Metal Pipe Repair: How to Fix & Protect Pipelines

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Metal Pipe Repair Leaking Pipe Industrial Pipeline Solutions Industrial Pipe

27th January 2025

Industrial metal pipes are essential to global infrastructure, facilitating the transportation of chemicals, water, and other vital resources across industries, utilities, and essential services. Remarkably, over 80% of pipelines worldwide are made of steel. These pipelines are engineered to withstand immense pressure, harsh environments, and years of operation. However, even the most durable industrial pipes are susceptible to leaks caused by wear, corrosion, or physical damage. Corrosion alone costs industries billions of pounds each year, underscoring the importance of reliable industrial pipeline solutions. For instance, steel pipes exposed to seawater without proper protection can corrode at a rate of 0.1–0.2mm annually, jeopardising their performance and longevity.


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.


Resimac Metal Pipe Repair Products

Resimac provides a wide range of solutions to repair leaks and protect industrial pipes:


Choosing the Right Resimac Metal Pipe Repair System

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

Properties 108 Pipe Repair Tape 109 Self Amalgamating Tape 110 Rubber Tourniquet 301 Epoxy Resin & Hardener
Type Moisture cured PU Silicone Rubber 2 Part, Solvent Free Epoxy
Typical Application Long term solution to water leaks Low pressure water leaks Short term solution to water leaks Anti corrosion, chemical resistance
Pipe diameters Up to 450mm (18″) Up to 150mm (6″) Up to 150mm (6″) All Diameters
Live Repair (Water) Yes Yes Yes No
Curing time 30 Mins No Curing No Curing Overnight
Maximum pressure resistance 15 Bar (218psi) 3 Bar (45psi) 5 Bar (72psi) 20 Bar
Temperature Resistance Up to 120°C Up to 45°C Up to 45°C Up to 150°C

Resimac Real World Application

Steel Wastewater Pipe Repair

Situation

A failed weld joint on a steel wastewater pipe required urgent repair to prevent further leakage and corrosion.

Solution

The damaged area was repaired using a preformed steel plate bonded with 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

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.


Looking Ahead

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.


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