Tag: Wrap & Seal Pipe Burst Tape

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Case Study: Leaking Dishwasher 50mm Plastic Pipe Repair in Golf Clubhouse Kitchen

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

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

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

Case Study Data

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

Products Used

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

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

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

Case Study PDF

Download

Case Study Details

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

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

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

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

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

The split went around the diameter of the plastic pipe

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

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

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

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

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

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

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

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

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

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

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

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Case Study: Repair of Leaking Expansion Joint Fitted to Water Main Pipe on UK Road Bridge

A leaking expansion joint on a 225mm steel water main pipe undergoes repair with Wrap & Seal Pipe Burst Tape

Contracting a leak from an expansion joint – Wrap & Seal repair keeps water supply strong between two counties

A water company in southwest England repair a leaking aluminium expansion joint fitted to a 225mm steel water main pipe, running the length of a suspension bridge carrying a major A road over a river.

Case Study Data

Site
Road suspension bridge
Location
United Kingdom
Repair Type
Expansion joint repair
Defect
Leaking expansion joint fitted to a 225mm steel water main pipe

Products Used

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

SylWrap Pipe Repair Contractor Case
Three PB-50x4m Wrap & Seal Tapes were used from a Contractor Case containing enough products to make up to six pipe repairs

Case Study PDF

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Case Study Details

The 335-metre-long suspension bridge linked Devon and Cornwall with the main helping transport water between the two counties. The aluminium expansion joint was fitted to reduce stress on the steel pipe caused by the movement of the bridge.

After it became known the pipe was leaking, a team of engineers accessed the pipe. It ran beneath the road deck of the bridge in a severely constrained space.

The steel water main ran beneath the bridge road deck in a severely constrained space

They discovered a split in the expansion joint between two bellows, through which water was now flowing out. Comparing the position of the fitting from its previous mandatory safety inspection revealed it had moved and contracted significantly.

For this reason, the water company needed a flexible live leak repair solution which could seal the leaking expansion joint but also allow for future movement of the fitting.

The expansion joint was leaking through a split between the final two bellows on the righthand side

They therefore decided to use Wrap & Seal Pipe Burst Tape for the application. Wrap & Seal self-amalgamates as it is wrapped around a pipe, forming a rubber band which exerts pressure over the leak to contain pipe content.

On the day of the repair, the expansion joint had contracted to the point of failure. Whilst this meant the engineers were not battling a stream of water, it reduced the available space between the bellows into which Wrap & Seal could be applied.

Engineers apply Wrap & Seal Pipe Burst Tape during the repair of a 225mm steel water pipe expansion joint
Wrap & Seal was wrapped between the bellows, over the split in the joint

The versatility of Wrap & Seal still made a repair possible. Despite the space constraints, the engineers were able to stretch the tape by its maximum 300 percent to achieve full amalgamation.

Multiple Wrap & Seals wrapped on top of each other fuse together in the same way, increasing pressure resistance. Three PB-50x4m Wrap & Seals were applied until no more water was seeping from the pipe, leaving the engineers satisfied the leak had been fully arrested.

Wrap & Seal Pipe Burst Tape used to repair a leaking expansion joint on a 225mm steel water main pipe
The completed repair left a solid rubber band compacted over the leak, containing pipe content

By the time the repair was complete, a solid rubber band had been compacted over the leak, filling the gap between the two bellows. Measurements were then taken of the expansion joint, so a replacement could be made and fitted at a later date.

The three PB-50x4m Wrap & Seal Tapes used in the repair came from a SYL-PRO-50-150 SylWrap Pipe Repair Contractor Case, a product the water company had recently approved to be carried by all engineers for use on their network.

A Contractor Case is easily stored on-site or on a van and contains enough Wrap & Seal, Superfast Steel Epoxy Putty and SylWrap HD Pipe Repair Bandages to make up to six WRAS approved live leak repairs.

Feeding back to Sylmasta after the expansion joint repair, the engineers said: “The SylWrap Contractor Case was extremely useful in the scenario. Having a variety of products within the repair pack provided plenty of options to us once the problem had been fully evaluated.”

