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Case Study: Corrosion Protection of 600mm Ductile Pipe & Outlets in Underground Pumping Station

A ductile pipe system in an underground pumping station undergoes corrosion protection measures

Protection at the pumping station – corrosion prevention measures for a complex ductile pipe system

A water company take corrosion protection measures to avoid the future weakening of a 600mm diameter ductile pipe system with three outlets to isolation valves in an underground pumping station.

Case Study Data


Site
Underground pumping station
Location
UK
Repair Type
Corrosion protection
Defect
600mm ductile pipe showing early signs of surface damage

Products Used


Liquid Metal Epoxy Coating
Brush applied coating which cures to a hard wearing, metallic surface for strengthening pipes and protecting against corrosion

SylWrap Pipe Repair Bandage
Composite repair wrap with water activated resin which sets rock hard to encompass pipes with an impact resistant outer sleeve

Case Study PDF


Case Study Details


Conditions inside the underground pumping station housing the pipework were damp, grimy and ripe for corrosion. Rainwater, dirt, sand and other contaminates were able to enter the chamber and settle on the pipework.

As a result, the ductile pipe system was beginning to show very early signs of exterior surface damage. This was of particular concern to the water company operating the pumping house because of the complexity of the pipework and the issues that would come in the event of heavy corrosion developing.

Diagram of the pipe system layout inside the underground pumping station

The main section of pipe entered the chamber through a wall. It was five metres long with three flanges at equal intervals. The three outlets branching off were two metres in length, had one flange each and a reducing spool to 200mm diameter at the isolation valves.

Carrying out any sort of leak repair or replacing sections of the system would present a serious challenge. Instead, the water company sought enhanced corrosion protection measures for the ductile pipe to lessen the chances of the line becoming breached.

Rust and dirt were cleaned from the pipe before it was coated with Liquid Metal Epoxy Coating. Liquid Metal is brush applied and cures to form a smooth, metallic, hard-wearing outer surface which acts as a shield against external corrosion.

The entire main section of pipe, the three outlets, reducing spools and all six flanges were painted in Liquid Metal. The protective layer provided by the epoxy coating was then further reinforced using SylWrap Pipe Repair Bandage.

SylWrap Bandage is a composite wrap with a water-activated resin. It is wrapped and smoothed around pipework, curing in minutes to provide a rock-hard, impact resistant layer of protection.

The engineers carrying out the repair wrapped all sections of the pipe system in four layers of SylWrap, running the Bandage as close to the flange plates as possible to ensure maximum coverage.

Despite the space constraints where the pipe ran close to the floor, the engineers were still able to successfully apply SylWrap around the bottom of the line. Once SylWrap had been applied, another coating of Liquid Metal was added over the top as an additional corrosion prevention measure.

With the repair completed, the water company could now be satisfied that the two coatings of Liquid Metal and several layers of SylWrap Bandage would offer robust protection for the ductile pipe against corrosion.

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

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

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

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

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

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

Case Study Data


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

Products Used


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

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

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

Case Study PDF


Case Study Details


A SylWrap Pipe Repair Contractor Case contains enough products to seal up to six live leaks, making it the ideal kit to keep on-site for rapid response to emergences. The sugar mill had approved its use several years earlier, since when repairs had been made to multiple sections of pipework.

These included 90 degree elbow bends in elevated pipelines and a particularly challenging Y-joint leaking from the exact point where three separate pipes connected. Most of these pipes carried hot water.

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

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

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

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

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

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

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

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

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

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

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

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

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Case Study: Repair of Leaking & Corroded Shared Water Supply Pipe Connected to Eight Cottages

Liquid Metal Epoxy Coating used in the repair of a corroded shared water supply pipe

Cottages counter corrosion – the Sylmasta Pipe Refurbishment System is used to repair and reinforce a water supply line shared by eight properties

Four cottages in a terrace of eight in London use the Sylmasta Pipe Refurbishment System to repair and reinforce their respective sections of a 48 metre long shared water supply pipe weakened and breached by corrosion.

Case Study Data


Site
Terraced cottages
Location
London, UK
Repair Type
Leak repair and pipe reinforcement
Defect
Heavily corroded 48 metre long steel shared water supply pipe breached in places

Products Used


Superfast Aqua PW Epoxy Putty Stick
Fast working, WRAS approved epoxy putty with excellent wet surface adhesion used to seal leaks in pipework

Liquid Metal Epoxy Coating
Brush applied coating which cures to a hard wearing, metallic surface for strengthening pipes and protecting against corrosion

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin which sets rock hard to encompass pipes with an impact resistant outer sleeve

Case Study PDF


Case Study Details


The row of eight terraced cottages were built in the middle of the 19th century. They were connected to the public water network at a later date, which led to a somewhat unusual setup involving an above-ground shared supply pipe.

