Industrial Pipe Repair Solutions That Restore Integrity Without Shutdowns

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Yes—engineered composite wraps and live leak sealing techniques can be safely applied to many pressurised and operating systems, allowing repairs to be completed without shutdowns where conditions permit. For systems carrying hazardous or flammable media, enhanced controls and risk assessments are implemented, and repairs are assessed on a case-by-case basis. Where a flammable meadia leak cannot be safely stabilised without surface preparation, the line must be isolated to ensure personnel safety and regulatory compliance.

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When correctly engineered and installed in accordance with ISO 24817 and ASME PCC-2, composite repairs provide long-term, permanent solutions with design lives of up to 20 years. The composite laminate forms a fully bonded, impermeable barrier that restores pressure-retaining capacity while isolating the substrate from corrosion and erosion mechanisms, enabling sustained asset integrity and life extension.

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Composite repairs are well suited to addressing damage caused by external corrosion, corrosion under insulation (CUI), and mechanical damage such as dents, gouges, and fretting on both metallic and GRP pipework. Defects resulting from internal corrosion or erosion require additional assessment; where reliable wall-thinning data is available, the composite repair can be engineered based on the predicted defect size at the end of the repair’s design life, with the governing limit being either defect growth or design life, whichever occurs first. Cracks can also be repaired, provided the root cause is eliminated—if not, crack propagation may continue beneath the composite laminate—while live leak sealing is suitable for pinholes and through-wall defects where conditions allow.

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No—composite repairs are cold-applied systems that do not require cutting, welding, or hot work, significantly reducing safety risk, permit burden, and execution complexity. Where surface preparation is undertaken by Icarus Composites, we use ATEX-certified equipment, including an MBX Bristle Blaster, making it suitable for use in potentially explosive atmospheres. When ambient temperatures are insufficient for curing, electrically controlled heating blankets may be used under strict safety controls, including temperature monitoring, exclusion zones, and permit compliance; this is occasionally required for the Helios 158 system (≥25 °C) and always required for the Hyperion 223 system, which requires ≥50 °C to achieve initial cure.

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All repairs are fully engineered to internationally recognised standards and executed under ISO 9001-certified quality procedures, in accordance with ISO 24817 and/or ASME PCC-2. Repair materials are validated through UKAS-accredited laboratory testing, providing independently verified performance data. During installation, trained technicians work to defined hold points with inspections recorded in detailed QA/QC documentation, capturing evidence of environmental conditions, surface preparation, laminate build-up, and full cure to ensure the repair fully complies with the approved specification and applicable standards.

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Composite repair and leak sealing systems can be mobilised and installed rapidly, making them ideal for urgent repairs, unplanned leaks, and safety-critical industrial assets where downtime must be minimised. Our teams are available to respond seven days a week, and once key information—such as design and operating pressure and temperature, process media, defect details, access constraints, and photographs—is provided, a compliant repair specification can often be issued within hours. Because our wet-layup composite systems require no prefabrication, technicians can mobilise immediately, with on-site material stocking further reducing response and repair times.