Oil Pipeline Repair for Safe, Rapid Restoration Without Shutdown

Our engineered composite repair systems restore the integrity of damaged oil pipelines without shutdown, welding, or pipe replacement. By enabling live leak sealing, pressure-rated reinforcement, and long-term corrosion mitigation, we help operators eliminate risk, protect production, and extend asset life by decades. The result is safer operations, predictable maintenance, and significantly lower whole-life repair costs.

No shutdown, no production loss
Certified, engineered repairs to international standards
Long-term corrosion and defect mitigation
Rapid mobilisation with minimal site disruption

Explore our repair solutions

Engineered and Delivered in Full Compliance with ISO 24817 and ASME PCC-2

All oil and gas pipeline repairs are analytically designed, installed, and documented in accordance with ISO 24817 and ASME PCC-2, the internationally recognised standards for composite repairs. This ensures every repair is pressure-rated, fully auditable, and accepted by integrity engineers and asset owners.

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The Most Reliable Oil & Gas Pipeline Repair Solution for Extending Asset Life Without Shutdown

No shutdown, no production loss

Engineered composite wraps and live leak sealing allow repairs to be completed while the pipeline remains in service, avoiding costly downtime and deferred production.

Certified, engineered repairs to international standards

All repairs are designed and executed in accordance with ISO 24817 and ASME PCC-2, providing pressure-retaining, fully auditable solutions accepted by operators and regulators.

Long-term corrosion and defect mitigation

Composite systems arrest active corrosion, reinforce wall loss, and redistribute stresses, extending asset service life by decades rather than months.

Rapid mobilisation with minimal site disruption

Lightweight materials, cold-applied systems, and compact tooling enable fast deployment in remote or constrained environments, reducing safety exposure and overall repair cost.

Engineered Composite Wrap Systems for Pressure Retention

Our composite wrap systems are analytically designed to restore and reinforce the pressure-containing capability of damaged pipelines suffering from corrosion, wall loss, dents, or mechanical defects. By redistributing hoop and axial stresses away from the degraded steel and into the composite laminate, the repair reinstates structural integrity without cutting or welding. The outcome is a fully pressure-rated repair that extends asset life by decades while eliminating the safety risks, permitting delays, and costs associated with pipe replacement.

Restores pressure-containing capability without cutting, welding, or pipe replacement.
Redistributes hoop and axial stresses away from degraded steel into the composite laminate.
Designed and verified in accordance with ISO 24817 and ASME PCC-2 requirements.
Extends remaining service life by decades with a fully auditable, permanent repair.

Online Leak Sealing on Pressurised Oil & Gas Pipeline

Icarus Composites specialises in live leak sealing technologies that allow active leaks to be sealed while the pipeline remains in operation. Using controlled injection and engineered composite overbuilds, leaks are arrested at source and permanently encapsulated. This enables operators to stop product loss, mitigate environmental and safety risks, and maintain uninterrupted production—avoiding emergency shutdowns and unplanned outages.

Seals active leaks while the pipeline remains in operation.
Eliminates product loss and reduces environmental and safety risk immediately.
Avoids emergency shutdowns, depressurisation, and production downtime.
Compatible with composite overbuilds for permanent pressure-rated repairs.

Corrosion Reinforcement and Wall-Loss Restoration

Our systems are specifically engineered to arrest corrosion under insulation (CUI), external corrosion, and localised metal loss. Following surface preparation and profiling, the composite repair rebuilds load-bearing capacity and isolates the substrate from further environmental exposure. The result is a long-term corrosion mitigation solution that stabilises degradation, reduces inspection frequency, and significantly lowers whole-life maintenance costs.

Arrests active corrosion under insulation (CUI) and external corrosion mechanisms.
Rebuilds structural capacity in areas of localised metal loss.
Isolates the substrate from further environmental exposure.
Reduces inspection frequency and long-term maintenance expenditure.

Rapid, Cold-Applied Repairs for Remote and Hazardous Sites

All Icarus composite repair systems are cold-applied and lightweight, requiring no hot work, heavy lifting, or complex infrastructure. This makes them ideal for offshore platforms, refineries, remote pipelines, and hazardous areas where access and safety constraints dominate repair decisions. Operators benefit from faster mobilisation, reduced HSE exposure, and predictable repair schedules—delivering safe, compliant repairs with minimal operational disruption.

No hot work required, minimising fire and explosion risk.
Lightweight systems simplify access in confined or elevated locations.
Rapid mobilisation with minimal tooling and site infrastructure.
Shorter repair windows with reduced HSE exposure for site personnel.

