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Case Study: Leaking Cast Iron Wastewater Pipe Repair in a London Hotel

Pipe repair carried out to a wastewater pipe made of cast iron in a central London hotel
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Getting a room – Sylmasta solve the problem of a leaking wastewater pipe in an iconic London hotel

An iconic central London hotel faced having to shut one of its most prestigious rooms after a wastewater pipe in the ceiling above developed a large circular crack which initially proved impossible to repair.

Several attempts had been made to fix the leaking cast iron pipe, but its location within the hotel made it particularly troublesome. The pipe was crammed into a gap between the floor of one level and the ceiling of another, leaving virtually no room to work.

There was certainly not enough space to get an effective wrap of pipe repair tape around the leaking pipe. This is where the first repair attempts had gone wrong; although the hotel had managed to cover the crack, the tape had not bonded or formed as is should to seal the leak because it could not be stretched to the required amount.

The 2” x 1” hole therefore required an alternative repair method. To complicate the matter further, the crack was on an elbow joint which added another layer of complexity to the job.

Sylmasta decided that the most effective pipe repair product to seal the hole would be Superfast Steel Epoxy Putty. The size and the position of the crack still possessed some challenges, which were eventually overcome by some out-of-the-box thinking by the Sylmasta technicians.

The Superfast Steel Stick was hand kneaded as normal, but rather than being pushed immediately into the crack it was instead formed into a disc larger than the hole in order to completely cover it. This disc of epoxy putty was then attached to a strip of polythene sheeting.

The sheeting would support the epoxy putty whilst it was stretched over the crack in the pipe. Once in position, the edges of the disc were pushed tightly down onto the cast iron pipe to form a good seal with the surface of the pipe.

Once the epoxy putty was in place, the whole repair was overwrapped with a SylWrap Pipe Repair Bandage. SylWrap is water activated and sets rock-hard to provide an impact resistant layer over the initial repair. It does not need to be stretched for an effective application, meaning that it could easily be applied to the cast iron pipe despite the space constraints.

After the repair was completed, the hotel was able to reopen to the public the popular room which had been affected by the leaking wastewater pipe. The solution is permanent and was carried out at a fraction of the cost of hiring a plumber or replacing the damaged pipe.

It also saved time with the repair being effective in less than an hour. Sylmasta have since recommended that hotels take stock of the SylWrap Pipe Repair Contractor Case, a kit which contains enough products to carry out up to six pipe repairs.

A Contractor Case can be easily stored on site, enabling an emergency pipe repair to be carried out as soon as situation arises. All the products included in the Contractor Case are WRAS approved, making them safe to use with drinking water.

Products used
Repair Photos

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

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


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Case Study: Swimming Pool Filtration System Pipe Repair, UK

Repair of a plastic PVC pipe which formed part of a swimming pool filtration system in a leisure centre
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The swimming pool filtration system repair which kept a leisure centre’s head above water

When plastic PVC pipework which formed part of the swimming pool filtration system in a British leisure centre developed a 2” crack, a repair looked impossible until Sylmasta swam to the rescue.

The section of pipework in question had for many years been resting on a steel bracket. Over time, this had caused the PVC to weaken and sag, which ultimately is what led to the problematic crack developing.

What made the leak so challenging was the location of the pipe. It was 3” off the ground and surrounded by other components of he swimming pool filtration system, making access for a repair extremely difficult.

Once that problem had been overcome, next was the fact that the crack itself was at the bottom of the pipe, facing towards the ground. This severely restricted the sort of pipe repair that could be carried out, not to mention that if the pressure was turned off, the person carrying out the repair from above could no longer tell exactly where the crack was without water gushing from the hole.

The maintenance company responsible for the leisure centre would normally have two repair methods for a leaking pipe in a swimming pool filtration system. The first would be to remove the damaged section and plastic weld it. If the damage was too severe, they would simply replace the pipework.

To remove this particular section of pipe however would have required the disassembly of half the filtration system. It would have been a time consuming and costly exercise which would have required the closure of the swimming pool to complete.