This steel pipe connected with a water main underground at one end of the terrace. It rose up the side of the first cottage and was then fixed at a height of around three metres to the back wall of all eight properties, along which it ran for 48 metres.

The height of the line meant it was surrounded by extensions built onto the cottages, downpipes, guttering and other installations and improvements added to the buildings over time. Access to certain sections was therefore severely restricted.

Each cottage was responsible for the section of pipe outside their property, giving them around six metres to maintain and upkeep. Lagging had been added around all 48 metres of the line to protect it during winter.

Unfortunately, low-quality insulation material was used which soaked up moisture like a sponge, causing water and condensation to become trapped against the steel. Over time, this led to heavy corrosion and a weakening of the pipe.

When temperatures in London dropped as low as -8°C in an unusually cold spell and water inside the pipe froze, the brittle metalwork was unable to cope. Several cracks appeared outside one cottage, requiring repair.

The lagging was removed from the leaking section to access the pipe, at which point the extent of the corrosion problem became clear. The other seven cottages were inevitably going to suffer from bursts on their sections in future if something were not done.

Initially, the cottages contacted their water company for help. Because the pipe was a shared supply line and not part of the public network, the water company said they had no responsibility for it. It was therefore down to the eight property owners to find a solution themselves.

The cottages were quoted £22,000 to replace the entire line. Some of the property owners did not wish to contribute £2,750 towards the cost, preferring instead to take a chance their section would not burst.

It next became clear that replacing individual sections of pipe for those cottages wanting to avoid future leaks would not be practical either. New fittings would struggle to connect with old, brittle pipes not being replaced.

Installation would also be disruptive to those cottages not undertaking work, with shared electrical boxes and satellite dishes having to be taken out of service whilst new sections of pipe were fitted.

With no common route forward found, the cottage with the leaking section contacted Sylmasta for advice on sealing the holes on their part of the line. At this point, the owner also explained the complications caused by the shared water supply pipe and the concern about how it might deteriorate further.

Sylmasta suggested that in addition to sealing the cracked section of pipe outside one cottage, their Pipe Refurbishment System be used to reinforce individual sections along the line for those property owners wanting protection against future leaks.

Two cottages requested their sections be attended to, and so Sylmasta sent an approved contractor to London to carry out the repair and strengthening of the shared water supply pipe.

Once the lagging had been removed, the first stage of the Pipe Refurbishment System involved application of the leak sealant – in this case, Superfast Aqua PW Epoxy Putty.

Superfast Aqua PW was chosen for its excellent wet surface adhesion to alleviate concerns the pipe may have been weeping water. It has WRAS approval, meaning it is certified as safe to come into contact with potable water.

Aqua PW is supplied in a pre-measured 114g stick. The required amount of putty was cut from the stick, kneaded by hand and then pushed into the cracks and damage in the pipe whilst soft. Within 20 minutes, it cured to form a rock-hard sealing material.

The second stage of the Pipe Refurbishment System saw Liquid Metal Epoxy Coating applied to strengthen the line and protect it from corrosion. Liquid Metal was painted on by brush to sections of the pipe outside every cottage who wanted their part of the line reinforced.

Repair of a shared water supply pipe made using Liquid Metal Epoxy Coating

Once cured, Liquid Metal formed a smooth, metallic, hard-wearing outer surface around the pipe to act as a shield against external corrosion. Should the brittle steel be breached from the inside by freezing temperatures in future, the Liquid Metal shell will contain the contents of the pipe.

SylWrap HD Pipe Repair Bandage was added as the final stage of the Pipe Refurbishment System, to provide the shared water supply pipe with another layer of protection. SylWrap HD is a composite repair wrap with a water-activated resin which sets rock-hard in minutes when wrapped and smoothed around pipework.

Nine SylWrap Bandages were applied per cottage to build up thickness to four layers, with the application taking place whilst the Liquid Metal remained tacky to improve adhesion to the pipe. Once cured, SylWrap HD formed an impact resistant shell encompassing the pipe.

