Case Study Overview

Site Luxury complex
Location United Arab Emirates
Repair Type No pressure pipe repair and reinforcement
Defect Leaking ABS pipe flange in chilled water district cooling system

Repair Products

Superfast Aqua PW Epoxy Putty,
SylWrap HD Pipe Repair Bandage

Case Study PDF

Case Study Details

Chilled water and district cooling systems are used throughout the United Arab Emirates to provide an energy efficient method of air conditioning.

Water is stored and cooled in a central plant. It is then pumped around buildings, complexes and even entire districts via vast pipe networks operating at between 5 and 7 bar pressure.

Some of these systems provide air conditioning to hundreds of different homes and workplaces from a large-scale plant. The Empower Business Bay plant in Dubai for example serves 188 multi-use buildings and skyscrapers. Future expansion is planned to take that number over 300.

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

Sylmasta were contacted by an engineering company responsible for a private chilled water district cooling system at a luxurious complex containing over 500 apartments, a leisure centre, shops, restaurants and a 5-star hotel.

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

To evaluate Sylmasta products, the company built test rigs with 50mm, 100mm and 150mm ABS pipes. Each rig was one-metre long and connected with stub flange sets and MS end flanges.

One side of the flange ends was made intentionally weak so that it would begin leaking when pressure was increased. The pipe was filled with water through a valve. Once it was full, pressure was applied.

At 4 bar, a leak was noticed at the weakened flange end. The area was instantly cleaned and then sealed using Superfast Aqua PW Epoxy Putty. Aqua PW was chosen for its high underwater adhesion properties, enabling it to bond to the ABS even though the pipe surface was wet.

Enough putty was cut from the stick for application all around the weak flange plate. The putty was kneaded by hand and applied to the pipe whilst still soft.

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

SylWrap HD Pipe Repair Bandage was then wrapped over a 250mm section of the pipe either side of the leak. It cured to create a thickened, impact-resistant sleeve around the leak, further enhancing the seal provided by Superfast Aqua PW.

The repair was left for 90 minutes to reach working strength and then pressure tested. Pressure was gradually increased towards 8 bar, reflecting the maximum the chilled water system reached.

Throughout each of the three pressure tests to the different sized rigs, 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 the 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.

In their report compiled after all 50mm, 100mm and 150mm tests had been completed, the company 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 high underwater adhesion seals pipes even when surface is wet

SylWrap HD Bandage
Composite wrap which cures to form a thickened, reinforced layer to restore pipe integrity

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