Commercial Structural Repairs Services

Structural Composite Repair Solutions Designed for Strength, Durability, and Longevity

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Structural Restoration & Load Capacity Reinstatement

Commercial and industrial structures are required to safely carry sustained and variable loads throughout their service life. Over time, structural components can lose capacity due to a combination of mechanical damage and material degradation, driven by:

  • Corrosion and section loss
  • Cyclic loading and fatigue
  • Accidental impact or overstress
  • Ageing infrastructure and historic design limitations

As degradation progresses, structures may no longer meet their original design intent, resulting in reduced load-bearing capacity, excessive deflection, or localised failure risk.

At Icarus Composites, our engineered composite repair systems are designed to restore structural capacity by reinstating stiffness and original load paths without introducing excessive additional weight or residual stress.

Key performance benefits include:

  • Lightweight, load-bearing composite reinforcement
  • Restoration of structural capacity and stiffness
  • No hot work, cutting, or structural removal
  • Compatibility with restricted access and live environments

The result is a durable, compliant repair solution that safely restores load-carrying performance while minimising disruption to ongoing operations.

Surface Protection: Abrasion, Impact & Environmental Resistance

Commercial and industrial structures are required to safely carry sustained and variable loads throughout their service life. Over time, structural components can lose capacity due to a combination of mechanical damage and material degradation, driven by:

  • Corrosion and section loss
  • Cyclic loading and fatigue
  • Accidental impact or overstress
  • Ageing infrastructure and historic design limitations

As degradation progresses, structures may no longer meet their original design intent, resulting in reduced load-bearing capacity, excessive deflection, or localised failure risk.

At Icarus Composites, our engineered composite repair systems are designed to restore structural capacity by reinstating stiffness and original load paths without introducing excessive additional weight or residual stress.

Key performance benefits include:

  • Lightweight, load-bearing composite reinforcement
  • Restoration of structural capacity and stiffness
  • No hot work, cutting, or structural removal
  • Compatibility with restricted access and live environments

The result is a durable, compliant repair solution that safely restores load-carrying performance while minimising disruption to ongoing operations.

Profile Restoration & Geometric Reinstatement

Structural components often rely on precise geometry to function correctly, whether for load transfer, fit-up, or interface with adjacent equipment. Over time, original profiles can be compromised due to:

  • Corrosion and material loss
  • Mechanical wear and abrasion
  • Impact damage or deformation
  • Poor historic repairs or fabrication defects

Deviations from original geometry can lead to misalignment, stress concentrations, and reduced structural performance.

At Icarus Composites, composite build-up systems are used to accurately restore original geometry and functional surfaces, reinstating design intent without replacing the component.

Key performance benefits include:

  • Accurate profile restoration of metal and GRP components
  • Precision machining to match original geometry
  • Restoration of tolerance-critical surfaces
  • Seamless integration with existing structures
  • Flange face forming and tolerance-critical surface restoration

The result is a geometrically accurate repair that restores functionality, fit, and load transfer while extending asset life.

Structural Strengthening & Life Extension

Many commercial and industrial structures remain fundamentally sound but require strengthening to meet updated loading requirements, extend service life, or manage fatigue-related degradation. Common drivers for intervention include:

  • Ageing infrastructure approaching design life
  • Increased operational loads or change of use
  • Fatigue accumulation in high-stress areas
  • Inspection findings identifying future risk

Without proactive intervention, these assets may require costly replacement or extensive refurbishment.

At Icarus Composites, composite strengthening systems are applied strategically to improve structural performance and extend asset life as part of a long-term integrity strategy.

Key performance benefits include:

  • Structural strengthening without added mass
  • Fatigue mitigation and stress redistribution
  • Asset life extension of up to 20 years
  • UV-resistant finishes for exposed environments

The result is a long-term, cost-effective solution that maximises asset value while deferring capital expenditure.

Composite reinforcement can be applied proactively to strengthen ageing or fatigue-prone structures, extending service life while deferring capital replacement. Repairs are designed for long-term durability in exposed and industrial environments.