What the maintenance company needed was a product which could carry out a permanent, live leak repair within a confined space. After seeking technical assistance from Sylmasta, we were able to supply a Universal Pipe Repair Kit to fix the leaking PVC plastic pipe.

Because water pressure needed to be maintained during the repair, Wrap & Seal Pipe Burst Tape was used to seal the leak. It is normally recommended that Wrap & Seal be stretched to the maximum of 300% its length the provide a tight seal around the leak area, where it will fuse into a solid rubber band capable of withstanding pressure up to 30bar.

With just 3” to play with between the pipe and the ground, the maximum stretch was unachievable. Not that this mattered as the Pipe Burst Tape was still more than capable of repairing the leak. It was then overwrapped with a SylWrap Pipe Repair Bandage, which set rock hard in 30 minutes for a permanent solution. The impact resistant layer provided by the Bandage ensured that the steel bracket would cause no further damage to the PVC plastic pipe.

So impressed with the speed and ease of repair were the maintenance company that they have subsequently recommended that leisure centres and swimming pool servicing companies take stock of SylWrap Pipe Repair Kits for any future emergencies.

“Leaks often occur at times when spares are challenging to obtain, such as evenings and weekends, so I suggested they consider stocking SylWrap products as a solution for fixing a leaking pipe quickly as soon as it is reported.”

In the future, these companies may benefit from taking on the SylWrap Pipe Repair Contractor Case. Each case contains enough products to carry out up to six repairs at a cheaper cost-per-repair than when buying inidividual Universal Pipe Repair Kits. They are easy to store either on site or on the van, providing an on-hand solution for whenever emergencies arise.

Products used
Repair Photos

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

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


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Case Study: Sprinkler System Pipe Repair, UK

The repair of a leaking pipe in a sprinkler system at a British furniture company's workshop carried out using a SylWrap Standard Pipe Repair Kit
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Fixing a leaking sprinkler system in a British furniture company’s workshop

A furniture company in the United Kingdom were faced with a real problem when a section of pipework in their sprinkler system developed a pinhole leak which required an immediate repair.

The pipe in question was located high up in the roof of a warehouse, close to the incoming electricity supply. Any water that passed through the leaking section was therefore in danger of coming into contact with the electrics or falling onto the products being stored and manufactured below.

Initially, the furniture business contacted their sprinkler maintenance company. After inspecting the problem, the maintenance company advised that they would have to replace the entire length of pipe.

Because of the pipe’s position in the roof and the complications involving the electrics, this would have been a costly and time consuming repair. The furniture company doubted whether it would even be possible.

They therefore attempted to fix the leaking sprinkler system with a pipe repair clamp. This proved to be impossible however due to the tee pipe coming off the opposite side, directly above where the pinhole leak was located.

It was then that they turned to Sylmasta. The damaged section of the sprinkler system was turned off due to the problem, which meant that we were able to recommend the SylWrap Standard Pipe Repair Kit.

Superfast Steel Epoxy Putty was used to plug the pinhole. The hand-kneaded putty has a work life of approximately 3 minutes, within 5-10 minutes it will harden and form a cohesive bond and after one hour, the system being repaired can be put back into service.

The pinhole was then overwrapped using a SylWrap Pipe Repair Bandage. The water-activated bandage sets rock hard in 30 minutes, providing a permanent repair for the sprinkler system pipe.

One of the concerns that the furniture company had was that the repair needed to be resistant up to 8 bar pressure. The SylWrap Standard Pipe Repair Kit can handle pressure of 30 bar, so this was not a problem.

Following the repair, the furniture company got in touch to say, “I found the repair putty and the bandage very easy to use and will no doubt be using Sylmasta products again.”

Products used
Repair Photos

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

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


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Case Study: Hot Water Pipe Repair on a Farm, United Kingdom

Repair of a leaking hot water pipe on a farm carried out using a SylWrap Universal Pipe Repair Kit
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Pipe repair on a farm which will keep the hot water on until the cows come home

A farm in the United Kingdom was undergoing building works when contractors accidentally drilled through an underground heating pipe buried under a paved yard between two buildings, requiring an emergency repair.

