Posted on

Case Study: Seawater Storage Tank Floor Repair at Gas Processing Plant in Saudi Arabia

Sylmasta AB Original Epoxy Putty used to repair cracks in the floor of a seawater storage tank

Corrosion could have floored this seawater storage tank – until a repair involving Sylmasta AB Original Epoxy Putty

The floor of a seawater storage tank at a gas processing plant in Saudi Arabia undergoes repair after gaps appeared between rubber sheeting, leaving the concrete which coated the bottom of the tank unprotected and exposed.

Case Study Data


Site
Gas processing plant
Location
Saudi Arabia
Repair Type
Floor repair
Defect
Gaps between rubber sheeting leaving concrete tank floor exposed

Products Used


Sylmasta AB Original Epoxy Putty
Waterproof, hard-wearing epoxy putty with a longer work time used to permanently fill gaps and cracks

Case Study PDF


Case Study Details


The plant collected gasses produced during the extraction of crude oil – such as propane, butane, methane and ethane – and converted them into a number of different chemicals exported worldwide for industrial and agricultural use.

Seawater was extracted from the Persian Gulf and stored in vast metal tanks for use in cooling and other processes on site. The interior of each tank was concrete coated and then lined with rubber matting for protection against corrosion.

Problems with one tank led to it being drained for inspection. This revealed sections of the rubber matting on the floor of the tank had become loosened, lifted and completely broken apart in some places, leaving the concrete lining exposed.

There was a risk that this exposure could lead to seawater finding a way through the concrete and coming into contact with the metal frame beneath. This would put the tank in danger of serious and irreparable damaged caused by corrosion. All gaps in the rubber sheeting therefore had to be sealed before the tank could go back into service.

The engineering team carrying out the seawater tank repair decided to use Sylmasta AB Original Epoxy Putty for the application. AB Original is ceramic-filled, making it stronger and harder wearing than other epoxy putties. It is fully waterproof, adheres to wet surfaces and its high chemical and corrosion resistance mean it is often used as a sacrificial layer.

AB Original was mixed by hand. Whilst soft enough to shape and manipulate, it was forced into the gaps and cracks between the rubber sheeting and smoothed off with water and a hand tool.

The two hour work time of AB Original allowed large amounts of putty to be mixed and applied without the threat of premature curing. Once hardened, the putty permanently filled every gap with a waterproof material, protecting the concrete lining from seawater exposure.

After the application of AB Original, fibreglass sheets were layered over the rubber matting and coated with an epoxy resin. This created a new reinforced floor surface over the damaged rubber, offering yet another layer between seawater and the metal frame of the tank.

The plant could then put the tank back into operation safe in the knowledge that the metalwork was now far better protected by a combination of concrete, AB Original, rubber matting and an epoxy composite 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

Posted on

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 silicone 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


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

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 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.

Wrap & Seal is made from self-amalgamating silicone. When stretched and wrapped, it 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

Posted on

Case Study: Power Station Repair Extensive Damage to Alloy 20 Pump Lid Caused by Impeller

Ceramic Brushable Green Epoxy Coating is used to repair a badly damaged Alloy 20 pump lid at a power station water treatment plant

Keeping a lid on the cost of repair for a power station treatment plant pump in Puerto Rico

A power station in Puerto Rico repair a treatment plant pump lid made from Alloy 20 which would have cost $4000 to replace after it suffered extensive damage when an impeller fell out of place.

Case Study Data


Site
Power station treatment plant
Location
Puerto Rico
Repair Type
Damage repair
Defect
Gouged and scratched Alloy 20 pump lid

Products Used


Ceramic Brushable Green
Brushable epoxy coating used to repair surface damage and offer greater protection of the Alloy 20 pump lid

Case Study PDF


Case Study Data


The pump lid came from a mud pool at the power station treatment plant. It was 500mm in diameter and made from Alloy 20 (nickel-chromium-molybdenum stainless steel) for its high chemical and corrosion resistance.

Extensive damage had been caused when an impeller blade came out of place and fell directly onto the lid, leaving numerous scratches and several very deep gouges across the surface.

