High-performance composite repair solution for pipe reinforcement
Overview
The aim of the job, performed in Europe in April 2025 by
3X ENGINEERING (3X)
specialists was to repair a 6" buried onshore gas pipeline with a dent and scratches. An impact caused the defects. The pipeline had a 64 bar pressure and 50°C temperature.
To restore pipe integrity, 3X high-performance composite solution REINFORCEKiT® 4D (R4D) was used.
Scope of work
Defect characteristics as below:
Dent’s dimensions: 600 mm x 140 mm x 10.1 mm
Depth of dent (% of OD): 6% / Metal loss: 22% (1 mm)
According to ISO 24.817 standard and FEA simulation, it was determined to apply 22 layers of R4D (Kevlar® tape impregnated with
bi-component epoxy resin) to repair the pipeline.
Surface preparation was completed using Bristle Blaster® machine to achieve a valid cleanliness
degree (St3 equivalent to SA2.5) and a good surface roughness (leading to 80μm Rz), then confirmed using the surface roughness tester.
After checking hygrometric conditions, the surface was cleaned with acetone before composite wrapping.
The composite repair was completed following below stages:
- F3X8 filler was firstly applied over the defect to remodel the surface.
- A first layer of 3X resin was then applied to
provide good adhesion with the composite material.
- Twenty-two layers of R4D were wrapped around the pipe for a total repair length of 90cm.
- Final layer of resin was applied over the repair and id plate was installed for traceability.
Results
Resin samples were collected during each stage for quality control. Hardness measurements,
performed after job completion, confirmed the successful repair. The composite repair is designed for a 20 year lifetime.
