Author: Scott McCarthy

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Case Study: Repair & Refurbishment of Corroded 20 Metre Long Porth Pipe Bridge

The repair and refurbishment of a pipe bridge crossing the Rhonda River made using the Sylmasta Pipe Refurbishment System

Troubled bridge over water – the repair and refurbishment of a dilapidated steel pipe bridge crossing the Rhonda River

Sylmasta and Arch Services repair and refurbish a dilapidated 20-metre long pipe bridge crossing the Rhonda River in Porth, South Wales, helping to save Dwr Cymru Welsh Water from an expensive replacement of the heavily corroded structure.

Case Study Data

Site
Pipe bridge
Location
Porth, South Wales
Repair Type
300mm steel pipe bridge repair
Defect
Significant cracking and weakening of line caused by corrosion

Products Used

Liquid Metal Epoxy Coating
Brush applied to coat pipes and structures with an ultra-smooth, hard wearing, metallic surface

SylWrap CR Pipe Repair Bandage
Composite repair wrap specially formulated to prevent corrosion and strengthen pipes in aggressive environments

Case Study

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Case Study Details

Sylmasta were contacted by Dwr Cymru Welsh Water for advice on repairing and extending the lifespan of a dilapidated pipe bridge crossing the Rhonda River in Porth, South Wales. The bridge was gravity fed and made up of a 300mm diameter, 20 metre long steel pipe rested inside an angle-iron structure for support and protection.

For such a complex project, it was recommended that the four-stage Sylmasta Pipe Refurbishment System be used as a starting point. A final decision on the repair elements required would be decided once the pipe had been fully inspected.

Dwr Cymru official contractors appointed Arch Services of Porth to carry out the work, and it was agreed that Sylmasta would keep in close communication throughout the project to deal with any questions that might arise.

A heavily corroded pipe bridge prior to undergoing repair by Sylmasta
The steel pipe was covered in corrosion, which had eaten through in places

On inspection, the pipe was discovered to be totally covered in corrosion. This had eaten completely through the steel in several places along the top of the pipe, leaving large holes in the brittle surface.

As these holes were too large or delicate to be repaired with epoxy putty, Arch decided to use fibreglass patches layered over the cracked sections of pipe to seal the leaks. The entire pipe was then coated with Liquid Metal Epoxy Coating.

Liquid Metal is a metal-filled, brushable epoxy. After being coated onto the pipe, it cured to form a smooth, metallic, hard-wearing surface. Several layers of Liquid Metal were used to create an impermeable skin around the original pipe, preventing any further corrosion to the steel and ensuring fluids could no longer escape.

Liquid Metal Epoxy Coating applied to pipe bridge in South Wales to rebuild the corroded outer layer of the pipe
Liquid Metal created an ultra-smooth, hard-wearing metallic surface around the pipe

The 90 minute gel time of Liquid Metal allowed significant amounts of epoxy to be mixed without the threat of premature curing. Arch Services used a roller to apply each coating to a 1mm – 2mm thickness, also painting with Liquid Metal the corroded steel hoops and beams which held the pipe in place.

To further reinforce the pipe and reinstate its integral strength, it was wrapped with four layers of SylWrap CR Corrosion Protection Wrap. SylWrap CR is a composite repair bandage incorporated with highly effective corrosion inhibitors.

SylWrap CR was carefully applied along the length of the pipe, further reinforcing the repair

It has been specially formulated for the prevention of corrosion and the protection and strengthening of pipes, metalwork, and other structures in harsh and aggressive environments.

SylWrap CR was applied to the pipe whilst the final coating of Liquid Metal remained tacky. The resin in SylWrap CR was activated with water and the bandage tightly wrapped and smoothed around the pipe.

SylWrap CR Corrosion Protection Wrap used to reinforce and repair a pipe bridge in Porth, South Wales
The completed repair along the 20 metre length of the pipe

Within minutes, SylWrap CR cured to form a rock-hard, impact resistant shell around the pipe. Arch Services were particularly careful in ensuring that no area of the pipe was left without SylWrap CR. This required precision application close to the steel hoops.