A replacement lid would have cost $4000 and required shipping to Puerto Rico, potentially leaving the pump out of service for a significant amount of time and causing disruption to operations.

The power station instead used Ceramic Brushable Green Epoxy Coating to repair the pump lid. Ceramic Brushable is reinforced with silicone carbide, giving it a toughened, ultra-smooth finish.

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

A pump lid made from Alloy 20 undergoes repair at a power station treatment plant after being damaged by an impeller
The pump lid having been fully repaired by Ceramic Brushable Green Epoxy Coating

The lid was removed from the pump. Part A and Part B of Ceramic Brushable Green were mixed and then applied via brush. The first few coatings were used to repair the damage by filling in the gouges and scratches, found mostly in the centre of the lid.

This was followed by additional layers being added across the entire 500mm area, creating a new reinforced surface over the original Alloy 20 to offer protection to the lid.

Once the final coating of Ceramic Brushable Green had begun to harden, the lid was turned on a lathe to finish it. The two colour tones on the complete repair show where the lid is angled towards the edge.

After a full cure had been achieved, the lid was fitted back in place and the water treatment plant could return to full service. The power station were extremely pleased with the application as it prevented a costly replacement which would have resulted in downtime at the site.

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

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

Posted on

Case Study: Trenchless Pipe Installation Protection of 150mm Steel Natural Gas Pipeline

SylShield is used to offer protection to welds and joins in a steel natural gas pipe to undergoe trenchless installation in Czech Republic

Czech mate – SylShield protection enables the trenchless installation of a natural gas pipeline in south east Czechia

In its first deployment in the field, SylShield was used for the protection of welded joints on a 150mm diameter steel pipeline carrying natural gas when it was rerouted beneath a road and river via horizontal directional drilling, a form of trenchless pipe installation.

Case Study Data


Site
Natural gas pipeline
Location
Czechia
Repair Type
Pipe and weld protection
Application
Protecting 150mm steel pipeline undergoing trenchless installation via horizontal directional drilling

Products Used


SylShield Pipe & Weld Protection Wrap
Composite repair wrap three times thicker than standard SylWrap HD for protecting pipes during trenchless installation

Case Study PDF


Case Study Details


Horizontal directional drilling involves connecting together sections of a pipeline above ground via welding or a similar process, digging a borehole and pulling the completed line through to install it.

This removes the need to dig huge and disruptive trenches across vast swathes of land. It also allows pipes to be installed beneath roads, rivers, seas and other areas which would otherwise be challenging to pass. In some cases, pipes many kilometres in length are dragged through the ground and installed using horizontal direction drilling.

The pipeline arrived on site in numerous separate sections before behind welded together

The high-pressure natural gas pipeline in the south of Czechia was being rerouted to improve energy security for the country. It was to pass under a local road and stream, meaning that horizontal directional drilling was the most suitable form of trenchless installation.

Pipes undergoing trenchless installation are given protection against the potential damage caused by dragging them underground. The 150mm diameter steel pipe being used in this application was coated in both epoxy and a 3mm thick fibreglass composite.

A 150mm natural gas pipeline to undergo trenchless pipe installation prior to having SylShield protection wrap applied
Joins on the pipe (black section) where welding had taken place could not be protected by epoxy or fibreglass, as the rest of the steel was

Joins on the pipe are more challenging to protect. The points at which sections are welded together cannot be covered with epoxy, fibreglass or any other type of factory applied protection. This is where SylShield came in.

The company installing the line were a long-time client of Sylmasta. They got in contact to ask if there was a potential solution for protecting the joints in the pipe, in addition to the heat shrink sleeves used as standard.

SylShield Pipe & Weld Protection Wrap is the toughest, most robust composite wrap in the SylWrap range three times the thickness of a standard SylWrap HD Pipe Repair Bandage. It has been specifically designed for the protection of pipelines during trenchless pipe installation.

Working to a tight deadline, Sylmasta were able to produce the required number of SylShield wraps at their factory in England on the Thursday and deliver them to Czechia. The installation team collected the products from a DHL depot on Monday morning and set to work immediately.

