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Case history
50 mm boosted cold water main
Live-line BioWrap 102 reinforcement of cracked Friatherm Durapipe around a temporary repair clamp.
Customer/site: Confidential
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50 mm Friatherm Durapipe boosted cold water main repair
Engineered BioWrap 102 overwrap encapsulating a temporary clamp and adjacent elbow
1Type B repair area
50 mmboosted cold water main
6–8BioWrap 102 layers
2 yearsdesign life · Nov 2024
Project overview
Asset and service conditions
- Location: Confidential – UK entertainment venue
- Asset: 50 mm boosted cold water main
- Service medium: Mains water
- Substrate: Friatherm Durapipe polypropylene
- Geometry: Straight pipe, elbow and temporary repair clamp
- Design / operating: 10 bar (assumed) / 6 bar; 60°C (assumed) / 25°C
Customer requirement
- Restore structural integrity following a leaking axial crack.
- Reinforce the temporary clamp and adjacent pipework on a live line.
- Reduce propagation risk through extended landing areas and elbow encapsulation.
- Provide completion certification, QA records and photographic evidence.
Challenge
- The axial crack created a Type B leaking defect; its root cause had not been established.
- The temporary metal clamp and adjacent elbow created abrupt transitions requiring controlled profiling.
- Congested building-services access restricted preparation and laminate application.
- The live-line design used 0 mm remaining wall and extended the repair to manage possible crack propagation.
Before condition
Engineered repair method
01
Review and design
Live-line ISO 24817 design issued using Type B conditions and 0 mm remaining wall.
02
Surface preparation
Clamp bristle-blasted; PP pipe and elbow abraded and chemically cleaned.
03
Profiling
Clamp protrusions removed and BindFast 1 formed smooth 30° transitions.
04
Composite application
6–8 BioWrap 102 layers applied over 1,000 mm, encapsulating clamp and elbow.
05
Cure and sign-off
16-hour ambient cure, compression film and ten Shore D readings above 80.
Repair data and technical controls
| Composite system | Repair areas | Layers applied | Design life |
|---|---|---|---|
| BioWrap 102 | 1 Type B repair area | 6–8 layers | 2 years |
Why this was a specialist repair
- Repair transitioned from straight PP pipe over a metal clamp and moulded elbow in restricted access.
- Unknown crack cause required extended landing areas and full elbow encapsulation.
Source evidence used
- IC-RS-241104-01 repair specification and calculation package.
- IC-CS-241104-01 completion certificate, QA records and job photographs.
Completed repairs
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Outcome
What was achieved
- One Type B repair completed over 1,000 mm of the 50 mm boosted cold water main.
- Temporary clamp and adjacent elbow encapsulated by 6–8 BioWrap 102 layers.
- Two-year guaranteed design life, completion certificate and QA records issued.
What this demonstrates
- Engineered reinforcement of cracked polypropylene pipework with mixed metal/plastic geometry.
- Live-line composite repair within a congested building-services void.
- Extended overwrap design where the crack root cause had not yet been confirmed.
Need an engineered repair assessment?
Send the minimum engineering inputs and Icarus Composites can confirm feasibility, repair approach and the next technical steps.
01 Defect photos
02 Dimensions
03 Pressure / temperature / service
04 Required design life
