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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 Hairline Crack Around Diameter of Porcelain Toilet Soil Pipe

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

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

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

Case Study Data


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

Products Used


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

Case Study PDF


Case Study Details


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

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

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

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

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

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

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

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

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

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

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

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

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

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Case Study: Leaking Welded Saddle Joint Repair on 150mm Steel Pipe at Pumping House

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

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

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

Case Study Data


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

Products Used


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

Case Study PDF


Case Study Details


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

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

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

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

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

The pipe was cleaned and prepared before repair

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

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

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

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

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

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

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

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

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

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

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

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

Case Study Data


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

Products Used


Wrap & Seal Pipe Burst Tape
Self-amalgamating 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: 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

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Case Study: Live Leak Pipe Repair of Above and Below Ground Water Supply Pipelines

A cracked water supply pipe in Libya having undergone a completed repair with a SylWrap Universal Pipe Repair Kit

Two for the price of one – Underground and overground live leak repair to a water supply pipe network in Libya

One above-ground water pipe and one below-ground water pipe servicing a town in Libya as part of a supply network required live leak repair to seal cracks through which significant levels of water were escaping.

Case Study Data


Site
Water supply network
Location
Brega, Libya
Repair Type
Live leak pipe repair
Defect
Cracks in two sections of 100mm steel pipe operating at 5 bar pressure

Products Used


Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape used to seal high pressure leaks on both sections of pipe

SylWrap HD Pipe Repair Bandage
Composite wrap applied to reinforce the repaired areas with a rock hard, impact resistant sleeve

SylWrap Universal Pipe Repair Kit
Kit containing Wrap & Seal and SylWrap HD for making fast, live leak pipe repairs

SylWrap Pipe Repair Contractor Case
Case with enough products to make multiple pipe repairs, which could have been used here if available rather than 2 x Universal Kits

Case Study PDF


Case Study Details


Around 80 percent of the population of Libya live along or near the northern Mediterranean coast. With freshwater scarce, they rely on supplies being pumped via pipelines from aquifers in the south – known as the Great Man Made River of Libya.

The town of Brega in the north east is serviced by a network of 100mm steel water pipes running both above and below ground, connecting to the Great Man Made River. At least one underground leak was known about through visible signs in the earth surrounding the pipe.

Attending to the problem had never been a priority because of the complexity and cost involved in excavating the pipe, shutting down the line and then either repairing or replacing the leaking section.

The leak was not visible and so it could be ignored. This school of thought was changed when a section of above ground pipe developed a longitudinal split, through which significant amounts of water were escaping at around 5 bar pressure.

Water pouring from the split in the above ground pipe

A blind eye could not be turned to such a substantial leak causing flooding to the area underneath the pipe. The importance of the line meant it could not be isolated whilst the line was fixed or replacement took place.

It was decided to use a SylWrap Universal Pipe Repair Kit to make a live leak repair. All the products contained within the Kit are WRAS approved, meaning they are safe to use with drinking water.

First, Wrap & Seal Pipe Burst Tape was applied to seal the pipe. Made from self-amalgamating silicone, Wrap & Seal stretches by 300 percent and fuses to form a solid rubber band capable of sealing high pressure leaks.

The tape was anchored to the side of the split and then wrapped towards and over it. Once the split had been covered, layers of Wrap & Seal were built up until no more water was detected leaking from the pipe. This indicated a successful repair.

A SylWrap HD Pipe Repair Bandage applied to an above ground water supply line as part of a live leak repair
The above ground pipe successfully repaired with SylWrap HD

To reinforce the line, a SylWrap HD Pipe Repair Bandage was then applied. SylWrap is a composite wrap with a water activated resin which sets rock hard in minutes. It was wrapped and smoothed across the entire repair area, creating an impact resistant protective shell around the pipe.

Completing the repair took less than 30 minutes. Having seen how quick and easy the SylWrap Universal Kit was to use, the decision was taken to proceed with the repair of the leaking underground section of water supply pipe.

An underground water supply pipe is excavated and leak sealed using a SylWrap Pipe Repair Kit
The below ground pipe having been excavated and repaired

A trench was dug to reach the line with enough clearance underneath so that both Wrap & Seal and SylWrap HD could be applied. The defect in this pipe was a smaller crack easily arrested using the same repair method as with the above ground pipe.

Two leaking sections of water supply pipe had now been successfully repaired without disruption to homes and businesses in Brega. More importantly, there was now an awareness of how quick and easy pipe repair can be.

Future leaks are now set to be tackled with SylWrap Pipe Repair Kits as soon as they are identified, something which can help make a huge difference in an arid country like Libya.

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

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

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Case Study: Steel District Heating System Pipe Suspended in Ceiling Live Pinhole Leak Repair

A steel pipe in a district heating system leaking from a pinhole undergoes a live leak repair using a SylWrap Pipe Repair Contractor Case

Saved from substantial district heating damage – the energy company rewarded for equipping all their vans with a SylWrap Pipe Repair Contractor Case

A pinhole leak in a 50mm steel pipe suspended in the ceiling as part of a building’s district heating system required an urgent live leak repair when escaping, pressurised water began causing substantial damage to surrounding surfaces.