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

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

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

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

Case Study Data

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

Products Used

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

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

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

Case Study PDF

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Case Study Details

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Case Study: Emergency Live Leak Pipe Repair Keeps Heating on at Nursing Home

SylWrap Universal Pipe Repair Kit seals a leaking heating pipe at a nursing home

Winter is coming – and a SylWrap Universal Pipe Repair Kit keeps the heating on at a nursing home

The maintenance manager of a nursing home drives to Sylmasta HQ, collects a SylWrap Universal Pipe Repair Kit and makes a live leak repair to a 150mm metal pipe to keep the heating system running and residents warm.

Case Study Data

Site
Nursing home
Location
United Kingdom
Repair Type
Live leak pipe repair
Defect
Pinhole leak in 150mm metal heating pipe

Products Used

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

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap which sets rock hard in minutes to reinforce and protect repairs

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

Case Study PDF

Download

Case Study Details

Sylmasta offices received an early morning phone call from a panicked maintenance manager of a nursing home in the south of England. A 150mm metal pipe in the heating system running through loft space had developed a pinhole leak.

A constant, steady drip of water was escaping the pipe and saturating the surrounding loft space. Shutting off the pipe to stop the leak whilst waiting for a plumber or heating engineer to make a repair or replacement would have left the nursing home without heating. This was not an option with winter approaching.

The nursing home therefore needed to make a live leak repair that same day to ensure residents were kept warm and prevent significant water damage in the loft space.

Heating pipe at a UK nursing home leaking through a pinhole before undergoing repair with a SylWrap Universal Kit
A steady drip of water was escaping a pinhole in the metal heating pipe, saturating the surrounding loft space

Immediately after the phone call, the maintenance manager drove 20 miles to Sylmasta HQ in Sussex to collect a SYL-616-UP SylWrap Universal Pipe Repair Kit. A Universal Pipe Repair Kit seals leaking pipes even when pressure cannot be turned off by following a simple two-stage process.

Wrap & Seal Pipe Burst Tape was used to repair the pinhole leak. Wrap & Seal is a self amalgamating waterproof tape which stretches by three times its length. As it is wrapped and applied around a pipe, it fuses to form a solid rubber band containing pressurised live leaks.

One 25mm x 2m Wrap & Seal was applied to the heating pipe, easily withstanding the pressure the pipe was operating at to seal the leak. The second stage of the repair involved overwrapping the tape with a SylWrap HD Pipe Repair Bandage.

SylWrap Pipe Repair Bandage used to seal a leaking heating pipe at a nursing home in England
Wrap & Seal Pipe Burst Tape sealed the pinhole leak with the repair area reinforced with SylWrap HD Bandage

SylWrap HD is a composite wrap with a water activated resin which sets rock hard in minutes. It was wrapped and smoothed around the pipe, curing to form an impact resistant protective shell reinforcing the Wrap & Seal for a permanent repair.

It took the maintenance manager under 30 minutes to repair the leaking pipe once they arrived back at the nursing home, leaving residents none the wiser there was a problem with the heating system.

Not only did a SylWrap Pipe Repair Kit ensure there was no impact to residents, but it cost less than £80 – representing a significant saving compared with an emergency callout for a plumber at a time when many nursing homes in the UK are in deep financial trouble.

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: Oil Refinery Repair Cooling Pipe System Attacked by Microbially Induced Corrosion

An oil refinery repair welded joints leaking due to microbially induced corrosion in the stainless steel water cooling pipe system

MIC at oil refinery – leaking joints in a water cooling system undergo repair to keep facility online despite microbially induced corrosion

A significant pipe repair programme at an oil refinery seals leaks in a stainless steel water cooling system after microbially induced corrosion caused the failure of welded joints across the site.

Case Study Data

Site
Oil refinery
Location
Middle East
Repair Type
Live leak pipe repair
Defect
Leaking welded joints in stainless steel water cooling system caused by microbially induced corrosion

Products Used

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

SylPad Pressure Resistance Multiplier
Increases the pressure resistance of Wrap & Seal by up to three times when making live leak repairs to pipes over 150mm diameter

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap sets rock hard, reinforcing and protecting the initial Wrap & Seal repair

SylWrap Pipe Repair Contractor Case
Easy-to-store Case containing enough Wrap & Seal and SylWrap to make multiple live leak repairs on pipes of various diameters

Case Study PDF

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Case Study Details

The stainless steel water cooling system at the oil refinery was meant to have a lifespan of up to 50 years, yet numerous welded joints across the site were already starting to fail after less than half that time.