The contractors had initially believed the pipe to be a drainage pipe. It was only once they had cut through it using a hole saw that they realised it actually contained two insulation lagged pipes and was supplying hot water from an outbuilding to the main building on the farm.

After an initial inspection, it looked like carrying out a repair to the pipe at the farm would be both difficult and expensive. It would involve digging out the pipe and cutting away the outer pipe and lagging in order to access the leaking area.

Instead of this complex and time-consuming repair, the contractors instead turned to a SylWrap Universal Pipe Repair Kit to fix the problem in a fraction of the time and for minimal costs.

Using a Universal Pipe Repair Kit meant that a minimal amount of lagging needed to be removed. There was also no need to isolate the flow as the Universal Kit works on live leaks even when pressure cannot be turned off.

The leak was easily sealed using Wrap & Seal Pipe Burst Tape. Wrap & Seal is a self-fusing pipe repair tape which stretches to 300% its length. The tape formed a solid rubber band over the hole which had been cut into the pipe, sealing it.

Wrap & Seal was then overwrapped with a SylWrap Pipe Repair Bandage. When water-activated, SylWrap sets rock hard in 30 minutes, providing an impact resistant layer.

Both Wrap & Seal and SylWrap Pipe Repair Bandage can withstand temperature extremes up to 200°C, ensuring that they were suitable for a repair involving a hot water installation.

The products are WRAS approved, meaning that they are safe for use with drinking water.

Products used
Repair Photos

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

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


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Case Study: Corroded Flour Mixer in a Bakery, Puerto Rico

Sylmasta Ceramic Brushable Green used to reapir corroded mixing blades in a flour mixer at a bakery in Puerto Rico
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Sylmasta Ceramic Brushable Green used to reapir corroded mixing blades in a flour mixer at a bakery in Puerto Rico

 

Sylmasta save a bakery in Puerto Rico a load of dough by repairing their corroded flour mixer

 

Corroded blades in a commercial bakery’s flour mixer looked like they would force a costly shutdown of equipment, until Sylmasta came along and saved the bakery a load of dough – in more ways than one.

 

The mixers in question were used by the bakery in Puerto Rico for mixing flour and other ingredients together to make turnovers sand other products.

 

During one of the regular inspections carried out to the blades, it was noted that they had suffered heavy corrosion and production had to be halted until the problem was resolved.

 

Replacing the flour mixer blades within the two machines would have cost $3,000 per blade. As if spending $6,000 on new parts wasn’t bad enough, the blades were not available from stock.

 

This meant that replacement blades would have to be built from scratch, a process that would have left the bakery unable to fulfil orders already made or take any more for the foreseeable future.

 

$6,000 to replace the corroded blades and many weeks of lost production. The bakery was looking at losing a lot of dough both in terms of money and the delicious baked goods that it made.

 

As a result, the bakery urgently needed to find a better solution to repair the corroded blades in their flour mixer. They turned to Sylmasta Ceramic Brushable Green.

 

Ceramic Brushable Green is a toughened, solvent-free, water-resistant coating that is painted onto machinery to reinforce and strengthen equipment.

 

It provided a protective layer for the blades against both corrosion and the general abrasion that comes when mixing flour and other ingredients in the baking process.

 

Because Ceramic Brushable Green offers such a smooth finish and is easily applied, the bakery was able to restore its flour mixing machines to full working order almost immediately.

 

The blades themselves ended up looking like new at a fraction of the cost of a replacement. They won’t need to be serviced again for a long time either because of Ceramic Brushable Green’s high abrasion resistance.

 

Products used

 

Repair Photos

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

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


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Case Study: CHP System Repair, United Kingdom

A CHP System Repair carried out on a leaking pipe in a pant at an automotive safety supplier in the United Kingdom
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CHP System Repair – Fixing a Leak in a Combined Heat & Power System with a high-temperature pipe repair

Combined Heat and Power Systems are used to increase energy efficiency and drive down costs in industrial sites. Typically, a CHP system can reduce energy bills by 20% and carbon emissions by 30% – as long as it is in full working order.

