A water company in the UK repair an aluminium expansion joint leaking from a split between two bellows, fitted to a 225mm steel water main pipe carried over a river by a major A road suspension bridge between two counties.

Case Study Overview

Site Suspension bridge
Location United Kingdom
Pipe Type 225mm steel water main pipe
Repair Type Leaking expansion joint repair
Products Wrap & Seal Pipe Burst Tape

Pipe Defect

The 335-metre suspension bridge provided an important transport and utilities link between the English counties of Devon and Cornwall. It carried an A road over a river, with the 225m steel water main pipe fixed directly beneath the road deck in a very constrained space.

An aluminium expansion joint was fitted to reduce stress on the pipe caused by the movement of the bridge. After it became known the pipe was leaking, a team of engineers accessed the main.

They discovered a split in the expansion joint between two bellows, through which water was flowing out. Comparing the position of the fitting with its most recent mandatory safety inspection revealed it have moved and contracted significantly.

Because of the importance of the pipe in transporting water between the counties, the main could not be shut off. A flexible live leak repair solution was needed to seal the expansion joint but also allow for future movement and contraction of the fitting.

SylWrap Solution

The water company had recently approved all its engineers to carry a SYL-PRO-50-150 SylWrap Pipe Repair Contractor Case, meaning the team had a suitable range of products to hand for making up to six live leak repairs.

On the day of the repair, the expansion joint had contracted to the point of failure. But even with the further reduced space between the bellows, the engineers were able to apply Wrap & Seal Pipe Burst Tape.

Despite the lack of room beneath the road deck, the engineers were able to stretch the tape by its maximum 300 percent to achieve full amalgamation.

Three 50x4m Wrap & Seals were applied until no more water was seeping from the pipe, leaving the engineers satisfied the leak was fully arrested.

By the time the repair was complete, the three tapes had fused together. They formed a solid rubber band which was compacted over the leak and filled the gap between the two belows.

Outcome

The repair was completed in under two hours, including accessing the pipe. The steel water main remained pressurised throughout, meaning no disruption to supplies. Road traffic continued over the bridge as normal.

Measurements were taken of the expansion joint after the repair, with the water company intending to fabricate and fit a replacement part at a later date.

Follow Up

Feeding back to Sylmasta afterwards, the engineers said: “The SylWrap Contractor Case was extremely useful in the scenario, and within the cramped work area.”

“Having a variety of products within the repair pack provided plenty of options to us once the problem had been fully evaluated.”

Products Used

Wrap & Seal Pipe Burst Tape
Repair tape self-fuses to a solid rubber band, sealing between expansion joint bellows

Pipe Repair Contractor Case
Easy-to-store Case containing enough Wrap & Seal and other products for multiple repairs

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