Case Study Data


Site
Public building
Location
United Kingdom
Repair Type
Live leak pipe repair
Defect
Pinhole in a 50mm steel district heating system pipe

Products Used


SylWrap Pipe Repair Contractor Case
The energy company responsible for the district heating system equip every van with a Contractor Case

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape used to seal the leak on the pipe despite the difficulty in gaining access to the ceiling

SylWrap HD Pipe Repair Bandage
Composite wrap applied to encapsulate the repaired section with an impact-resistant, protective sleeve

Case Study PDF


Case Study Details


The district heating system was operated by a United Kingdom based company who specialise in installing and maintaining sustainable energy generation systems in public buildings, residential developments, factories and manufacturing sites.

Because of the importance of pipes to these systems, Sylmasta already had an established relationship with the company prior to the repair. Each of the company’s vans are equipped with a SylWrap Pipe Repair Contractor Case in case of emergencies, enabling contractors to make up to four live leak repairs as soon as problems are identified.

A pinhole leak in a 50mm steel pipe in a district heating system prior to being repaired with a SylWrap Pipe Repair Contractor Case
Water jetting from the pipe was causing substantial damage to surfaces and surrounding pipework, both above and below

The repair in question was to a large pinhole leak in a section of 50mm pipe suspended in the ceiling of the building. Pressurised water was jetting out in numerous directions, causing substantial damage to surfaces and surrounding pipework both above and below the leaking pipe.

Flow could not be turned off, as this would have involved shutting down heating across the entire building. A live leak repair to the district heating system was therefore necessary, using lightweight materials which could be easily carried and applied from the top of a ladder used to reach the ceiling.

From the Contractor Case, Wrap & Seal Pipe Burst Tape was used to successfully seal the leak. Despite the difficulty in accessing the pipe caused by the minimal space to work in the ceiling cavity and the surrounding pipes, Wrap & Seal was still stretched by 300 percent, amalgamating to form a solid silicone band over the steel pipe.

Wrap & Seal successfully applied to seal the pinhole

The entire section was then encapsulated with a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets rock hard in minutes. Once cured, it reinforced the pipe from any future breakages.

After seeing the extent of the damage that escaping water managed to cause in the short space of time between the leak being identified and the Contractor Case arriving on site, the company were appreciative of their partnership with Sylmasta.

Had a Contractor Case not been so readily available, then this could easily have turned into a major incident for the district heating system and the building. Instead, the company’s reputation was enhanced for the swift manner in which they reacted to and repaired the problem.

Completed repair of a steel pipe in a district heating system suspended in the ceiling of a building
The repair was completed by encapsulating the entire section with SylWrap HD

The company have since used their Contractor Cases to make live leak repairs to pipes in various systems they operate made from aquatherm, a semi-rigid polypropylene material.

Aquatherm pipe is popular because it does not react with water, preventing leaching, corrosion, scaling and erosion – major causes of water contamination and long-term pipeline failure.

Once thought to be foolproof, it is now known that failures can happen in aquatherm. Reasons for this include excessive clamping, elevated temperatures, extreme vibrations, flow velocity, water pressure and chemistry, or the presence of copper ions.

There is also the danger posed when a section of aquatherm pipeline has been repaired by inserting copper or iron pipe, leading to different coefficients of thermal expansion and severe cracks.

In the event of any failures in aquatherm piping, the presence of Contractor Cases across the company’s fleet of vehicles means that leaks and bursts can be attended to instantly, instead of suffering delays waiting for materials or parts to be delivered.

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

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

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Case Study: Domestic Malleable Iron Water Pipe Repair in a Restricted Space

Wrap & Seal Pipe Burst Tape used to repair a 20mm domestic malleable iron water pipe in a restricted space

No space, no problem – Wrap & Seal makes a repair to a malleable iron water pipe with severely restricted access

A 20mm domestic malleable iron water pipe undergoes a live leak repair using Wrap & Seal Pipe Burst Tape despite space being severely restricted by the leaking section’s position in close proximity to a wall.

Case Study Data


Site
Domestic property
Location
United Kingdom
Repair Type
Live leak pipe repair
Defect
Small hole in 20mm malleable iron water pipe

Products Used


Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone tape which fuses to form a solid rubber band for high-pressure, live leak repairs

Case Study PDF



Case Study Details


The malleable iron pipe had developed a small hole facing towards a brick wall in an outside area of a domestic property in the UK. Water was escaping at around 3 bar pressure and flow through the leaking section of pipe could not be isolated.

Because this was a live leak repair, epoxy putty was ruled out as a sealing material. Wrap & Seal Pipe Burst Tape would therefore have to be used, making the repair particularly challenging due to the restricted space on two sides of the pipe.

Between the pipe and the back wall behind, there was around only 30mm clearance. Approximately 150mm of space existed between the pipe and the ground. Clearly, there was not going to be enough room for the user making the repair to stretch the Wrap & Seal by three times its length whilst it was wrapped, as would have normally been the case.