When a CHP system develops a fault or isn’t managed correctly, then these savings can be lost. This was a problem that an automotive safety supplier in the United Kingdom suffered from when a pipe in their CHP system began leaking.

CHP captures the heat produced when electricity is generated that would otherwise be wasted, using it to provide thermal energy such as steam or hot water. This can then be used for the heating or cooling of sites, producing domestic hot water or industrial processes.

CHP systems are built in on-site power plants, which is where the fault in the automotive safety supplier’s system was found. Although it wasn’t a major leak, water was dripping onto motors and gas tanks which were components in the system stored underneath the damaged pipe.

There were three issues which caused this repair to be a challenging one. The first was that the leak was on an elbow joint, making it difficult to get a tight seal around the damaged area in order to repair it.

The second was that CHP systems deal with extreme temperatures. The pipe requiring repair operated in excess of 120°C, so a solution that was effective in high temperature applications was required.

The third was that the automotive safety supplier were unable to take the CHP system out of service to carry out a repair. This meant that the fix needed to be carried out while the pipe continued to drip water, making a live leak repair necessary.

A SylWrap Universal Pipe Repair Kit containing all the equipment needed to carry out a quick and easy live leak repair was delivered to site.

Wrap & Seal Pipe Burst Tape was applied around the leaking elbow joint. Because the leak was dripping rather than spraying, the Wrap & Seal sealed the leak quickly. As a versatile pipe repair tape, it easily bonded around the shape of the elbow.

The Pipe Burst Tape was then overwrapped with SylWrap Pipe Repair Bandage, which is water-activated and sets rock-hard in minutes to form a protective layer. This ensures that the repair is permanent.

Both products are resistant up to 200°C, making them suitable for use in a CHP System repair – although the Pipe Repair Bandage did cure with a red tinge because of the temperature extremes. Should the automotive safety supplier have wanted the repair to appear more uniform with the rest of the pipe, then it is possible to paint the bandage.

After the CHP system repair had been completed, the company got in contact with Sylmasta to say that they were extremely impressed with the ease and speed which with which the pipe had been fixed.

The CHP system repair had also saved them considerable money and time by negating the need for either a replacement part for the system or a shutdown to carry out a repair.

Products used

Both of these products are available in the SylWrap Universal Pipe Repair Kit and the SylWrap Pipe Repair Contractor Case which contains enough equipment to carry out multiple fixes.

Repair Photos

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

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


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Case Study: Power Plant, Puerto Rico

A contaminated water pipe repair carried out in a Power Plant in Puerto Rico using Sylmasta products
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Riding the storm – how a Sylmasta contaminated water pipe repair helped keep power going in Puerto Rico during Hurricane Maria

When a contaminated water pipe in a Puerto Rican Power Plant began leaking in 2015, the Power Authority had two choices – find a way to carry out a repair without needing to take the pipe out of service or shutdown the generator it was connected to.

Thanks to Sylmasta, a live leak repair was possible. Which was just as well as within 18 months, Puerto Rico would need all the power capability it could muster after the most devastating natural disaster in the island’s recorded history.

The pipe in question was responsible for running contaminated water back to a treatment plant. At some point, a small crack had appeared in the bottom of the pipe which was now leaking water.

Nobody was quite sure how the damage had occurred, but equipment which had been stored under the pipe had recently been moved and may have inadvertently impacted on the pipework.

To carry out a repair with the pressure turned off or to completely remove and replace the damaged part, the generator that the pipe was connected to would have needed to be shutdown. This exercise would have been expensive and reduced the Plant’s capacity for generating power.

There was also a danger that once taken out of service, the repair could have taken a significant amount of time owing to how long it would take for new parts to be both delivered and fitted – or it may not have been completed at all.

Instead, the Power Authority turned to Sylmasta to supply a contaminated water pipe repair solution. Firstly, Wrap & Seal Pipe Burst Tape was applied to the pipe to seal the leak. Wrap & Seal stretches by 300% and is twice the thickness of any other self-fusing pipe repair tape, ensuring that it fixes leaking pipes even when pressure cannot be turned off.