The final result was a very smart pipe bridge now well protected from future corrosion and reinforced against breaches by Liquid Metal and SylWrap CR. Arch Services have subsequently become Sylmasta’s approved contractor for similar projects after their excellent documentation of the process and attention to detail.

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: Water Treatment Plant in Puerto Rico Repair Worn Pump Extracting from a Well

Ceramic Brushable Green Epoxy Coating used to repair a worn water well pump at a treatment plant in Puerto Rico

Pump it up – the repair which allowed a water treatment plant to keep pumping water from their below ground well

Sylmasta provide a long-term repair solution for a water treatment plant in Puerto Rico, whose pump extracting from a below ground well had become heavily worn due to minerals and sediment in the water.

Case Study Data

Site
Water treatment plant
Location
Puerto Rico
Repair Type
Damage repair
Defect
Heavily worn pump extracting water from a well

Products Used

Ceramic Brushable Green
Brushable epoxy coating used to refurbish and repair the worn pump, restore it to original thickness

Case Study PDF

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Case Study Details

The large water pump was used by the water treatment plant to extract water from a well. The water was then distributed around the entire site for various purposes, making the pump central to operations.

This natural groundwater contained minerals, sediments and impurities which caused deterioration to the pump. Over time, the pump became so worn and degraded that there was a substantial risk of bursting.

A burst would have been a disaster for the plant. Operations would have needed to be shut down and a replacement pump fitted. This would have been a costly and time-consuming exercise, potentially involving the fabrication of a new pump and its shipping to Puerto Rico.

Before the water well pump reached the stage whereby it needed to be replaced, the treatment plant decided to repair and reinforce the system using a hard-wearing, abrasion resistant coating.

Ceramic Brushable Green Epoxy Coating was used for the application. Ceramic Brushable is reinforced with silicone carbide, giving it a toughened, ultra-smooth finish.

It is painted onto surfaces which have suffered heavy damage or been weakened by corrosion and abrasion, restoring their strength and protecting the original part from further damage.

Ceramic Brushable Green Epoxy Coating used to repair a well water pump which had become extremely worn at a treatment plant in Puerto Rico
The well pump repaired and strengthened with Ceramic Brushable Green

The two parts of the epoxy coating were mixed in the prescribed ratios and then brushed onto the pump. The 90 minute gel time of Ceramic Brushable enabled more epoxy to be mixed and applied without the threat of premature curing.

Four coatings were used, each between 1mm and 2mm thick. This built up a substantial, reinforced shell around the worn pump to restore the weakened metalwork to its original thickness.

With a recoat time of around four hours, it took two days to complete the repair. The application took place over night whilst the site was shut down to limit disruption and the cost was insignificant compared to fitting a new pump.

The treatment plant now monitor the pump on a regular basis for future wear caused by corrosion and erosion. When there are concerns that it is becoming too weak, further coatings of Ceramic Brushable are added to restore integrity.

Speaking about the process, the maintenance manager at the plant said: “The pump deteriorates very soon but coating it in Ceramic Brushable helps a lot.” In this way, Sylmasta have provided a cost-effective and long-term solution.

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: Ceramic Mill Wheel Worn Shaft Repair & Rebuild After Replacement Deemed Impossible

A ceramic factory mill wheel shaft badly worn by abrasion undergoes repair and rebuild using Titanium Supergrade Epoxy Paste

No need to grin and bear wear and tear – the worn shaft repair to avoid a whole new mill wheel being installed at ceramic factory

After being told that disassembling a mill wheel to replace a damaged shaft was too complex and that the only solution was therefore a new wheel, a ceramic company in Mexico instead sought to repair the worn part without taking the system apart.