Microbially induced corrosion was found to be the cause, a type of corrosion relatively little is known about compared to other forms. It occurs when microbes fix to a surface, producing a biofilm layer where multiple bacteria combine to accelerate the corrosive process.

This biofilm affects the electrochemical environment in multiple ways, including changing ion concentrations, pH values, oxidation levels and creating hydrogen sulphide.

As more biofilm layers form, the bacteria and microbes are given greater protection from treatment methods such as biocides, chemicals and temperature treatments. It becomes increasingly difficult to slow corrosion or eliminate microbes from the pipe system.

Stainless steel normally has enhanced protection against corrosion thanks to its passivation layer, which prohibits microbes attaching and makes a surface less prone to developing biofilms. But if the passivation layer is damaged, microbially induced corrosion will take place.

Installation of the water cooling system at the oil refinery included welding joints together. Unbeknown to the refinery, this had weakened the internal passivation layer of the stainless steel pipework.

When the water cooling system went live, microbes in the water were able to settle on the uneven surface at each welded joint. Bacteria collected and a corrosive action began between the metal and the microbes, attacking the stainless steel from the inside.

Eventually, a series of leaks appeared at welded joints throughout the water cooling system. This represented a major problem at a relatively new and expensively built facility. Replacing the stainless steel pipework was not an option due to the cost and disruption it would cause.

With every welded pipe joint now a potential point of failure, the oil refinery contacted Sylmasta to find a repair solution. Sylmasta recommended the refinery stock a range of different sized Wrap & Seal Pipe Burst Tape and SylWrap HD Pipe Repair Bandages, which permanently seal live leaks when used in conjunction.

Online pipe repair capability was essential to the oil refinery as draining the system would result in at least five days loss of production, along with vast costs for diversion of water.

Over 500 SylWrap HD Bandages and 1,700 Wrap & Seal Tapes were sent to the refinery. Sylmasta also flew to the Middle East and spent a week training, testing and certifying refinery installers and supervisors on using the products.

Workers were shown how to apply Wrap & Seal for high-pressure live leak repair. Wrap & Seal stretches by three times its length and amalgamates together, fusing to form a solid rubber band containing pipe content.

Wrap & Seal Pipe Burst Tape used to repair leaking welded joints in a water cooling pipe system
Multiple Wrap & Seal Tapes applied to leaking welded joints in the water cooling system built repairs with pressure resistance up to 10 bar

Multiple Wrap & Seal Tapes applied on top of each other amalgamate in the same way, building pressure resistance up to 30 bar. This was more than suitable for the cooling system, operating at a maximum 10 bar pressure.

For pipework 150mm diameter or above, workers were also trained in using SylPad Pressure Resistance Multiplier. SylPad is applied alongside Wrap & Seal when making live leak repairs to pipes 150mm diameter and above.

It better concentrates the pressure resistance of Wrap & Seal directly over the leak by directing more of the Tape’s elastic force downwards. Depending on pipe size, nature of the leak and repair quality, SylPad can increase the pressure resistance of Wrap & Seal by up to three times.

The final stage of repair involves overwrapping with SylWrap Bandage. SylWrap is a composite repair wrap with a water-activated resin which sets rock hard in minutes. It provides an impact resistant protective sleeve, reinforcing the repair.

SylWrap Pipe Repair Bandage applied to leaking welded joints on a stainless steel water cooling system at an oil refinery
SylWrap HD provided a rock hard, impact resistant protective sleeve around repairs – which could be made to difficult sections of pipes, including where the water cooling system ran overhead

Since Sylmasta visited, the refinery have used their extensive supply of SylWrap products to repair numerous leaks in the water cooling system – including to sections of overhead and difficult-to-access pipework where the system passes through constrained spaces.

With eliminating microbially induced corrosion from the system impossible, instant live leak repair has proven the best solution for the refinery.

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: 6 Bar Live Leak Repair to 300mm Steel Pipe at Malaysia Water Treatment Plant

A live leak in a 300mm steel pipe at a wastewater treatment plant in Malaysia live leak repair

6 bar sealed – water company in Malaysia seal online leak on 300mm pipe after two weeks of leaking

Just one week after Sylmasta carried out a series of demonstrations and site visits in Malaysia, a water company make their first repair using a SylWrap Contractor Case to seal a 6 bar live leak on a 300mm steel pipe at a water treatment plant.