In addition to the two planned repairs, a third cottage owner asked for their section to be reinforced, having seen how straightforward and cost-effective the process was. Their part of the pipe had not been as badly weakened by corrosion and therefore required only Liquid Metal for suitable strengthening.

All three cottages were completed in a single day, since when a fourth has requested the approved contractor return and attend to their part of the pipe with whatever treatment necessary depending on its condition beneath the cladding.

Those cottages who used the Sylmasta Pipe Refurbishment System will now head into winter confident their sections of the shared water supply pipe will not be weakened further by corrosion or breached. The approved contractor then installed new lagging to replace the original insulation which had to be removed.

In the unlikely event that water and condensation again became trapped underneath the lagging, the barrier between moisture and the original metalwork provided by Liquid Metal and SylWrap HD would make future corrosion virtually impossible.

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: 3 Metre Section of Corroded Steel Gas Pipe in CHP System Repair & Refurbishment

A heavily corroded steel pipe in a CHP system carrying natural gas undergoes repair with the Sylmasta Pipe Refurbishment System

Combined Liquid Metal and SylWrap HD repair combined heat and power system natural gas pipe

An industrial plant repair and refurbish a three metre section of steel pipe carrying natural gas in a combined heat and power system after water trapped between the line and an incorrectly installed PVC tape caused heavy corrosion.

Case Study Data


Site
Industrial Plant
Location
Puerto Rico
Repair Type
Pipe refurbishment
Defect
Three metre section of corroded 100mm steel pipe in CHP system

Products Used


Liquid Metal Epoxy Coating
Brush applied coating which cures to form an ultra-smooth, hard wearing, metallic surface over pipes and structures

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

Case Study PDF


Case Study Details


The pipeline was 100mm in diameter and ran for 365 metres through the plant, carrying natural gas produced by a combined heat and power system. It was hung on a series of U-shaped supports welded to I-beams suspended from the roof of the building.

When originally installed, the pipe had been wrapped with a protective PVC tape. Unfortunately, incorrect application of the tape had left a three metre section where it was possible for water and condensation to become trapped between the tape and the line.

Removal of the yellow PVC tape revealed very heavy corrosion to the steel pipe

This had led to heavy corrosion, which was particularly prevalent at the bottom of the pipe and the area where the section in question rested on its U-shaped support. The weakened three metres of the natural gas pipe now required strengthening and repair before the steel became breached.

The plant decided to use the Sylmasta Pipe Refurbishment System to bring the damaged section of the line back up to specification, by reinforcing the metalwork and giving the pipe greater protection against future corrosion.

First, the U-Shaped support was cut away from the I-beam to enable better access to the corroded area. The PVC tape was removed and rust, grime and paint ground off. Alcoholic cloths were then used to remove any remaining residue from the grinding process.

Liquid Metal applied to repair a natural gas pipe suffering from heavy exterior corrosion
Liquid Metal was brush applied across the three metres of the pipe suffering from corrosion

To repair the damage and restore the pipe exterior, the three metre section was coated in Liquid Metal Epoxy Coating. Liquid Metal is brush applied and cures to form a smooth, metallic, hard-wearing outer surface which acts as a shield against external corrosion and chemical attack.

The 90 minute gel time of Liquid Metal allowed significant amounts of epoxy to be mixed and painted on without the threat of premature curing. A SylWrap HD Pipe Repair Bandage was then wrapped around the area of the line which had contact with the U-shaped support.

SylWrap HD Pipe Repair Bandage applied to a heavily corroded steel natural gas pipe
SylWrap HD was wrapped around the area of the pipe which came into contact with the U-shaped support, which was to be welded back in place to the I-beam above

SylWrap HD is a composite repair wrap with a water-activated resin. It was applied whilst the Liquid Metal remained tacky and cured within minutes to form a rock-hard, impact resistant outer shell around the pipe. This further increased the thickness of the weakened section and provided an additional layer of protection.

A second layer of Liquid Metal was applied across the three metre section, including over the SylWrap HD. Although an additional coating on top of the composite bandage is not a required step of the Sylmasta Pipe Refurbishment System, the plant wanted to make the line look aesthetically pleasing with a final metallic finish.

A second Liquid Metal coating was applied over the SylWrap, the U-support welded back in place and the pipe fixed to it via a support clamp

Once the pipe had been refurbished, the removed U-shaped support was welded back to the I-beam. The line was then fixed to the U-shape via a new pipe support clamp fitted to prevent movement caused by vibration. The clamp was also coated in Liquid Metal.

