into the middle, through which the smaller steel pipe was attached and welded.

Since the work had been carried out, the system had become badly corroded and was now leaking from numerous areas around the welded joint.

When a similar problem had developed on another heating pipe, the church had fitted a pipe repair clamp at considerable expense. Such a repair method was not possible on this occasion as the new leak was in a restricted space with no room for a clamp to be applied.

Initially, the church called in welders to try and fix the problem, but this just caused further leakage and left an even more uneven pipe surface needing to be sealed.

Diagram showing the repair in question

The main leak was between the steel plate and the 100mm cast iron pipe with particularly heavy corrosion at the point where they met. Once the corrosion was filed back, this was relatively straightforward to repair using a SylWrap Universal Pipe Repair Kit.

Wrap & Seal Pipe Burst Tape was applied around the pipe, fusing to form a solid rubber band over the problem area to seal the leak. This was then overwrapped with a SylWrap HD Pipe Repair Bandage, providing a rock hard, impact resistant shell to reinforce the initial repair.

More challenging was the repair of the joint between the smaller 50mm steel pipe and the steel plate. Here, leaking was caused by uneven welding, whilst a threaded section of pipe close by was also suffering from a leak.

It became clear that a softer repair material was needed to smear into the threaded section and to penetrate into the weld. Because of the complexity of the repair, Sylmasta recommended Sylmasta AB Original Epoxy Putty.

AB Original is a smooth-setting epoxy with a two hour cure time. This longer working time allowed for the putty to be more carefully applied, encapsulating the whole section where the 100mm pipe, the 50mm pipe, and the steel plate all met.

The church were supplied with 1kg of Sylmasta AB, more than enough for their application. Unused AB Original stays fresh when left in its original packaging, ensuring the church has a supply of epoxy putty for any future applications.

Sylmasta AB Original putty was smoothed over the welded joint, filling in all imperfections and sealing all leak areas. It has excellent corrosion resistance, further protecting the pipe from future attack, and provided a smooth, ceramic-like finish to the application.

When the church first contacted Sylmasta, they had been looking for a repair method that would temporarily fix the leaking central heating system until funds allowed for either a longer lasting solution or for a new pipe to be installed.

Instead, the repair provided by Sylmasta will be permanent and was made at a fraction of the cost of other options, saving the church a considerable amount of money.

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

Posted on

Case Study: Stainless Steel Pipe Repair Inside a Biomass Plant Heating Tank

A stainless steel pipe in a biomass power plant at a UK farm required a different live leak repair using a SylWrap Universal Pipe Repair Kit

SylWrap and biomass – the repair of an inaccessible stainless steel pipe in a biomass plant heating tank

Small pieces of farmyard debris had inadvertently entered a Norfolk farm’s biomass plant as part of feedstock, breaching a stainless steel pipe at the top of a 20 feet tall heating tank which now required a flexible and lightweight repair carried out from a ladder.

Case Study Data


Site
Biomass plant on an agricultural site
Location
Norfolk, United Kingdom
Repair Type
Leak Repair
Defect
Damaged stainless steel pipe

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 the pipe from further damage

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

Case Study PDF


Case Study Details


Anaerobic digester biomass plants are becoming more common on farms in the United Kingdom. They turn waste organic material – known as feedstock – into gas used for fuel and nutrients for crops. Feedstock can include specially grown plant matter, other waste plant material and animal manure.

At the core of a biomass plant system is its digester. Here, the feedstock is fed into an airless container where it ferments. A gas called biogas is captured from the process and used for fuel. The farm uses this fuel to power itself and can even sell surplus energy to the national grid.

The remaining material is known as digestate and is separated into liquid and solid form. The liquid digestate is sprayed back onto the farm as fertiliser. The dried-out solids have multiple uses, including in animal bedding and creating fibre plant pots.

Before adding the initial feedstock to the digester, the biomass plant on the farm in Norfolk had a pre-heating tank. Here, the farm mixed feedstock with some liquid digestate and heated it to the same temperature as the main digester. This enabled them to avoid adding cold feedstock straight to the digester, which can impact on the fermentation process.

A leaking stainless steel pipe in a biomass power plant boiler is repaired with a SylWrap Universal Pipe Repair Kit
The damaged pipe was located high up the inside of the heating tank

Multiple stainless steel pipes were located around the inside of the heating tank. It was one of these towards the very top which had become damaged when small pieces of farmyard debris had inadvertently been mixed in with the feedstock and dropped into the tank from the inlet above.

The farm’s preferred method of dealing with pipe repair applications was to weld. This though was not feasible; the leaking stainless steel pipe was located in a confined space at a height of 20 feet with access only available via a ladder.

To repair the leaking pipe in the biomass boiler power plant, the farm therefore needed a flexible repair method involving lightweight materials which could be easily applied from the top of a ladder.

The damaged section of steel pipe was only accessible from the top of a ladder

Sylmasta recommended a SylWrap Universal Pipe Repair Kit for the application. Wrap & Seal Pipe Burst Tape was wrapped around the pipe, fusing into a solid rubber band over the leak area for a high-pressure repair.

A SylWrap HD Pipe Repair Bandage was then applied over the top of the Wrap & Seal. SylWrap HD features a water-activated resin. It cures within five minutes to provide a rock-hard, impact resistant layer to the pipe.

The materials in the SylWrap Universal Pipe Repair Kit are temperature resistant to 200ºC, enabling the repair to withstand conditions within the heating tank. To further protect the pipe, a steel deflector plate was tied to the top of the SylWrap HD Bandage.

A steel deflector plate was tied to the top of the SylWrap HD Bandage after completion of the repair

Completing the repair took less than 30 minutes, cutting downtime of the biomass plant to a minimum. It was carried out by the farm’s own engineers, negating the need to hire contractors, and cost a fraction of fitting a replacement pipe.

The engineer in charge of the repair told Sylmasta afterwards he was pleased with how straightforward the application had been. With pipes a huge part of biomass systems and agriculture in general, Sylmasta are now advising on other ways in which their pipe repair solutions could benefit the sector.

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