Case Study Data

Site
Water treatment plant
Location
Malaysia
Repair Type
Live leak pipe repair
Defect
4mm hole in 300mm steel pipe

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, reinforcing and protecting the initial repair

SylWrap Pipe Repair Contractor Case
Easy-to-store Case containing enough products to make multiple live leak repairs on pipes of various diameters

Case Study PDF

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Case Study Details

The pipe had been leaking for around two weeks through a 4mm hole. It could not be shutdown because of its importance to operations at the treatment plant, leaving a steady 6 bar jet of water escaping and saturating the floor.

Such a leak would normally be sealed by the water company using a pipe repair clamp. The hole though was located on a section of pipe with a saddle joint welded on, sitting approximately 15mm above the original line. A clamp would therefore be ineffective.

6 bar live leak at a wastewater treatment plant in Malaysia before repair using a SylWrap Pipe Repair Contractor Case
Water was escaping the pipe through a 4mm hole at 6 bar pressure, saturating the surrounding floor

After a visit and presentation from Sylmasta a week earlier, the water company operating the treatment plant had taken a supply of SYL-PRO-866 SylWrap Pipe Repair Contractor Cases for sealing multiple leaks on pipework between 300mm and 600mm diameter.

One of the water company’s maintenance teams who Sylmasta had worked with whilst in Malaysia were tasked with using a Contractor Case to make a live leak repair to the pipe at the water treatment plant.

The leak was sealed with Wrap & Seal Pipe Burst Tape. Wrap & Seal stretches by three times its length and fuses together as it is wrapped around a pipe, forming a solid rubber band which seals the leak.

Applying multiple Wrap & Seals on top of each other builds pressure resistance. In high pressure repairs, tapes continue to be added until no water is seeping through and the user is satisfied the leak has been fully arrested.

Three 50mm x 11m Wrap & Seals were used by the maintenance team until the repair could withstand the 6 bar pressure. A SYL866HD SylWrap HD Pipe Repair Bandage was then applied to reinforce and protect the Wrap & Seal.

SylWrap Pipe Repair Bandage applied to a live leak in 300mm steel pipe at a wastewater treatment plant in Malaysia
Wrap & Seal was used to build a repair pressure resistant to 6 bar before overwrapping with a SYL866HD SylWrap HD Bandage

SylWrap HD has a fast-working, water activated resin. It was wrapped directly over the repair area, where it set rock hard within minutes to form an impact resistant outer shell.

Completing the repair took one hour. Having seen how quickly and easily it is to make a live leak repair when maintenance teams are equipped with a Contractor Case, the water company is already planning to expand their use – including onto the public supply network.

All the products in the Case have WRAS approval, meaning they are certified to British standards as safe to use with drinking water.

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

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

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Case Study: Alcohol Line Live Leak Pipe Repair at Sugar Mill in Costa Rica

Live leak pipe repair made to an alcohol line at a sugar mill in Costa Rica

The alcohol line repair which had a sugar mill in Costa Rica raising a glass of guaro to the SylWrap Pipe Repair Contractor Case

Having a SylWrap Pipe Repair Contractor Case on site enabled a sugar mill in Costa Rica to make an instant live leak pipe repair when a pinhole was discovered in an alcohol line running vertically up a tower.

Case Study Data

Site
Sugar mill
Location
Costa Rica
Repair Type
Live leak pipe repair
Defect
Pinhole leak in 70mm alcohol line

Products Used

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

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap which sets rock hard to reinforce and protect repairs

SylWrap Pipe Repair Contractor Case
Products were part of a Contractor Case kept on-site, capable of making up to six live leak repairs

Case Study PDF

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Case Study Details

A SylWrap Pipe Repair Contractor Case contains enough products to seal up to six live leaks, making it the ideal kit to keep on-site for rapid response to emergences.

The sugar mill had approved its use several years earlier. Because the milling season in Costa Rica lasts only around four months, efficiency is paramount. Any downtime, disruption or delays to production are costly.

Numerous repairs had since been made by the sugar mill using their stock of Contractor Cases. These included 90 degree elbow bends in elevated pipelines and a particularly challenging Y-joint leaking from the exact point where three separate pipes connected. Most of these pipes carried hot water.