Case Study Data

Site
Ceramic factory
Location
Mexico
Repair Type
Damaged part rebuild
Defect
Mill wheel shaft badly weakened by abrasion

Products Used

Titanium Supergrade Epoxy Paste
Epoxy paste with high compressive strength and extreme temperature resistance for repairing and rebuilding worn parts


Case Study Details

The 150mm shaft was part of a mill wheel at a production plant operated by a company specialising in ceramic, glass and concrete manufacturing. Such abrasive work had left the shaft suffering from extreme wear after years of service.

When the company consulted experts about replacing the shaft, they were told it was too complex. To remove the damaged part and fit a replacement, the entire wheel would have to be disassembled. The size and weight of the wheel meant that this was impossible.

The shaft on the mill wheel had been damaged by abrasion

Even if the wheel could be taken apart, there was a danger that once dismantled it may be reassembled incorrectly and fail to work. There was nobody with the technical knowledge to carry out such an application because it had never been tried before.

The company were therefore told that the only solution was to remove the existing wheel and fit an entirely new system. Given that the only fault was with the shaft and the rest of the wheel was in good working order, this seemed like an unnecessary waste of time and resources to the company.

A worn shaft attached to a ceramic factory mill wheel prior to undergoing repair using Titanium Supergrade Epoxy Paste
The shaft could not be replaced without disassembling the wheel

Instead, they sought a method of repairing the worn shaft without taking the system apart. Sylmasta recommended the use of Titanium Supergrade Epoxy Paste to rebuild the outside of the shaft, which had been worn away and damaged by abrasion.

Titanium Supergrade was chosen because of its high compressive strength. It also offers extreme temperature resistance up to 250°C. It is reinforced with corrosion-resistant metal platelets which give it a smooth finish.

The shaft underwent an extreme mechanical clean prior to repair

An extreme mechanical clean was carried out to the shaft prior to the repair. This removed rust, dirt, grime and other materials which had coated the part over its life.

As soon as the preparation was completed, Part A and Part B of the epoxy paste were mixed together. Titanium Supergrade has a work time of three hours, allowing for careful application without the threat of premature curing.

Titanium Supergrade Epoxy Paste was mixed and applied to the shaft

Once successfully mixed, the paste was applied around the entire shaft. A putty knife was used to first push it into imperfections on the shaft, filling all areas of damage.

After the damage had been repaired, further paste was applied to rebuild the shaft by several millimetres. When abrasion now occurred, it would be the new material formed by Titanium Supergrade wearing away, rather than the metalwork of the original shaft.

  • Damaged shaft worn down by abrasion in a ceramic mill after undergoing repair and rebuild with Titanium Supergrade Epoxy Paste
Completed repair with the shaft thickened and rebuilt

In this way, Titanium Supergrade offers a long-term solution. Further epoxy paste can be applied to rebuild the worn shaft again when the existing repair wears through, keeping the part operational for as long as the wheel remains in service.

A full cure was achieved in 24 hours, after which the system went back into operation. The repair helped the company save a huge amount of money compared to the suggested solution of replacing the entire mill wheel.

The company are now planning to use Titanium Supergrade to rebuild other worn machine parts across their production facilities instead of replacement wherever possible.

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: External Surface Damage Repair to Restore Integrity of 400mm GRP Pipe

A GRP pipe suffering from external surface damage undergoes repair and strengthening with a Superfast Steel Epoxy Putty Stick

Repair damage now, avoid leak later – the oil refinery who reaped the benefits of external pipe surface restoration

When construction work revealed a 400mm GRP pipe suffering from areas of external surface damage, an oil refinery in Saudi Arabia decided to restore the integrity of the line to lessen the chances of a future breach requiring leak repair.

Case Study Data

Site
Oil refinery
Location
Saudi Arabia
Repair Type
Pipe surface profile restoration
Defect
External damage to 400mm GRP pipe

Products Used

Superfast Steel Epoxy Putty
Fast-working epoxy putty smoothed over areas of damage and weakness for restoring pipe strength and integrity

Case Study PDF

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Case Study Details

Ongoing construction work at the oil refinery resulted in the excavation of an underground section of 400mm GRP pipe. The external surface of the line was discovered to be damaged, with two areas suffering from heavy scoring.

