Aging infrastructure creates costly risks for industrial facilities. When a critical discharge pipe at a chemical plant began to fail, traditional repair methods weren’t an option. Instead of a costly, time-intensive replacement, Underwater Construction Corporation (UCC) used a highly specialized and rarely offered technique: internal underwater CFRP pipe repair.
While many underwater construction contractors offer external carbon fiber wraps, UCC is one of the few with the expertise, equipment, and dive teams required to perform internal carbon fiber reinforcement safely and effectively. This unique capability allowed us to restore a vital part of the plant’s water intake system, extend its service life, and keep operations on schedule, all during a planned outage. Learn more about our complete carbon wrap solutions for structural repair and reinforcement.
The Challenge: Failing Pipes and Limited Options
The plant’s discharge piping, essential for providing cooling water, was showing severe deterioration. Corrosion and holes were causing flooding and threatening operations. Because much of the pipe was encased in concrete and wrapped in asbestos, external repair wasn’t possible without major demolition and abatement.
The facility needed a repair method that could be completed from the inside of the pipe, would meet its pressure and flow requirements, and could be installed quickly during a scheduled outage. Cost and downtime were major consideration as a full replacement would have been expensive and highly disruptive.
The Solution: Internal CFRP Pipe Repair from the Inside Out
UCC partnered with the plant’s engineers to design a custom solution: a 16-layer internal carbon fiber reinforcement system applied by our commercial diving team. Working inside the pipe, our divers effectively built a new structural pipe within the old one, turning the deteriorating pipe into a permanent form for the CFRP system.
This innovative approach eliminated the need for demolition, avoided asbestos exposure risks, and was installed in just two weeks. Because it was performed during a planned outage, the plant maintained its production schedule. This was the third of six discharge pipes UCC is scheduled to repair, one each year, allowing the plant to phase its upgrades over time and spread costs across multiple budget cycles.
Extended Life and Long-Term Reliability
The repaired pipe is now fully reinforced and designed to perform for decades, providing the same service life as an external wrap. The solution stopped flooding, restored the integrity of the water intake system, and gave the plant confidence to move forward with its larger capacity upgrades.
UCC’s specialized expertise in internal underwater CFRP pipe repair continues to help the plant meet its long-term asset management goals. With three additional pipes scheduled for repair in the coming years, this phased program will keep operations reliable while minimizing cost and downtime.
Plan Your CFRP Repair with UCC
If your facility faces similar challenges – aging pipes, limited access, or time-sensitive outage windows – UCC can help. Our internal underwater CFRP pipe repair services deliver a permanent, engineered solution with minimal disruption. Contact us today to discuss your project and find out how we can help extend the life of your critical infrastructure.