Previous repairs made by the mill using Contractor Cases

The leaking alcohol line was 70mm in diameter and transported alcohol juice extracted from sugar cane during fermentation, which would eventually be used in the production of spirits including rum and guaro, the official liquor of Costa Rica.

It ran vertically up the tower, with the leak developing in a weakened section as the line passed through a circular hole in one of the upper floors. Alcohol juice was left spraying through the pinhole at around two bar pressure.

Alcohol juice extracted from sugar cane escaping through a pinhole leak in a 70mm steel pipe before repair
Alcohol juice spraying out of the pinhole leak in the pipe

As the pipe could not be isolated, Wrap & Seal Pipe Burst Tape was used as the leak sealant. Wrap & Seal is made from self-amalgamating silicone. When stretched by up to three times its length as it is wrapped around a pipe, the Tape fuses to form a solid rubber band capable of sealing live leaks .

Despite the space constraints around the pipe where it passed through the hole in the floor, the engineer making the repair managed to stretch the Tape to a suitable length so that it amalgamated successfully.

Wrap & Seal Pipe Burst Tape seals a live leak in an alcohol line at a sugar mill in Costa Rica
Wrap & Seal Pipe Burst Tape sealed the live leak

Once the engineer was satisfied the leak had been fully arrested and alcohol was no longer escaping, a SylWrap HD Pipe Repair Bandage was applied over the top to reinforce the Wrap & Seal.

SylWrap HD is a composite repair wrap containing a water activated resin. As it was wrapped and smoothed around the Wrap & Seal, it cured to form a rock-hard protective sleeve over the pipe.

SylWrap HD Pipe Repair Bandage applied during the live leak repair of an alcohol line at a sugar mill
SylWrap HD reinforced the repair with an impact resistant layer of protection

Both Wrap & Seal and SylWrap HD have WRAS approval, meaning they are safe to use with drinking water. The sugar mill were therefore reassured that neither product would affect the alcohol juice inside the pipe.

Because the sugar mill already had all the products required to repair the pipe on-site in their Contractor Case, it took less than 20 minutes to seal the alcohol line from the moment the pinhole was discovered.

Only a minimal amount of alcohol juice escaped thanks to the speed and ease of the repair. All systems remained fully operational, meaning there was no disruption whilst the application took place.

Had a Contractor Case not been available, a much greater quantity of juice would have been lost. The mill may have even been forced to shut down the leaking section until such time as it could be repaired at significant cost both financially and to production.

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 Hairline Crack Around Diameter of Porcelain Toilet Soil Pipe

Wrap & Seal Pipe Burst Tape seals a hairline crack in a porcelain toilet waste pipe repair

Soil pipe sealing – Wrap & Seal forms a rubber ring to repair a porcelain toilet

A homeowner carries out a DIY pipe repair to a porcelain soil pipe which developed a hairline crack around its entire diameter after an unstable bathroom floor caused the toilet to shift away from the wall it was connected to.

Case Study Data

Site
Bathroom
Location
United Kingdom
Repair Type
Leak repair
Defect
Hairline crack in porcelain soil pipe

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape which formed a watertight rubber ring to encompass and seal the pipe

Case Study PDF

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Case Study Details

The porcelain soil pipe connected the bowl of the toilet with the sewer pipe behind. The increasingly unstable bathroom floor meant that whenever anyone sat on the toilet, it tilted forward and pulled the pipe away from its fixed connection to the back wall.

Eventually, the stress being put on the pipe by the frequent movement of the toilet caused a hairline crack to appear around the entire diameter, through which water dripped whenever the toilet was flushed. This had the potential to make the floor even more unstable.

A hairline crack in a porcelain toilet waste pipe caused by an unstable floor
The crack caused by movement of the toilet pulling the porcelain soil pipe away from its connection to the bathroom wall

The homeowner was planning a full bathroom renovation to address the floor issue, which would include replacing the toilet. They therefore wanted a quick, easy and cost-effective DIY method to repair the porcelain soil pipe until said renovation took place.

There were several challenges with the repair. The crack was too thin to force epoxy putty into and was located on a bend in a difficult position, close to the back wall and with minimal space between the pipe and floor.

The continued movement of the toilet also had to be taken into account. Any repair needed to offer a degree of flexibility, as rigidly fixing the pipe back in place would leave the potential for cracks to develop elsewhere.