Although the pipe was not yet leaking, the refinery were concerned that the weakening of the exterior would lead to a future breach of the line.

The damaged external surface of the GRP pipe

If this happened, they would then be faced with the inconvenient and costly exercise of again excavating the reburied line to fix the problem. Should any future leak prove to be too challenging repair, an even more costly pipe replacement might be required.

Keen to avoid that fate, the refinery decided to seek a method to repair the external damage whilst the pipe remained excavated and accessible. This would strengthen the line and restore its integrity.

Superfast Steel was pushed onto the pipe, filling imperfections in the line

Sylmasta supply several products for damage repair. For this particular application, Superfast Steel Epoxy Putty was deemed the best solution due to the relatively small areas requiring repair, and the speed and ease with which it can be worked.

Superfast Steel comes in pre-formatted 114g stick. Multiple sticks were used for the repair. Chunks of putty were cut from the stick and kneaded by hand. Once the putty had turned to a uniform colour and whilst remaining soft, it was pushed down onto the pipe and smoothed over the scored areas.

A GRP pipe in Saudi Arabia suffering from external surface damage undergoes repair with Superfast Steel Epoxy Putty Stick
The putty cured to a material hard as steel over the weakened parts of the pipe

Within 10 minutes of mixing beginning, the putty began to harden. Once fully cured, it permanently imbedded into imperfections in the line. In effect, the putty created a new waterproof layer hard as steel over the weakened parts of the GRP pipe. The entire repair took less than two hours to complete.

Had the area of damage been larger and deeper, then Industrial Metal Epoxy Paste would have been recommended. Industrial Metal is trowel applied and with a longer work time, allowing more to be mixed and spread over significant sections of weakened pipes requiring rebuild.

Superfast Steel Epoxy Putty Stick used to restore external surface profile of a GRP pipe in Saudi Arabia
The completed repair with all damage filled

The GRP line could have been further reinforced using a SylWrap HD Pipe Repair Bandage. However, the trench dug as part of the construction work was not deep enough to effectively wrap a bandage around the bottom of the pipe.

Not wanting to excavate further down, the refinery decided to rely on Superfast Steel to strengthen the line. Several years later and the underground line had still not been breached. Superfast Steel had done its job.

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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How to fix a leaking pipe using a cost effective DIY Pipe Repair Kit

A SylWrap Pipe Repair Kit is used to seal a crack on a 90-year-old malleable iron water supply pipe

Quick and easy permanent pipe repair without hiring an expensive plumber

When pipes burst or start leaking, the money involved in repairing them can soon add up. Hiring a plumber is not cheap, which is why more people are turning to DIY pipe repair kits when they need the tools and know how to fix a leaking pipe.

The Covid-19 pandemic and the lockdowns it brought saw an increase in those willing to take on DIY repairs in all kinds of areas, including pipes. Homeowners sought out pipe repair kits to permanently fix leaks and bursts without requiring a plumber to enter their property.

DIY repairs have remained popular in the post-lockdown world – and it is easy to see why. Whereas a plumber can charge up to £60 an hour plus an emergency call out fee of £120 (according to Checkatrade), a SylWrap Pipe Repair Kit capable of sealing a live leak on your average domestic copper pipe is available for under £20 including delivery.

Repairs are quick and easy to make and permanent with no training required. You simply follow the instructions provided and within 30 minutes, leaking pipes of any size and material can be sealed – even when pressure cannot be turned off should be unable to locate your stopcock or isolate the pipe for another reason.

We will now take you through the two-stage process of how to fix a leaking pipe using a SylWrap Pipe Repair Kit. All the products contained within the Kit are WRAS approved, meaning they have been certified to British standards as safe to use on pipes and fittings which come into contact with drinking water.

Stage one: Seal the leak

Stage one of making a DIY pipe repair involves sealing the leak. If you can turn the pressure off and the pipe is dry, then this is done using Superfast Epoxy Putty. If you cannot turn the pressure off and water is leaking from the pipe, then this is done using Wrap & Seal Pipe Burst Tape.

