Pioneering pipeline repairs

Among ICR Group’s most notable achievements is the development of Technowrap, a composite repair and reinforcement system. Over the past two decades, Technowrap has proven itself to be a reliable and effective alternative to traditional steel repairs, restoring the structural integrity of pipework, pipelines, tanks and other industrial components while minimising downtime and operational interruptions.

Technowrap reduces the carbon footprint of maintenance operations, cutting emissions by as much as 66% compared to conventional replacement methods. Technowrap’s ability to maintain structural integrity without halting operations has made it a preferred choice for clients around the globe. This success sets the stage for the next evolution in composite repair technology: the Pipeline Repair System (PRS).

A new era for pipeline repair

As the demands on infrastructure continue to grow, so too do the challenges associated with maintaining and repairing these critical assets. Recognising the need for faster, more reliable repair solutions, ICR has embarked on the development of Technowrap PRS (PRS), the next generation of its renowned Technowrap system. PRS is being engineered to address specific challenges in pipeline maintenance, particularly in situations where speed of application is critical.

ICR is utilising technology readiness levels (TRL) to structure the development of PRS, ensuring that all key milestones are achieved. This approach allows ICR to deliver a product that exceeds the industry’s evolving requirements. The new system aims to offer improved reliability, efficiency and environmental benefits, positioning it as a genuine upgrade in the field of composite repair.

Gareth Urukalo, Technical Authority at ICR, said: “PRS represents a significant leap forward in our ability to deliver fast, reliable and sustainable pipeline repairs. By integrating advanced composites and focusing on environmental benefits, we’re creating a system that not only meets the immediate needs of our clients but sets a new industry standard for efficiency and safety.”

Problem solving

Corrosion remains one of the most pervasive issues affecting pipelines worldwide. Traditional repair methods, often involving steel replacements, are not only costly but also time-consuming, requiring operational shutdowns that can significantly impact production. PRS is developed with a clear objective: to create a repair system that can be applied quickly, reducing costly excavation time and maintaining operational efficiency. Initially, PRS will target transportation pipelines suffering from corrosion. However, ICR has a broader vision for this product in 2025 and beyond.

As its use expands, PRS will also address other common defects such as cracks, wrinkle bends and external loading scenarios, all supported by bespoke testing programmes. The flexibility and adaptability of PRS are expected to make it an indispensable innovation in the arsenal of pipeline operators, offering a comprehensive solution to a wide range of challenges.

Advanced material technology: inspired by aerospace and motorsport

In developing PRS, ICR has drawn inspiration from industries that push the boundaries of material science, such as aerospace and motorsport. These fields are well known for pioneering the use of advanced composites, which offer exceptional strength-to-weight ratios and durability under extreme conditions. By incorporating these techniques into PRS, ICR is able to optimise the repair system’s properties, ensuring it delivers consistent, high quality results in the field.

One of the key advancements in PRS is the use of more sophisticated lay-up procedures. These procedures help to improve the overall properties of the composite material by reducing void content and optimising the fibre-to-resin ratio; critical factors that determine the strength and reliability of the repair. Initial testing of PRS has shown a low coefficient of variation across all mechanical properties, indicating that the system will provide repeatable and dependable repairs, regardless of the application environment.

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