Corroded Metal Pipe Repair: How to Fix & Protect Pipelines.

Industrial metal pipes play a crucial role in global infrastructure, enabling the transport of chemicals, water, and other essential resources across industries and utilities. Notably, steel accounts for over 80% of pipelines worldwide, thanks to steels strength and durability. These metal pipelines are designed to endure extreme pressure, harsh environments, and long-term use. However, even the toughest industrial pipes are vulnerable to leaks due to wear, corrosion, or physical damage. Corrosion alone costs industries billions annually, highlighting the need for robust pipeline solutions. For example, unprotected steel pipes exposed to seawater can corrode at a rate of 0.1–0.2mm per year, compromising their integrity and lifespan.

Metal Pipes in Industrial Applications.

Metal pipes play an essential role in industrial operations. Each type serves a specific purpose, ensuring the safe and efficient transport of resources. Below are their most common applications:

• Wastewater Pipes: These pipes transport treated or untreated sewage and frequently face abrasion and chemical attack.
• Drinking Water Pipes: Designed for potable water, they must meet hygiene standards and resist internal corrosion.
• Chemical Coolant Pipes: Found in chemical plants, these pipes handle highly corrosive materials and extreme temperatures.
• Seawater & Underwater Pipes: Operating in marine environments, they must withstand saltwater corrosion and biofouling.
• Oil and Gas Pipelines: These pipelines transport crude oil, natural gas, or refined products while enduring pressure, temperature changes, and corrosive elements.
• Steam Pipes: Used in power plants, steam pipes manage high pressures and extreme heat.
• Slurry Pipes: Common in mining, they carry slurries while withstanding wear from abrasive solids.
• Compressed Air Pipes: These distribute pressurised air and must resist moisture and corrosion.
• Heating, Ventilation and Air conditioning (HVAC): These pipes transport air that may contain abrasive dust or hazardous gases, requiring resistance to wear and corrosion.

By proactively addressing these challenges, Resimac’s industrial pipeline solutions help extend the lifespan of metal pipes while minimising costly downtime.

Choosing the Correct Resimac Metal Pipe Repair System.

Finding the correct pipe repair solution depends on many factors such as pipe size, leak severity, and operating conditions. Below is a comparison of Resimac’s pipe repair systems:

Resimac Application of Corroded Metal Pipe Repair Solution.

Steel Wastewater Pipe Repair.

Problem: A weld joint failed on a steel wastewater pipe requiring urgent repair to prevent leakage and corrosion.

Solution: The failed weld joint area was repaired using a preformed steel plate bonded with Resimac 101 Metal Repair Paste. To reinforce the pipe, glass tape encapsulated with 301 Epoxy Resin and Hardener was applied, ensuring resistance to internal pressure and corrosion.

Application Details:

1. Workers drained the pipe and took it out of service.
2. The substrate was prepared using mechanical grinders to meet ISO 8501/4 ST3 (SSPC SP3 ST3) standards.
3. A 2mm layer of 101 Metal Repair Paste was applied to the substrate and steel plate, which were pressed together until cured.
4. Three layers of glass tape were incorporated into 301 Epoxy Resin and Hardener and applied around the pipe circumference for reinforcement.
5. The repair area was overcoated with 501 CRSG for additional chemical resistance and durability.

Results & Benefits of Resimac Metal Pipe Repair Solutions.

This repair restored the pipe’s structural integrity, effectively sealed the leak, and extended the pipe’s operational lifespan. The combined system provided long term protection against internal pressure, corrosion, and chemical exposure, ensuring reliable performance in demanding environments.

Preventing leaks is always more cost effective than repairing them. Industries can safeguard metal pipes from corrosion, abrasion, and chemical attack through protective coatings and proactive maintenance. These measures reduce downtime, lower repair costs, and ensure long term operational reliability.

For more information about Resimac’s repair systems and protective coatings, visit our product range or contact us directly.