Each welded joint and heat shrink sleeve was overwrapped with SylShield. The resin was activated with water and SylShield wrapped and smoothed around the pipe. Within minutes, it cured to form a rock-hard sleeve encompassing the joint to protect it from the rigours of horizontal directional drilling.

As each section was wrapped with SylShield, shrink wrap was applied over the top to secure the composite against the pipe and improve lamination. The shrink wrap was then spiked, ensuring that the carbon dioxide released during the curing of SylShield could escape rather than becoming trapped.

SylShield used for the protection of a natural gas line ahead of trenchless pipe installation
A natural gas line given protection before trenchless pipe installation with SylShield Pipe & Weld Protection Wrap
Once the joins in the line had been protected, the pipe was ready to be pulled through the ground and installed via horizontal directional drilling

By Monday evening, the entire line had been welded together, protected with SylShield and pulled through the borehole under the road and stream to complete the trenchless installation. Sylmasta had played a small but important part improving natural gas supplies to Czechia.

Afterwards, the team leader responsible for the project emailed to say: “The installation was a success and we particularly appreciated the timely delivery of the SylShield wraps. Big thanks to Sylmasta for meeting the tight deadline, which even we thought would be unrealistic.”

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

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

Posted on

Case Study: Repair of Leaking Stainless Steel Pipe Inside Farm Biodigester Tank

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

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

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

Case Study Data


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

Products Used


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

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

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

Case Study PDF


Case Study Details


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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Posted on

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

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

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

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

Case Study Data


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

Products Used


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

Case Study PDF


Case Study Details


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

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

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

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

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

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

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

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

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

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

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

Posted on

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

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

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

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

Case Study Data


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

Products Used


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

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

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

Case Study PDF


Case Study Details


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

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

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

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

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

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

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

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

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

Posted on

Case Study: Environment Agency Repair Crack in Underwater Wall Between River & Trout Farm

A crack in an underwater wall between a river and a trout farm undergoes repair with Sylmasta AB Original Epoxy Putty

River repair runs smooth – a crack in an underwater wall between a river and a trout farm is permanently sealed

The Environment Agency repair an underwater wall discovered to be cracked when a system monitoring how much water was being taken from a Yorkshire river by a local trout farm began returning inaccurate readings.

Case Study Data


Site
Sluice between river and trout farm
Location
Yorkshire, United Kingdom
Repair Type
Crack repair
Defect
700mm long crack in underwater wall

Products Used


Sylmasta AB Original Epoxy Putty
Super-strength epoxy putty effective underwater used to permanently seal holes and cracks

Case Study PDF



Case Study Details


Trout farms in North Yorkshire are allowed to draw a limited amount of water from local rivers and streams. Extraction is normally controlled by a sluice connecting a farm to a river, which also enables the Environment Agency to monitor water levels to ensure no more than the permitted amount is taken.

Anomalies with data from one farm alerted the Environment Agency to a potential issue, initially believed to be with the sluice or the monitoring equipment. An inspection revealed that the problem was actually a 700mm long crack in a wall next to the sluice. The crack widened into a sizable hole as it reached the riverbed.

The sluice controlling the extraction of water from the river to the trout farm

Water from the river was now escaping through the crack and into the trout farm, making readings of the flow through the sluice completely inaccurate. The wall needed to be sealed to prevent water loss and ensure that the true level of water being taken by the farm could be recorded.

Sylmasta AB Original Epoxy Putty provided the ideal solution. AB Original is a ceramic-filled, high strength epoxy putty which cures underwater. It comes with a two hour work time, meaning that significant amounts of putty could be mixed to fill the crack without the threat of premature curing.

A 700mm long crack in an underwater wall prior to undergoing repair with Sylmasta AB Original Epoxy Putty
Significant levels of water were escaping from the river through the crack in the wall, seen here both above and below the waterline

An engineer from the Environment Agency attended the site with a large quantity of AB Original. Part A and Part B were kneaded in dry conditions. Once the putty had turned a uniform white colour and whilst it still remained soft, it was pushed into the crack.