Proven on Live, Pressurised Oil & Gas Pipelines

Oil Pipeline Repair Solutions for Every Operating Challenge

Live Oil Pipeline Leak Repair on Pressurised Assets

Stops active leaks immediately without shutting down the pipeline, protecting personnel, the environment, and production continuity.

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Corrosion Under Insulation (CUI) Pipeline Repair

Arrests hidden corrosion and restores structural integrity without insulation removal over large areas or pipe replacement.

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Wall Loss and Structural Reinforcement of Aging Pipelines

Reinforces weakened pipe sections to safely extend service life and defer costly replacement or rerouting projects.

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Emergency Oil & Gas Pipeline Repairs in Remote Locations

Delivers rapid, cold-applied repairs with minimal equipment, enabling safe intervention where access, logistics, or time are critical.

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Trusted to Repair Offshore Oil & Gas Pipelines in High-Risk Environments

Offshore 6" Natural Gas Line

Icarus Composites delivered an engineered composite repair to a 6” offshore natural gas line suffering from extensive external corrosion across multiple defect locations, restoring structural integrity while the line remained live. The ISO 24817–compliant repair used the BioWrap 102 composite system to provide a pressure-rated solution with a guaranteed 5-year design life, avoiding shutdown, hot work, or pipe replacement.

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Engineered Products and Services Assuring Oil & Gas Pipeline Integrity

ISO 24817 & ASME PCC-2 Compliant Repair Design

All repairs are analytically designed and installed in accordance with internationally recognised composite repair standards, ensuring pressure integrity and regulatory acceptance.

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Independently Verified Material Performance

Composite systems are mechanically and thermally tested by UKAS-accredited laboratories to validate performance under Oil & Gas operating conditions.

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Proven on Live and Offshore Oil & Gas Assets

Our repair systems and procedures have been successfully deployed on live, offshore pipelines, demonstrating reliability in high-risk, high-consequence environments.

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Need a repair? Contact our Engineering Team today

Ready to add engineered composite wraps and live leak sealing to your service portfolio? Tell us about your business and we'll get in touch.

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Prefer to speak to us directly?

Contact our team and we'll guide you step-by-step on the journey to getting your assets repaired.

Phone:

+44(0)1706 334178

Email:

contact@icarusgroup.co.uk

Website:

www.icaruscomposites.co.uk

Location:

Cambridge, United Kingdom

Frequently Asked Questions (FAQ)

Can composite repairs be installed on live oil and gas pipelines?

Yes—engineered composite wraps and live leak sealing can be safely applied to pressurised pipelines without shutdown, hot work, or loss of production when correctly assessed and designed.

Are composite repairs accepted by oil and gas operators and regulators?

Yes—all repairs are designed and installed in accordance with ISO 24817 and ASME PCC-2, the internationally recognised standards for composite pipeline repairs.

How long do composite repairs last on oil and gas pipelines?

When correctly engineered and installed, composite repairs provide a long-term solution with design lives of up to 20 years, supported by documented calculations, QA records, and warranties. The achievable design life is governed by the root cause of the defect; where the damage mechanism can be arrested, extended design lives can be assigned. For example, defects caused by external corrosion can often be given a 20-year design life, as the fully bonded composite wrap isolates the pipe from oxygen and moisture, preventing further degradation.

Can composite systems repair active leaks?

Yes—our live leak sealing technologies can arrest active leaks under pressure. Where active leaks are present, each repair is assessed on a case-by-case basis, with hydrocarbon leak repairs only proceeding where risks can be fully controlled and safely mitigated. Once the leak is sealed we overwrap the leak sealing method with an engineered composite wrap for a permanent, pressure-rated repair.

How do composite repairs perform in offshore and corrosive environments?

Composite materials are inherently corrosion-resistant and ideally suited to offshore and marine environments. Once installed, the composite laminate forms a fully bonded, impermeable barrier that prevents oxygen, moisture, and other electrolytes from reaching the steel substrate, effectively arresting external corrosion and corrosion under insulation (CUI). This delivers long-term corrosion mitigation while simultaneously restoring and maintaining structural integrity.

What testing and quality assurance supports your composite repair systems?

All systems are validated through UKAS-accredited laboratory testing and delivered under ISO 9001-certified quality processes, ensuring consistent performance, full traceability and compliance to ISO 24817 & ASME PCC-2.

Book your pipe repair today