Sylmasta recommended encompassing as much of the pipe as possible with Wrap & Seal Pipe Burst Tape to create a watertight rubber ring bonded to the porcelain. This would seal the leak, allow the pipe an element of movement to reduce stress, and prevent water escaping from any other cracks which developed elsewhere in the porcelain.

A hairline crack in a porcelain toilet soil pipe having undergone repair with Wrap & Seal Pipe Burst Tape
Wrap & Seal Pipe Burst Tape created a rubber ring around the entire leak area, sealing the crack

Wrap & Seal is made from self-amalgamating silicone which fuses to itself to form a solid rubber band as it is wrapped around a pipe. One 50mm x 4m tape was enough to cover the leak and the surrounding area susceptible to future cracks.

Despite the space constraints between the back wall, the floor and the toilet bowl, the homeowner was able to stretch the tape to three times its length whist wrapping, creating maximum tension.

The tape easily fused, fully sealing the leak and preventing any more water escaping when the toilet was flushed. Completing the porcelain soil pipe repair took less than 15 minutes and cost under £30, including delivery of the Wrap & Seal Pipe Burst Tape.

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

Call: +44 (0)1444 831 459
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Case Study: Leaking Welded Saddle Joint Repair on 150mm Steel Pipe at Pumping House

A leaking saddle joint welded on a 150mm steel pipe undergoes repair after being found to be leaking from both ends

Saddle up for a complex repair – sealing a leaking welded saddle joint with a 20mm step using Wrap & Seal Pipe Burst Tape

A 150mm steel pipe connected to a pumping house in Malaysia which was leaking from both ends of a welded saddle joint is sealed in a successful repair built up and over a 20mm step between the line and the joint.

Case Study Data

Site
Pumping house
Location
Malaysia
Repair Type
Live leak repair
Defect
Leaking saddle joint on a 150mm steel pipe with a 20mm step

Products Used

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

Case Study PDF

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Case Study Details

The 150mm steel pipe ran water out of the pumping house. The saddle joint had been welded in place to reinforce a capped tee and sat approximately 20mm higher than the original line. One end of the joint was suffering from heavy corrosion.

Water had been found seeping from both ends of the joint, leaving the pipe surface noticeably wet and the ground beneath the pipe sodden. The pipe could not be isolated or replaced because this would involve shutting down the pumping station.

Several repair attempts had failed, including a clamp
A 150mm steel pipe with a heavily corroded saddle joint prior to undergoing leak repair
One end of the saddle joint was suffering from heavy corrosion whilst water was seeping from both

Several repair attempts had been made using different methods by the water company operating the facility, including the use of a clamp and epoxy putty, but none had been successful. The pipe had therefore been left to leak.

Whilst on a visit to Malaysia, a technician from Sylmasta was asked to accompany a engineering team to inspect the pipe and see if a solution could be formulated. They recommended using Wrap & Seal Pipe Burst Tape to start a repair on the original steel pipe and build it up and over the weld, encompassing and sealing either end of the saddle joint.

The pipe was cleaned and prepared before repair

First, an angle grinder was used to sand down the pipe, clean it of loose material and remove corrosion. A first Wrap & Seal Tape was then applied directly next to the step. Wrap & Seal is self-amalgamating and stretches by three times its length, fusing together to form a solid rubber band.

Diagram explaining how to repair a leaking saddle joint weld with a step using Wrap & Seal Pipe Burst Tape
Wrap & Seal application started on the pipe next to the saddle, was built up until level with the step and then continued across onto the joint

With each rotation, the Tape moved closer to being level with the top of the saddle joint. The application continued until enough Wrap & Seal had been applied to bridge the 20mm step between the pipe and the saddle.

Once this had been achieved, Wrap & Seal was applied 50mm across the saddle to achieve a good connection. It was then returned to directly over the edge of the joint.

Once Tape had been built up and over the saddle, wrapping continued immediately over the leak area
Wrap & Seal Pipe Burst Tape applied to a leaking saddle joint in a successful repair despite a 50mm step being present
The finished repair with both ends of the saddle joint sealed

Here, a ridge was created directly over the leak area to increase the pressure resistance of the repair. It was estimated that three Wrap & Seal Tapes needed to be used to seal one end, after which the process was repeated at the other end of the saddle joint.

Because the welded saddle joint had been seeping water slowly, the only way to check whether the application had been effective was to inspect several days later. When the pipe surface was found to be dry, the 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: 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