The application began above the waterline, proceeding below it and then right the way down to where the crack met the waterbed. High-strength adhesion was achieved between the putty and the wall. Once cured, AB Original formed a rock-hard material to permanently fill the crack.

Sylmasta AB Original Epoxy Putty used to repair a crack in an underwater wall located alongside a river
AB Original was pushed into crack, curing to permanently seal the gap in the wall

After the repair was completed, water levels were carefully monitored. A very small leak remained, identified as being at the crack’s widest point near the riverbed. During the initial repair, it had been impossible to tell if all underwater areas in the wall had been sealed.

Further AB Original was applied at the base of the wall on a return visit. This brought the amount of water being drawn by the farm from the river back to expected levels, indicating that the crack had been successfully repaired.

Given the challenging nature of underwater repairs, the Environment Agency were delighted to have discovered such a versatile material capable of being effective underwater. They have since begun using AB Original for other applications and projects.

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

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

Posted on

Case Study: Fence Spurs Suffering from Concrete Cancer Filler Repair Using Epoxy Putty

Fence spur badly damaged by concrete cancer undergoes filler repair using Sylmasta AB Original Epoxy Putty

On the fence – installing replacement trellis provides the spur for a homeowner to repair posts suffering from concrete cancer

A homeowner installing a replacement trellis fence uses Sylmasta AB Original Epoxy Putty to repair damage to the original fence posts caused by concrete cancer, rather than having to undertake the mammoth task of replacing every spur.

Case Study Data


Site
Domestic property
Location
United Kingdom
Repair Type
Concrete filler repair
Defect
Fence spurs badly damaged by concrete cancer

Products Used


Sylmasta AB Original Epoxy Putty
Hard-wearing epoxy putty which offers excellent corrosion protection and can be used as a permanent repair filler

Case Study PDF



Case Study Details


Concrete cancer occurs where steel reinforcements inside of concrete begins to corrode. This causes the steel to expand and as a result, the surrounding concrete to fall away and disintegrate.

Having been in place for 30 years, the fence posts were already badly damaged. When disturbed during the replacement of the trellis, they shed several more large chunks of material.

Replacing every spur would have been a mammoth task and so the homeowner instead sought a means to repair the existing posts. They needed a material which would act as a concrete filler to repair the damage whilst at the same time offering greater protection against corrosion to lessen the impact of concrete cancer in future.

Sylmasta recommended the use of Sylmasta AB Original Epoxy Putty for the application. AB Original is a hard wearing, ceramic-filled putty with high corrosion and chemical resistance. It is suitable for indoor and outdoor use and comes with a two-hour cure for complex repairs.

The longer work time was particularly important for this application. Over 10kg of epoxy putty was needed to repair every concrete spur. Large quantities of putty could be mixed in one go and applied to significant areas of damage without the threat of premature curing.

Sylmasta AB is available in three colours as standard – white, grey and black. Grey was chosen for this repair because of its resemblance to concrete. Part A and Part B were mixed in equal measures. Whilst soft, the putty was pushed into the spur, filling cracks and replacing chunks of concrete which had been destroyed.

AB Original adhered easily to the existing concrete. Once cured, it formed a rock-hard material to permanently repair the damage caused by concrete cancer. Had the homeowner wanted the putty to blend in more with the existing spurs, then they could have pushed concrete dust into the soft Sylmasta AB before it fully hardened.

This technique is found in the Sylmasta Brick Repair Kit, containing AB Original and brick dust. It is used for the seamless repair of bricks, filling in defects caused during construction work or by processes such as lime blow.

The repair of every concrete fence spur was completed in the homeowner’s spare time over several weekends. They were very pleased with the result. AB Original successfully repaired the damage caused by concrete cancer and improved the appearance of the fence posts, without taking the considerable amount of time replacing every spur would have.

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

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

Posted on

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

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

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

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

Case Study Data


Site
Wastewater treatment plant
Location
South East England
Repair Type
Flange repair and reinforcement
Defect
Tree root ingress between flange plates on 18000mm underground pipe

Products Used


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

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

Case Study PDF


Case Study Details


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

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

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

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

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

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

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

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

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

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

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

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