Repair of a 20mm domestic malleable iron water pipe in a restricted space at a domestic property
To apply the tape, it was stretched towards the user where there was most space

The tape was anchored 50mm to the right of the leak and held tightly against the pipe by property owner carrying out the repair, using their thumb. They then stretched the tape as far towards them as space would allow with their other hand, before pulling it under the pipe and up through the restricted space between the pipe and the back wall.

As the first wrap around was completed, the tape was stretched half the width across the Wrap & Seal still being held down to the pipe with the thumb. This anchored the tape firmly to the pipe.

The wrapping process continued in this manner, with the tape being stretched as much as possible into the space away from the wall before the user looped it under the pipe and up through the gap at the back.

The tape was then wrapped under the pipe and up through the restricted space between the pipe and back wall

Despite the fact that it was not possible to stretch the tape by its maximum 300 percent, the self-amalgamating silicone still fused effectively to form a solid rubber band over the leak. The 3 bar pressure was easily held by the repair.

Once the end of the tape was reached, the pipe was dried off. No more water could be felt escaping, indicating that the repair had been a success.

The property owner was delighted to have been able to carry out a safe DIY pipe repair in spite of the initial challenges that seemed to come with the application, and at a fraction of the cost of hiring a plumber.

Wrap & Seal has WRAS approval, meaning it is certified as safe to British standards to use on pipes which carry drinking water.

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

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

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Case Study: Live Leak Pinhole Repair on 150mm Elbow at Pumping House in Malaysia

A SylWrap Live Leak repair made to a pinhole leak on a 6 bar 150mm elbow joint with a pinhole leak

Fixing an elbow – a pumping house in Malaysia stays operational thanks to a SylWrap live leak repair

When a 150mm steel pipe elbow in a Malaysia pumping house developed a pinhole leak through which water was spraying out at 6 bar pressure, the company responsible for the facility turned to Sylmasta for a rapid live leak repair.

Case Study Data


Site
Pumping house
Location
Malaysia
Repair Type
Live leak repair
Defect
Pinhole leak in 150mm steel pipe elbow joint

Products Used


Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape used to seal the live leak on the elbow joint

SylWrap HD Pipe Repair Bandage
Composite repair wrap applied to reinforce the initial repair via an impact resistant protective layer

SylWrap Pipe Repair Contractor Case
Contains enough products to make up to six live leak repairs, now approved for use on Kuala Lumpur’s vast network

Case Study PDF


Case Study Details


The steel pipe was an important part of the system at the pumping house, operated by a water company. A pinhole leak had appeared on an elbow joint weakened by corrosion where two sections of metalwork joined together.

Because the leak was on an elbow, a repair clamp could not be fitted. The pipe could not be taken out of operation for repair or replacement due to its importance to operations at the pumping house.

A pinhole leak on an elbow joint in a Malaysia pumping station prior to undergoing a live leak repair
The pinhole was located on an elbow
A pressurised jet of water escaping from a 150mm pipe elbow in a Malaysia pumping station
Pressurised jet of water spraying from the pinhole leak

The water company’s maintenance team therefore used a SylWrap Universal Pipe Repair Kit to carry out a live leak repair which would be effective on the 150mm elbow operating under 6 bar pressure.

Wrap & Seal Pipe Burst Tape was used to seal the pinhole leak in the pipe. Wrap & Seal is made from self-amalgamating silicone. It stretches by 300 percent and fuses to form a solid rubber band over holes and cracks in pipework.

Wrap & Seal Pioe Burst Tape used to repair a pinhole leak on a 150mm pipe elbow in Malaysia
Wrap & Seal Pipe Burst Tape was stretched by its maximum 300 percent
Wrap & Seal successfully sealed the pinhole leak

Once the Tape had successfully sealed the hole in the pipe, it was overwrapped with a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite wrap with a water activated resin which sets rock hard in minutes.

The Bandage was wrapped around the elbow and smoothed down whilst water from a bucket was poured over it at sporadic intervals. Once cured, SylWrap HD provided an impact resistant shell around the elbow, preventing it from any future leaks or bursts.

Within 30 minutes of the start of the application, the maintenance team had successfully repaired the elbow with no interruption to operations at the pumping house.

SylWrap HD Pipe Repair Bandage used to reinforce a repair on a 150mm elbow joint in a Malaysia pumping station
SylWrap HD Bandage was used to reinforce the repair
The repair was completed in less than 30 minutes

Both Wrap & Seal and SylWrap HD are WRAS approved, meaning that they are certified as safe to use on pipes and fittings carrying drinking water according to British Standards.

Numerous other successful pipe repair applications have since been made in Malaysia using Wrap & Seal and SylWrap HD supplied in a SylWrap Pipe Repair Contractor Case.

This has led the Case to be approved by the national supplier in Malaysia for carrying out leak repairs across Kuala Lumpur’s vast pipe network.

Each Contractor Case contains enough products to make up to six live leak repairs on pipes of all diameters and types without the need for any training.

The Case can be easily stored on-the-van, providing a lightweight and more versatile alternative to carrying around heavy, bulky pipe repair clamps.

When leaks and bursts on the water network are identified, a contractor simply has to reach for the Case on their van to repair the problem in under 30 minutes.

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