Firstly, the no pressure repair method. Epoxy putty consists of two components, resin and hardener. Both these parts are soft until mixed together, after which a chemical reaction takes place to turn the putty into a material as hard as steel.

Superfast Epoxy comes with the resin and hardener in a pre-formatted stick. To use, you simply cut enough putty from the stick to cover the hole or crack in the pipe and knead it by hand.

Within a few minutes, the putty will turn to a uniform colour. Whilst soft, it is then pushed into the hole or crack. After 5 to 10 minutes, it will harden, filling the hole or crack and sealing the leak.

Superfast Copper Epoxy Putty used to seal a hole and fix a leaking pipe
Using Superfast Epoxy Putty to fill a hole in a pipe

Epoxy putty is pressure resistant up to 30 bar. The highest that most home water systems operate at is 3 bar, so Superfast is more than capable of repairing any domestic and most industrial pipes, easily withstanding the pressure.

For live leaks, Wrap & Seal is instead used. This waterproof repair tape is made from self-amalgamating silicone and stretches by up to 3 times its length. When wrapped around a leaking pipe, it will fuse to form a solid rubber band over the hole or crack, sealing it.

The more Wrap & Seal Tapes you use, the greater the pressure resistance. One Tape is normally more than capable of holding 3 bar on a domestic pipe. To know how many Tapes are needed to fix a leaking pipe of larger diameters, Sylmasta have produced a Wrap & Seal Calculator for calculating the quantity needed for bigger repairs.

Wrap & Seal Pipe Burst Tape used to fix a leaking pipe by creating a high pressure waterproof rubber band
Wrap & Seal stretched, wrapped and fused to seal a leak

One Wrap & Seal Tape will take less than 10 minutes to apply. Once you have completed stage one of the repair using either the Tape or Epoxy Putty, then comes stage two – reinforcement.

Stage two: Reinforce the pipe repair

The repair is made permanent by reinforcement using a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water-activated resin. It is dipped in water, wrapped and then smoothed around the area of the pipe which had been leaking.

Within minutes, the bandage will begin to harden. Once fully wrapped and cured, it provides a rock hard, impact resistant sleeve encompassing the pipe and protecting the initial seal.

  • SylWrap HD Pipe Repair Bandage used to reinforce a 100mm UPVC pipe leaking from a step joint
Pipes reinforced using SylWrap HD having been successfully sealed

Choosing the right Kit for your pipe repair

There are two SylWrap Pipe Repair Kits – the Standard Kit contains only Superfast Epoxy Putty and SylWrap HD Bandage and makes repairs to pipes where pressure can be turned off.

The Universal Kit includes Wrap & Seal Pipe Burst Tape along with Epoxy Putty and the Bandage. This Kit repairs live leaks where pressure cannot be turned off.

Once you have identified which Kit you need, then each product page contains a drop down list with various pipe diameters. Simply select the size of the pipe you are wanting to fix, and it will tell you the specific sized Kit you need.

Step-by-step instructions are supplied with every Kit and if you need any further assistance, then there are several videos showing how to fix a leaking pipe on each of the Kit pages.

If you have any questions about which product is most suitable for your repair or require technical assistance, then please contact Sylmasta via email or on +44 (0)1444 831459 and a technician will be happy to advise you.

DIY Pipe repairs – from homes to businesses to industry

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Case Study: Rapid 5 Minute Epoxy Adhesive Used to Repair Broken Ceramic Teapot Lid

Repair of a broken teapot lid made of ceramic using Sylmasta Rapid Epoxy Adhesive

Tea for two – Rapid 5 Minute Epoxy Adhesive keeps a teapot brewing with the repair of a ceramic lid cracked into two pieces

A ceramic teapot lid cracked into two pieces when it was accidentally dropped on a hard floor undergoes a permanent repair using Sylmasta Rapid 5 Minute Epoxy.

