Power Generation Repair for Critical Piping Systems — Rapid, Engineered Solutions Without Shutdown

Our power generation repair solutions are engineered to arrest corrosion, restore structural integrity, and extend the service life of critical piping systems—without shutdowns or hot work. Using fully bonded, standards-compliant composite wraps and online leak sealing techniques, Icarus Composites delivers permanent repairs that reduce safety risk, minimise operational disruption, and protect generation output. The result is predictable, auditable asset integrity across high-temperature, high-pressure power plant environments.

Minimised Outage Time
High-Temperature and Pressure Capability
Reduced Safety and Environmental Risk
Extended Asset Life at Lower Cost

Explore our repair solutions

ISO 9001–Certified Composite Repair Delivery

‍All Icarus Composites repair activities are delivered under an ISO 9001–certified quality management system, providing auditable control over engineering, materials, installation, and documentation.

The Most Reliable Composite Repair Solutions for Maintaining Power Generation Uptime

Minimised Outage Time

Composite wraps and online leak sealing are applied without hot work or full system shutdown, allowing critical power generation assets to remain operational while repairs are completed.

High-Temperature and Pressure Capability

Engineered composite repair systems are designed to withstand the elevated temperatures and pressures typical of power generation piping, restoring structural integrity and pressure containment in accordance with international standards.

Reduced Safety and Environmental Risk

Cold-applied composite repairs eliminate welding and cutting, significantly reducing fire risk, confined space hazards, and the likelihood of unplanned fluid or steam release.

Extended Asset Life at Lower Cost

Composite wraps arrest corrosion, erosion, and wall loss, extending the service life of ageing pipework and components at a fraction of the cost and disruption of replacement.

Engineered Composite Pipe Repairs for Live Power Generation Systems

Our composite wrap systems are structurally designed to restore pressure integrity and load-bearing capacity on live pipework, allowing repairs to be completed safely without interrupting power generation.

Restores pressure containment and structural capacity on degraded pipework without removing sections.
Enables repairs on live systems, avoiding forced outages and lost generation revenue.
Adapts to complex geometries including bends, reducers, and welded joints.
Provides a long-term engineered solution rather than a temporary clamp or patch.

Online Leak Sealing Without Shutdown or Hot Work

Using controlled injection and sealing techniques, active leaks are sealed at source while the system remains pressurised, eliminating the need for welding, cutting, or forced outages.

Seals active leaks while the system remains pressurised and in service.
Eliminates hot work, reducing fire risk and simplifying permit requirements.
Prevents escalation of small leaks into major failures or emergency shutdowns.
Allows rapid intervention in high-risk or difficult-to-access areas.

High-Temperature Corrosion and Wall-Loss Mitigation

High-performance composite materials encapsulate degraded areas, arresting further corrosion and redistributing stresses to prevent crack propagation and future failure.

Arrests ongoing corrosion and erosion by isolating the defect from the operating environment.
Redistributes hoop stress away from weakened pipe sections, reducing failure risk.
Performs reliably in elevated temperature service typical of power generation assets.
Extends the remaining life of ageing infrastructure without replacement.

ISO 24817 & ASME PCC-2 Compliant Repair Design and Installation

Every repair is engineered, calculated, and installed in accordance with recognised international standards, ensuring predictable performance, regulatory acceptance, and long-term reliability.

Provides assurance to asset owners, insurers, and regulators through recognised standards.
Ensures repairs are engineered based on load cases, defect geometry, and operating conditions.
Delivers predictable, repeatable performance with documented calculations and QA records.
Supports long-term integrity management strategies rather than short-term fixes.

All of our composite repair systems are mechanically and thermally tested by a UKAS-accredited laboratory

Power Generation Repair Solutions for Every Piping Challenge

High-Temperature Steam and Condensate

Composite repairs restore pressure integrity and structural strength on steam and condensate lines while tolerating elevated operating temperatures and thermal cycling.

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Corrosion Under Insulation (CUI) in Power Plant Pipework

Composite wraps permanently encapsulate CUI-affected areas, arresting corrosion and preventing further wall loss without removing insulation or replacing pipe sections.

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Live Leak Repair on Pressurised Power Generation Systems

Online leak sealing enables active leaks to be safely sealed at source while systems remain in operation, avoiding unplanned outages and safety risks.

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Structural Reinforcement of Ageing Power Plant Piping

Engineered composite reinforcement redistributes loads and reduces stress concentrations, extending the service life of ageing pipework and delaying costly replacement.

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Trusted to Repair Critical Power Generation Assets Without Shutdown

Corroded 12” Fuel Oil Line – ISO 24817 Composite Repair

Icarus Composites successfully completed an ISO 24817–compliant composite repair to a severely corroded 12” carbon steel fuel oil line, restoring structural integrity and pressure containment without pipe replacement. Using the Attalus SnapCure 140 composite system, the repair arrested ongoing corrosion, extended the asset’s service life by 20 years, and was delivered with full QA/QC documentation and warranty.

view full case study

Proven in High-Temperature, High-Pressure Power Plant Environments

ISO 24817 & ASME PCC-2 Engineered Repair Design

Every power generation repair is fully engineered and calculated to internationally recognised standards, ensuring predictable structural performance under high-temperature and high-pressure operating conditions.

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Independently Verified Material Performance

All composite repair systems are mechanically and thermally tested by UKAS-accredited laboratories, providing independently validated data for long-term service in power generation environments.

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Auditable Quality Control and Installation Assurance

Each repair is delivered under an ISO 9001–certified quality management system with full inspection, testing, and documentation to support asset integrity and regulatory compliance.

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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 used on live power generation pipework?

Yes—engineered composite wraps and online leak sealing can be safely applied to live, pressurised systems, enabling repairs to be completed without shutdown or loss of generation. In many cases, maintaining the asset in service is preferable, as the operating temperature can aid resin cure and help achieve optimal mechanical properties in the composite repair system.

Are composite repairs suitable for high-temperature power plant applications?

Composite repair systems are selected and engineered based on operating temperature, pressure, and thermal cycling, making them suitable for steam, condensate, and auxiliary systems common in power generation. Our highest temperature composite repair system, Hyperion 223, is capable of operating at temperatures up to 203°C.

Do composite repairs meet power generation industry standards?

All repairs are designed and installed in accordance with ISO 24817 and ASME PCC-2, which are widely accepted across power generation, oil & gas, and heavy industry.

How long do composite repairs last in power generation environments?

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 repairs arrest corrosion under insulation (CUI)?

Yes—composite wraps fully encapsulate affected areas, isolating the pipe surface from oxygen and moisture to arrest ongoing corrosion and prevent further wall loss.

How is repair quality verified and documented?

Each repair is delivered under an ISO 9001–certified quality system and includes inspection records, material traceability, cure verification, and full QA/QC documentation for audit and compliance purposes.

Book your pipe repair today