HDPE Slurry Line Repair – Flotation Cell Discharge

Location

Mineral Processing Facility

Application Area

HDPE DN500 Flotation Cell Discharge Line –
Stub-End Joint Perforation

Project Overview

A 1” external perforation formed on an HDPE slurry line due to abrasive wear at the stub-end joint. The repair site was complicated by misaligned flanges and difficult bolt access, challenging both sealing and re-torquing efforts.

Challenges Faced

Severe internal abrasion from slurry flow

Misaligned joint making sealing difficult

Narrow bolt gaps limited repair access

Risk of leak worsening under operating pressure

Objectives

Seal the 1” leak quickly without interrupting operations

Reinforce the joint against further abrasion

Provide a durable solution until permanent replacement

Execute the repair rapidly with minimal downtime

Repair Solution & Process

Products Used

UPS ASME EMERGENCY PIPE REPAIR BANDAGE UPS 19060 SG THISTLEBOND STICK GRADE METAL

Application Steps

Surface
Cleaning

Mechanical cleaning of the HDPE pipe surface to remove any contaminants or oxidation.
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Leak Sealing with Epoxy Putty

UPS THISTLEBOND STICK GRADE METAL epoxy was mixed and pressed directly into the perforation to stop the leak.

Bandage
Application

The dry UPS ASME EMERGENCY PIPE REPAIR BANDAGE was carefully threaded and wrapped through tight bolt gaps.

Activation & Wrapping

Water was sprayed after wrapping to activate the resin system. A total of three layers of bandage were applied.

Curing & Return to Service

The pipe was repressurised after approx. 1 hour of cure time. Total application time was under 20 minutes.

Results & Key Benefits

Full leak sealing achieved within the hour | Pipe remained in operation during and after the repair | Durable reinforcement against high-pressure slurry | Rapid, cost-efficient field solution requiring minimal equipment | Extended life of the HDPE line while replacement was scheduled

SUMMARY

This fast, high-integrity repair showcases the effectiveness of UPS products for tackling complex HDPE pipe failures in abrasive, high-demand environments — keeping operations flowing without compromise.