Wrap & Seal was then overwrapped with SylWrap Pipe Repair Bandage, which sets rock-hard to form a protective layer over the Pipe Repair Tape, providing a permanent repair.

The repair was carried out inside of 30 minutes at very little cost to the Power Authority. The true value of fixing the leaking contaminated water pipe though only became apparent in 2017 when Hurricane Maria hit Puerto Rico, Dominica and the U.S. Virgin Islands.

Hurricane Maria was the deadliest Atlantic Hurricane for nine years, a category five storm which ripped across the Caribbean. Central to the relief efforts both during and after Maria was keeping power going in Puerto Rico, something which the Sylmasta repair helped to do.

Six months after Hurricane Maria, the contractor who had carried out the repair got in contact. He said that without the Sylmasta repair, then the Power Plant would have had one less working generator at a time when Puerto Rico needed all the power available to it.

As a result, the Power Authority were extremely glad that such a quick and easy repair had been available to them.

Products used

Both of these products are available in the SylWrap Universal Pipe Repair Kit and the SylWrap Pipe Repair Contractor Case which contains enough equipment to carry out multiple fixes.

Repair Photos

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

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


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Case Study: Leaking Water Main, UK

A live repair carried out on a water main which had been leaking for the previous 15 years
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Fixing the unfixable – finding a solution for a water main repair which had been leaking for 15 years

For 15 years, nobody had been able to find a solution to fix a leaking water main located underground in the United Kingdom. That was until a SylWrap Universal Pipe Repair Kit carried out a permanent water main repair inside of an hour.

Why had it taken such a long time to find a suitable repair method? There were two major challenges which needed to be overcome for this water main repair to be successful, which explains why it had remained in a damaged state for a decade-and-a-half.

The first challenge was that the 40mm carbon steel water main was located in a confined space underground. Access was extremely restricted, meaning that a repair was difficult to carry out. Only a single contractor could realistically access the water main at any one time and there was no room for any heavy equipment. This also made a water main replacement even more difficult.

The second challenge was that because of the importance of the water main involved, shutting off the flow was impractical. The only solution therefore was to find a way to carry out a live leak repair in a restricted space which would be effective when pressure could not be turned off – something which had proven elusive until now.

Sylmasta recommended the use Wrap & Seal Pipe Burst Tape and SylWrap Pipe Repair Bandages for a repair, both of which can be found in the SylWrap Universal Pipe Repair Kit for sealing live leaks.

Because of the complexity of the repair, it was decided to use a double wrapping of Pipe Burst Tape in order to attempt to seal the leak. In normal applications, Wrap & Seal would be stretched by 300% and wrapped firmly around the leaking water main.

But given how little room there was to work under the pipe, there were concerns that maximum stretch of the Pipe Repair Tape wouldn’t have been possible during this particular application.

Once the water main repair began however, it soon became clear that Wrap & Seal was effective in sealing the leak. Once applied, the Pipe Bust Tape was then overwrapped with SylWrap Pipe Repair Bandage which, after being activated with water, set hard within 30 minutes to form a rock-hard, impact resistant layer and complete a permanent repair.

The contractor carrying out the repair was delighted that after such a long period of time, they’d finally been able to offer a solution. They said afterwards, “The repair was a complete success as we knew it would be. The information that you provided greatly supported the project and more importantly, future projects.”

It had only taken 15 years, but finally the leaking water main had been repaired.

Products used

Both of these products are available in the SylWrap Universal Pipe Repair Kit and the SylWrap Pipe Repair Contractor Case which contains enough equipment to carry out multiple fixes.

Repair Photos

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

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


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Case Study: Residential Property, UK

A dream house in Essex at which Sylmasta Liquid Rubber helped to fix a roof terrace leak
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A dream house in Essex at which Sylmasta Liquid Rubber helped to fix a roof terrace leak

 

Sealing the Dream – how creative thinking and Sylmasta Liquid Rubber helped eliminate drips during a roof terrace repair on a dream home

 

A dream home being built in Essex encountered an unexpected issue when water began to drip from necessary expansion gaps between glass panels installed on a roof terrace and onto an enclosed balcony below.

