Carbon Fiber Reinforcement for Split and Damaged Process Pipe

RAK repaired two critical defects on a process pipe, including a full split beneath a u-bolt and a concealed hole under a saddle. After gaining access and stabilizing the pipe, the team applied a carbon fiber and fiberglass composite system to restore structural integrity. The repair was completed without replacement, providing a durable, cost-effective solution that extended asset life while maintaining uninterrupted operations.

The Problem

During routine inspection, two critical areas of a process pipe were found compromised. One section had a complete split beneath the u-bolt, while another had developed a small hole hidden under the saddle. Both defects posed a serious threat to system reliability, with the potential for leaks and unexpected downtime if not addressed quickly.

The Solution

The crew carefully removed the u-bolts and rubber covering to access the damaged pipe. Using a ratchet strap, the pipe was lifted and stabilized, allowing proper surface prep. Custom molds were fabricated directly from the pipe itself and slid into place over the affected areas. The repairs were then reinforced with a carbon fiber and fiberglass composite system, restoring full structural integrity. A final protective coating was applied to seal and finish the repair. This approach provided a durable, cost-effective alternative to pipe replacement, extending the life of the asset while minimizing disruption to operations.

Project Pictures

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