Superfast Aqua PW Epoxy Putty and SylWrap HD Pipe Repair Bandage make a leak repair qualified to ASME PCC-2 Appendix 402-III – Validation for Repair of Leaking Component standard by sealing a 25mm hole which then withstood three pressure tests up to 30 bar.

Case Study Overview

Site Test site
Location United Kingdom
Pipe Type 110mm carbon steel pipe spool
Pressure 30 bar
Repair Type Leak repair
Products Superfast Aqua PW Epoxy Stick, SylWrap HD Pipe Repair Bandage

Pipe Defect

ASME PCC-2 Appendix 402-III – Validation for Repair of a Leaking Component assesses the ability of composite repair systems for sealing leaking pipes, tanks and vessels containing non-hazardous fluids operating below 10 bar.

To qualify for ASME PCC-2 402-III, a repair must successfuly seal a leaking pipe which has been fully breached, restore pressure-retaining capibility to the line and show it will not degrade or be compromised over time under service conditions.

It is a standard used in the water industry to give confidence that repairs on the public supply network will be strong and long lasting. It is also applicable in other industries where high-pressure water pipes are found, such as cooling systems at oil refineries and power stations.

Testing took place at Sylmasta HQ in the United Kingdom. A 25mm hole was cut into a 110mm diameter carbon steel pipe. Once sealed, the repair needed to withstand three separate pressure tests up to 3 bar.

SylWrap Solution

Superfast Aqua PW Epoxy Putty was used to plug the hole. The pipe was abraded first. This removed any traces of rust, dirt or grime. It also created a textured surface for the repair to grip onto, improving adhesion.

The putty was kneaded by hand and formed into a 75mm diamter disc, ensuring full coverage of the hole. Before fully hardening, the putty disc was placed directly over the hole and pushed firmly down onto the pipe.

At the edges, the putty was smoothed off using a little water to remove any step from the surface. Superfast Aqua PW was left for 10 minutes until it gelled but was not fully hardened.

SylWrap HD Pipe Repair Bandage was then applied over a 225mm area of the pipe with the leak at its centre. As SylWrap HD was wrapped and smoothed around the pipe, it helped force the putty deeper into the hole for a more effective seal.

The cured SylWrap HD also created a thick, rock hard, impact-resistant outer sleeve which increased the hoop strength of the pipe.

Outcome

After the application was completed, the repair was left for 24 hours to achieve maximum properties before testing. Pressure was steadily increased for 30 seconds until 30 bar was reached.

After 60 seconds of the pipe being pressurised at 30 bar, the repair was inspected for any visible leakage. This test was carried out three times.

With no leak or defect detected during any of the three pressure tests, Superfast Aqua PW and SylWrap HD when used in conjunction are qualified to meet ASME PCC-2 402-III standard.

In addition to qualifying for ASME PCC-2-402-III, Superfast Aqua PW and SylWrap HD both have WRAS approval – meaning they are certified as safe for use on pipes carrying drinking water. This standard is another requirement for making repairs on the public water supply networks.

Follow Up

Since achieving ASME PCC-2 402-III qualifcation, Superfast Aqua PW and SylWrap HD have been approved for us sealing leaks in high pressure water systems, such as chilled district cooling in the United Arab Emirates.

For repairs to be fully ASME PCC-2 402-III compliant, installers must undergo training and certification on using Sylmasta products for leaking pipe repair. To find out more, please email sales@sylmasta.com

Products Used

Superfast Aqua PW
WRAS approved, fast working epoxy putty seals holes in pipework

SylWrap HD Bandage
Water-activated wrap sets rock hard to reinforce and strengthen pipework

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