 

One of the most striking features of this stunning property on the Thames Estuary is its roof terrace with panoramic views.

 

This wasn’t without problems however, due to the required space that had to be left between each of the glass panels placed around the edge of the terrace.

 

The section of roof terrace in question featured 26 glass panels, each of which were around 1.3m in length with a 25mm expansion gap between the panels.

 

Whenever it rained, or spray blew in off the Thames, water would drip off the roof and glass panels, through the gaps and onto the balcony underneath where electrical installations such as LED lights and speakers had been added.

 

This was creating a real issue which required a quick and easy solution. Thinking outside the box, the homeowner used a packing medium and Sylmasta Liquid Rubber to fill the gaps, preventing drippage and protecting the electrical equipment below.

 

Liquid Rubber is a tough and flexible compound which is normally used to repair conveyor belts, make moulds or add noise-reducing and abrasion-resistant linings to equipment.

 

For this installation, the homeowner creatively poured Liquid Rubber onto the packing medium which had been placed into the gap, sealing everything in place and solving the drip issue.

 

With Liquid Rubber setting to black, the application blended in perfectly with the resin that had been used on the rest of the installation. Even on close inspection, you are unable to tell that two different products have been used.

 

The roof terrace repair has ensured that there are no more drips and the homeowner has since told us that he was delighted with the solution.

 

Products used

 

 

Repair Photos

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

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


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Case Study: Waste Water Treatment Works, UK

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Clearing up a mess – how SylWrap Pipe Repair Solutions saved the day at a Waste Water Treatment Works

A Waste Water Treatment Works in the United Kingdom was undergoing a major infrastructure upgrade when contractors cut through a 450mm waste water pipe – with disastrous consequences.

The contractors mistakenly believed the pipe in question had been decommissioned and was due for removal. In actual fact, it was one of the most important live pipes at the site in Sussex as it was linked to all of the waste treatment ponds. As a result, there was no feasible way to stop the flow once the pipe had been breached.

The severity of the cuts inflicted on the pipe meant that from the moment it was damaged, a large amount of contaminated water began escaping. A quick waste water pipe repair was therefore required to prevent a catastrophic and embarrassing situation from unfolding.

The Waste Water Works got in contact with Sylmasta. Within an hour of receiving the call, all the SylWrap Pipe Repair equipment needed to permanently repair the badly damaged pipe had been delivered to the site.

Firstly, Wrap & Seal Pipe Burst Tape was applied to the pipe to stop the flow. Wrap & Seal’s self-fusing technology combined with the fact that it stretches to 300% its length ensured that it was able to seal the leak despite the high amount of pressure flowing through the pipe.

The Wrap & Seal was then overwrapped using SylWrap Bandages, reinforcing the repair and providing a permanent fix. Because SylWrap is water-activated, very little preparation was needed to complete the repair and it left the pipe with a rock-hard protective layer.

The ease with which SylWrap products can be applied and the speed at which they are effective meant that the repair was completed in under 30 minutes. In monetary terms, it cost the Waste Water Treatment Works less than £300 – and that included spare Wrap & Seal and SylWrap Bandages should they suffer another unexpected problem during the remainder of the redevelopment works.

Had SylWrap Pipe Repair products not been so readily available to offer a waste water pipe repair solution, this could have turned into a serious environmental issue for both the contractor and the site owner.

The cost of replacing the pipe combined with the associated clean up of the leaking contaminated water could also have run into many thousands of pounds.

Understandably, the project manager was extremely happy with how quickly and efficiently the problem was fixed. He got in contact shortly after, saying “Thank you so much, the pipe repair worked a treat.”

Products used

Both of these products are available in the SylWrap Universal Pipe Repair Kit and the SylWrap Pipe Repair Contractor Case which contains enough equipment to carry out multiple fixes.

Repair Photos

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

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


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