Refurbishing the pipe was carried out with no impact to operations at the plant. It prevented an expensive and disruptive future repair or replacement being needed when corrosion eventually ate through the line.

The ultra smooth finish provided by Liquid Metal compared to the pitting caused by corrosion

The plant were very happy with the outcome and how easy their maintenance team found the application. They are now intending to use Liquid Metal to extend the lifespan of other pipes and structures at both this facility and across other sites.

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: Burst Copper Pipe Repair in Portable Horse & Dog Shower Unit

A copper pipe burst during freezing winter weather undergoes repair with a SylWrap Standard Pipe Repair Kit

Replacement? Hold your horses – the repair of a burst copper pipe which had a horse shower running again in no time

When freezing winter weather led a copper pipe in a portable horse and dog shower to burst, it required a quick and simple repair method capable of being effective inside the cramped space of the unit.

Case Study Data


Site
Portable horse and dog shower
Location
United Kingdom
Repair Type
Leak repair
Defect
Split in copper pipe caused by freezing temperatures

Products Used


Superfast Copper Epoxy Putty Stick
Fast-working epoxy putty pushed into the crack in the copper pipe to seal it

SylWrap HD Pipe Repair Bandage
Composite repair wrap applied over Superfast Copper to reinforce the initial 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


Showerking are a Sussex-based supplier of portable hot shower units designed for horses and dogs. Units are typically stored in unheated outbuildings. Although designed to handle winter weather, copper pipe in the unit which has not been fully drained becomes prone to bursting during periods of exceptionally cold weather.

When temperatures in the United Kingdom dropped as low as -15°C, several Showerking owners reported burst pipes which rendered their units unusable. If they turned the shower on, water would spray out of the large crack created in the copper pipe.

Freezing temperatures had created a split in the copper pipe

Fortunately, Showerking had already contacted Sylmasta about the possibilities of pipe repair for horse showers. The SylWrap Standard Pipe Repair Kit provided the most suitable method as units would be turned off in the event of leaks or bursts, meaning no pressure to the pipe.

It had been established that the smallest Standard Pipe Repair Kit (SYL-106-NP) was ideal for application because of both the cramped space inside the unit and the difficult shape of the pipework. There were many bends which were unrepairable with a clamp.

Through the relationship between Showerking and Sylmasta, users whose horse showers had suffered burst pipes were directed to the exact product they needed to fix the problem, and had the straightforward repair process explained to them.

Superfast Copper Epoxy Putty used to repair a burst in a horse shower copper pipe caused by freezing temperatures
Superfast Copper Epoxy Putty was used to cover the split

Loose material was removed from the burst copper pipe before repair. Superfast Copper Epoxy Putty Stick was then used to seal the crack. Enough putty to cover the crack was cut from the stick and kneaded by hand until it turned a uniform colour.

Whilst soft, the putty was pushed onto the pipe, encompassing the entire crack. This completed the first stage of the repair. The second stage involved applying a SylWrap HD Pipe Repair Bandage over the Superfast Copper.

SylWrap HD is a composite repair wrap with a water-activated resin which sets rock hard. The bandage was wrapped and smoothed around the pipe as the Superfast Copper began to harden, forcing the putty into the crack to create a permanent, watertight seal.

Within five minutes of SylWrap HD being applied, the bandage had cured to form a rock hard shell reinforcing the pipe, and which also offered protection from expansion in the future. The completed repair was resistant to 30bar, making it more than capable of holding the pressure the horse shower unit operated at.

The repair took less than 30 minutes from start to finish and the SYL-106-NP Standard Pipe Repair Kit cost under £25 including delivery, returning the £180 Showerking unit to service the same day.

For more information about portable horse and dog showers, please see the Showerking website.

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

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

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Case Study: Live Leak Repair of 150mm Cement Coated Steel Pipe on Water Network in Mexico

An underground cement coated steel pipe leaking through an 80mm long split is repaired using a SylWrap Pipe Repair Contractor Case

Contractor Case calling – the cement coated steel pipe repair carried out by engineers in Mexico equipped for every leak

An underground cement coated steel pipe on a water network in Mexico undergoes a live leak repair after excavation followed by the removal of the outer coating revealed a 80mm long split in the line.

Case Study Data


Site
Underground water network
Location
Mexico
Repair Type
Live leak pipe repair
Defect
80mm split in a cement coated steel pipe carrying potable water

Products Used


Wrap & Seal Pipe Burst Tape
Self-amalgamating 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

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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

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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

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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

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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