A 2 metre section of steel pipe suffering from heavy corrosion undergoes a rebuild and reinforcement with Sylmasta AB Epoxy Putty and SylWrap CR Corrosion Protection Wrap

Industrial Site Rebuild & Reinforce Heavily Corroded 2 Metre Section of Steel Pipe

An industrial site in Saudi Arabia carry out the rebuild and reinforcement of a 2 metre section of heavily corroded steel pipe before the line became breached and required either replacement or a complex leak repair.

Case Study Overview

Site Industrial site
Location Saudi Arabia
Pipe Type 2 metre section steel pipe
Repair Type Pipe reinforcement
Products Sylmasta AB Original Epoxy Putty, SylWrap CR Corrosion Protection Wrap


Pipe Defect

The pipe was suffering from a 600mm patch of very heavy corrosion to its external surface. It was only a matter of time until this corrosion ate through the remaining brittle steel and breached the line.

When this happened, the line would have to be shut off for either a complex leak repair, or so a replacement section could be fitted. To avoid this, the site decided to rebuild and strengthen the pipe before it failed.

A 600mm patch of heavy corrosion had left the external pipe surface severely weakened

SylWrap Solution

The first stage of the repair involved rebuilding the area weakened by corrosion using Sylmasta AB Original Epoxy Putty. AB Original is a super strength putty filled with ceramic to make it harder wearing. It offers excellent protection against corrosion. In chemically aggressive conditions like the site in question, it acts as a sacrificial layer to protect pipes and metalwork.

Part A and Part B of the putty were kneaded by hand in equal measures. Once mixed and whilst still soft, AB Original was pushed down onto the pipe. It filled all imperfections, returning the pipe to its original thickness and restoring the integrity of the line.

After the putty had cured, SylWrap CR Corrosion Protection Wrap was then applied to offer further reinforcement to the steel pipe. SylWrap CR is a black-coloured composite repair bandage incorporated with highly effective corrosion inhibitors.

It has been specially formulated to protect pipes, metalwork and other structures in harsh and aggressive environments. SylWrap CR was activated with water, wrapped and smoothed along a 2 metre section of the pipeline, including over the putty.

Within minutes, it began to cure to a rock hard material. Once set, SylWrap CR formed an impact resistant shell around the pipe to further strengthen it from future corrosion attack and remove the prospect of a breach in the line.

Sylmasta AB Original Epoxy Putty used in the reinforcement of a steel pipe suffering from heavy corrosion
Sylmasta AB Original rebuilt the area damaged by corrosion
SylWrap CR applied for the reinforcement of a steel pipe and to protect it from corrosion at an industrial site in Saudi Arabia
The pipe was reinforced with SylWrap CR to complete the repair

Outcome

Completing the repair from the first kneading of Sylmasta AB to the finished application of SylWrap CR took half a day. The line remained operational throughout the repair, meaning there was no disruption to the site.

Rebuilding and reinforcing the corroded steel pipe cost a fraction of a future leak repair or replacing the entire section of line once corrosion had eaten all the way through.


Follow Up

The site were very pleased that they had opted to strengthen the line before a much more complex and expensive issue had developed. A follow up five years later revealed the reinforcement was still in excellent working order with no signs of deterioration.


Products Used

Sylmasta AB Original
Putty with excellent corrosion and chemical resistance used to rebuild and repair

SylWrap CR Wrap
Repair bandage with corrosion inhibitors for protecting pipes in aggressive environments


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Email: sales@sylmasta.com