Case Study Data

Repair Type
High-strength bonding
Defect
Ceramic teapot lid broken into two pieces

Products Used

Sylmasta Rapid 5 Minute Epoxy Adhesive
Epoxy adhesive with a 5 minute work time for high-strength, accurate bonding between materials

Case Study PDF

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Case Study Details

The ceramic teapot lid was broken when accidentally dropped onto a hard floor. Fortunately, it cracked into two pieces rather than shattering into many, meaning that it could be repaired relatively easily.

Sylmasta Rapid 5 Minute Epoxy Adhesive was chosen for the job of glueing the teapot lid back together. As an epoxy adhesive, Rapid 5 Minute offered much stronger bonding power than a traditional superglue.

The ceramic teapot lid had cracked into two pieces. Epoxy Adhesive was applied to the entire white break area on the smaller piece

Its longer working time also allowed for careful application of the adhesive along the complex shape of the break, and for the two pieces to then be fitted together more accurately. With superglue came the risk of an instant cure and misalignment, after which it would be too late to rectify the error.

Rapid 5 Minute is supplied with the two epoxy adhesive components – resin and hardener – stored separately. These were extruded onto a flat and stable surface which could be easily disposed of afterwards (an empty cereal box) and mixed together with a stirrer.

After 30 seconds, an even mix had been achieved. The epoxy was then spread using the stirrer over the entire break joint of the smaller piece of the teapot lid. Once the adhesive had been applied, the two parts of the lid were pressed together and carefully adjusted for a seamless fit.

A ceramic teapot lid having undergone repair using Sylmasta Rapid 5 Minute Epoxy Adhesive
Completed repair of the teapot lid

The two parts of the teapot lid continued to be pushed together for five minutes, the functional cure time of the epoxy. Once the adhesive had begun to bond, the lid no longer required pressure to keep the parts together.

It was left undisturbed for 30 minutes for the epoxy adhesive to achieve maximum properties. A full cure was achieved after one hour. The teapot could then be reunited with its lid following the successful repair.

The structurally strong bonds provided by Rapid 5 Minute will last for a very long time – providing nobody drops the teapot lid onto a hard floor to damage the ceramic again.

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

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

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Case Study: Live Leak 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 silicone 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 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. Made from self-amalgamating silicone, Wrap & Seal stretches by 300 percent and fuses 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: Dairy Delivery Truck 466 International Engine Cracked Timing Cover Repair

The repair of a crack in a 466 International engine timing cover made using Industrial Metal Epoxy Paste

The delivery truck timing cover repair which meant no crying over spilt milk for a dairy in Puerto Rico

Replacing a delivery truck’s 466 International engine timing cover after it developed a hairline crack was set to cost a milk company in Puerto Rico $1000 until Sylmasta formulated a faster, more cost-effective repair method.

Case Study Data

Repair Type
Timing cover repair
Defect
Crack in 466 International engine timing cover

Products Used

Industrial Metal Epoxy Paste
Epoxy paste used to fill the crack, permanently sealing it to prevent any further oil escaping

Case Study PDF

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Case Study Details

The delivery truck belonged to a milk company in Puerto Rico. Oil was discovered to be leaking from the timing cover of the vehicle’s 466 International engine. Once opened, a hairline crack was discovered in the casing.

A replacement cover would have cost $1000. Delivery of the part was estimated to take up to a week. The company needed the truck to be back in service as soon as possible and so they sought a faster, more cost-effective repair.

The opened timing cover during inspection
A crack developed in a 466 International Engine timing cover which then underwent repair with Industrial Metal Epoxy Paste
A hairline crack discovered in the centre of the metalwork

Sylmasta technicians were able to formulate a repair method for the timing cover, involving a degree of preparation followed by the use of Industrial Metal Epoxy Paste. Instructions were sent to the engineer, who had been asked to find a solution by the company.

Before the application of the paste began, Sylmasta recommended that the ends of the crack were drilled. This was to relieve stress concentration and prevent the crack from spreading further.

