After vigorous testing by an engineering company, Superfast Aqua PW Epoxy Putty and SylWrap HD Pipe Repair Bandage are approved for use sealing leaking ABS pipe joints in a chilled water district cooling system at a large luxury complex in the UAE.

Case Study Overview

Site Luxury complex
Location United Arab Emirates
Pipe Type 50mm, 100mm and 150mm ABS pipe
Pressure 8 bar
Repair Type Leaking joint repair
Products Superfast Aqua PW Epoxy Putty, SylWrap HD Pipe Repair Bandage

Pipe Defect

Chilled water and district cooling systems are used throughout the United Arab Emirates to provide energy efficient air conditioning. Water is cooled at a central plant and then pumped around buildings, complexes and even entire districts via pipes at between 5 and 7 bar pressure.

Large-scale district cooling can provide air conditioning for hundreds of different homes and workplaces from one plant. The Empower Business Bay Plant in Dubai serves 188 buildings for exmple, including skyscrapers. Expansion is planned to take that number to over 300.

Other complexes and skyscrapers have private chilled water cooling systems, supplying air conditioning for their own facilities. The Burj Khalifa has 34 kilometres of pipework circulating cooled water around the 830-metre tall building.

Sylmasta were contacted by an engineering company responsible for a district air conditioning system which cooled a luxury complex consisting of over 500 apartments, a leisure centre, shops, restaurants and a 5-star hotel.

They were looking for a quick and easy repair for sealing leaking joints in the ABS pipe network which pumped chilled water around the complex. Rapid response time was essential in the event of leaks to ensure the efficiency of the air conditioning system.

To evaluate Sylmasta products, the company built 50mm, 100mm and 150mm diameter ABS pipe test rigs reflecting the pipework found in the system. Each rig was one-metre long and connected with stub flange sets and MS end flange ends.

One side of the flange ends was made intentionally weak. When the pipe was filled with water, the weakened area began leaking once 4 bar pressure was reached. It was then over to Sylmasta products to prove they could seal the joint.

SylWrap Solution

The leak area was cleaned before repair using Superfast Aqua PW Epoxy Putty Stick. Superfast Aqua PW was chosen for its high underwater adhesion properties, enabling it to bond to the ABS pipe surface even though it was wet.

Enough putty was cut from the stick to cover the weak flange plate. The putty was kneaded by hand and applied to the pipe whilst soft.

Within 20 minutes, it cured to form a rock hard, waterproof material permanently bonded to the ABS. It covered all leak spots and restored pipeline integrity.

The repair was then reinforced with SylWrap HD Pipe Repair Bandage. SylWrap HD was wrapped over a 250mm section of the pipe either side of the leak. It created a thick, impact resistant sleeve around the pipe which further enhanced the seal provided by Superfast Aqua PW.

Outcome

Each test rig was given 90 minutes to reach working strength before being pressure tested. Pressure was gradually increased towards 8 bar, reflecting the maximum the chilled water system reached.

Throughout the pressure tests to the three different sized pipes, the gauge was monitored for any significant drops or irregular fluctuations.

Once 8 bar had been exceeded, the repair was left for 18 hours. When each pipe was inspected again, there were no visible cracks, leaks, deformations or signs of damage.

Based on the visual inspection and pressure test results, the engineering company concluded the SylWrap repair to have successfully restored the functionality and integrity of the ABS pipe.

Follow Up

The engineering company shared their final report with Sylmasta after all 50mm, 100mm and 150mm tests had been completed.

They wrote: “The repair material was applied correctly and adhered well to the pipe surface. The pressure test demonstrated the repair’s ability to withstand the specified pressure without any signs of leakage, failure, or abnormal pressure fluctuations.”

“We therefore consider this repair a suitable solution for any leakage on ABS pipes in chilled water cooling systems.”

Products Used

Superfast Aqua PW
Epoxy putty with underwater adhesion which seals pipes where surfaces are wet

SylWrap HD Bandage
Compostied repair wrap forms a thickened, reinforced shell to restore pipe integrity

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