Case Study: Repair & Refurbishment of Corroded 20 Metre Long Porth Pipe Bridge

Sylmasta and Arch Services carry out the refurbishment of a dilapidated 20-metre long pipe bridge crossing the Rhonda River in Porth, South Wales. The repair prevented Dwr Cymru Welsh Water from undertaking a complicated and expensive replacement of the corroded structure, saving the company an estimated £200,000.

Case Study Overview

Site Pipe bridge
Location Porth, South Wales
Repair Type Pipe refurbishment
Defect Heavily corroded 300mm steel pipe bridge over river

Repair Products

Liquid Metal Epoxy Coating,
SylWrap CR Corrosion Protection Wrap

Case Study PDF

Download Porth Pipe Bridge Refurbishment Case Study PDF

Case Study Details

Sylmasta were contacted by Dwr Cymru Welsh Water for advice on the repair and refurbishment of a dilapidated pipe bridge crossing the Rhonda River in Porth, South Wales.

The bridge was gravity fed and made up of a 300mm diameter, 20 metre long steel pipe rested inside an angle-iron structure for support and protection.

For such a complex project, it was recommended that the four-stage Sylmasta Pipe Refurbishment System be used as a starting point. A final decision on the repair elements required would be decided once the pipe had been fully inspected.

Dwr Cymru official contractors appointed Arch Services of Porth to carry out the work. It was agreed Sylmasta would keep in close communication throughout the project to deal with any questions that might arise.

20 metre long steel pipe bridge in South Wales prior to undergoing refurbishment via the Sylmasta Pipe Repair System
The steel pipe was covered in corrosion, which had eaten through in places

On inspection, the pipe was discovered to be totally covered in corrosion. This had eaten completely through the steel in several places along the top of the pipe, leaving large holes in the brittle surface.

As these holes were too large or delicate to be repaired with epoxy putty, Arch decided to use fibreglass patches layered over the cracked sections of pipe to seal the leaks. The entire pipe was then coated with Liquid Metal Epoxy Coating.

Liquid Metal is a metal-filled, brushable epoxy. After being coated onto the pipe, it cured to form a smooth, metallic, hard-wearing surface. Several layers of Liquid Metal were used to create an impermeable skin around the original pipe, preventing any further corrosion to the steel and ensuring fluids could no longer escape.

Liquid Metal painted onto a pipe bridge in Porth for refurbishment from heavy corrosion
Liquid Metal created an ultra-smooth, hard-wearing metallic surface around the pipe

The 90 minute gel time of Liquid Metal allowed significant amounts of epoxy to be mixed without the threat of premature curing. Arch Services used a roller to apply each coating to a 1mm – 2mm thickness, also painting with Liquid Metal the corroded steel hoops and beams which held the pipe in place.

To further reinforce the pipe and reinstate its integral strength, it was wrapped with four layers of SylWrap CR Corrosion Protection Wrap. SylWrap CR is a composite repair bandage incorporated with highly effective corrosion inhibitors.

Arch Services of Porth carrying out the refurbishment of a heavily corroded steel pipe crossing the Rhonda River
SylWrap CR was carefully applied along the length of the pipe, further reinforcing the repair

It has been specially formulated for the prevention of corrosion and the protection and strengthening of pipes, metalwork, and other structures in harsh and aggressive environments.

SylWrap CR was applied to the pipe whilst the final coating of Liquid Metal remained tacky. The resin in SylWrap CR was activated with water and the bandage tightly wrapped and smoothed around the pipe.

SylWrap CR Corrosion Protection Wrap used to reinforce and repair a pipe bridge in Porth, South Wales
The completed repair along the 20 metre length of the pipe

Within minutes, SylWrap CR cured to form a rock-hard, impact resistant shell around the pipe. Arch Services were particularly careful in ensuring that no area of the pipe was left without SylWrap CR. This required precision application close to the steel hoops.

The final result was a very smart pipe bridge now well protected from future corrosion and reinforced against breaches by Liquid Metal and SylWrap CR.

Arch Services have subsequently become Sylmasta’s approved contractor for similar projects after their excellent documentation of the process and attention to detail.

Refurbishing the pipe bridge took three days to complete and cost £12,000 in total. Replacement in contrast had been estimated at over £200,000 and a month-long project requiring permits, assessments, fabrication of a new pipe, installation, removal of the old bridge and its safe disposal.

Products Used

Liquid Metal
Brush applied to coat pipes and structures with an ultra-smooth, hard wearing, metallic surface

SylWrap CR Bandage
Composite wrap with corrosion inhibitors for added protection in aggressive environments

Related Case Studies

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

Share this post