Repair instructions, showing the V-shaped grooves to be cut along the top and bottom of the crack and the overlap of epoxy paste

A coarse 3-square file was used to cut a V-shaped groove along the length of the crack, widening the gap in both the top of the metalwork and underneath. This increased the available surface area to which Industrial Metal could bond. The V-grooves were then degreased to remove contamination.

Part A and part B of Industrial Metal were mixed in the instructed ratio. A spatula was used to force the paste into the crack, completely filling both V-grooves. The paste was also overlapped by 20mm either side of the crack to ensure full adhesion.

Crack in 466 International timing cover undergoes repair using Industrial Metal Epoxy Paste
The crack seamlessly filled in and repaired once Industrial Metal had cured

Industrial Metal has a work time of 60 minutes, allowing it to be carefully applied to the crack without needing to worry about premature curing. A full cure was achieved in 24 hours, after which the paste set to form a solid metallic material which seamlessly filled and repaired the crack.

One day after the application had been completed, the delivery truck was back on the road with the timing cover no longer leaking. The company were very pleased with the technical advice offered by Sylmasta, and the speed and ease with which they had been able to complete the repair.

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

Download

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

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Case Study: Filler Repair of 50mm Crack Between Toilet Waste Pipe & Bathroom Floor

Cracks left during the installation of a toilet waste pipe undergo repair using Sylmasta AB Epoxy Putty as a filler material

No falling through the cracks – Sylmasta AB Repair Epoxy Putty connects a toilet waste pipe during bathroom renovation work

A hole cut into a bathroom floor during renovation work was made too big for the toilet waste pipe it was to house, meaning a waterproof repair material was needed to permanently fill gaps of up to 50mm width between the pipe and the floor.

Case Study Data

Site
Bathroom
Location
United Kingdom
Repair Type
Filler repair
Defect
50mm wide crack between toilet waste pipe and bathroom floor

Products Used

Sylmasta AB Original Epoxy Putty
Waterproof, hard-wearing epoxy putty with a longer work time used to permanently fill all gaps between the pipe and the floor

Case Study PDF

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Case Study Details

Renovations at a property in the United Kingdom involved the toilet being moved to a new location within an improved bathroom. To prepare for the move, the contractors carrying out the work cut a hole out of the floor where the toilet waste pipe was to connect with the sewer pipe.

When the toilet waste pipe was fitted in place, it was discovered that the hole which had been cut was too big. This left gapping all the way around between the base of the pipe and the floor. At its largest, the gapping extended to 50mm wide.

Large gapping between the pipe and the floor needed to be filled

The contractors wanted a straightforward method to fill the cracks so that the plumbing in of the toilet waste pipe could be completed. Sylmasta recommended the use of Sylmasta AB Original Epoxy Putty.

AB Original is a ceramic-filled, general purpose, waterproof epoxy putty which is the hardest wearing available. It comes with a two-hour work time for use in larger and more complex repairs.

It was calculated that around 1kg of AB Original would be needed to repair the toilet waste pipe. This was delivered to the property, where the resin and the hardener were mixed in equal measures and kneaded by hand.

Epoxy putty used to full in cracks between a toilet waste pipe and a bathroom floor in a repair required during renovation work
AB Original was worked and pushed into the crack
The putty was smoothed off using water

Once the putty had turned an off-white colour to indicate successful mixing, it was pushed into the gapping between the waste pipe and the floor whilst it remained soft enough to shape and manipulate.

The longer cure time of Sylmasta AB meant that more of the putty could be mixed in one go without the threat of premature curing. As the putty was applied, it was smoothed off with a little water and a filling knife and then left to harden.

Completed epoxy putty filler repair of cracks between a toilet waste pipe and the floor
The completed repair with all gapping successfully sealed

A full cure was achieved in 24 hours, leaving the cracks permanently filled with a waterproof material sharing similar properties to the floor. The renovation of the bathroom was able to continue with virtually no disruption to timeframe.

When it came to the installation of a new bathroom floor surface further along the renovation process, AB Original would withstand being tapped, drilled, screwed, sawed, ground, filed, painted and any other treatment needed to complete the improvements.

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