JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 67

Repair and replacement of concrete pipes with carbon composites

Fig. 2:
Installation of the
SAERfix carbon
non-crimp
fabrics
(self-adhesive)
Repairs and
inspection

Primer application
and protection

1

2

Surface
preparation

3

4

Infusion and
vacuum system

5
Nanoceramic
coating

Fig. 3: The five process steps

Characterization tests were
conducted by accredited external
laboratories to verify the properties: tensile strength, compression, adhesion, glass transition
temperature, hardness, thermal
expansion coefficient and cathodic disbondment, among others.
Likewise, real-scale tests were
carried out to check the validity
of the system developed and the
feasibility of application by the
workers, conducting hydraulic
pressure tests on different samples.
The main challenge was to use
an application methodology
respectful of the workers' safety
and the environment, avoiding
the continuous exposition and
inhalation of vapours coming
from the materials used. This
was made possible by the design
of the infusion and vacuum
system, transporting the epoxy
resin with positive pressure in
a closed system with localized
vapour emission points with
filters. This transport operation is
carried out from the outside of the
pipeline, being able to work 100
or 200 metres away, between the

preparation area and the action
area inside.
In-situ execution
The in-situ execution process,
which lasted for 8 months, consisted of the following stages:
- Surface preparation: abrasive
blasting, surface reconstruction and deionized water
cleaning.
- Primer application and protection: using an epoxy resin and
a peel-ply fabric to avoid contamination during the transit
of workers inside the pipe.
- Infusion and vacuum system:
placement of the carbon fibre
fabric and consumables for
subsequent impregnation and
vacuum consolidation control.
- Removal of consumables,
inspection and repairs if necessary.
- Nanoceramic coating to waterproof the pipe and system
start-up.
The process used 20,500 m²
of carbon fabrics, 25,000 kg of
epoxy resin, 13,200 valves, 28,150
m of vacuum tubing, 5,300 m² of

Fig. 4:
Infusion and
vacuum system,
design and
installation

vacuum infusion bags and 4,500
kg of nanoceramic coating.
Benefits and key advantages
- Reliability. The carbon fibre
pipeline was calculated, tested,
and manufactured in-situ with
a system that provides the best
possible properties (reality vs.
theory) without using ovens or
autoclave systems.
- Durability. The estimated
lifetime is the next 40 years.
- Safety. Safety was taken in consideration during the construction and installation phases,
including for the workers and
in terms of environmental
impact. No excavations with
risks for the nuclear power
plant reactor were needed,
avoiding process stops as well
as technical and construction
difficulties. The environmental
impact of the solution was
the minimum possible as no
means of excavation or crane
were required, avoiding the
corresponding diesel consumption and CO2 emissions,
as well as the vapours generated by conventional cutting and
welding work.
- Quickness. The whole process
was up to 50% faster than
traditional excavation repair
works, minimizing the risk in
case the existing concrete pipe
was needed to cool the reactor
(during the work).
N°119 March 2018

- Cost effectiveness. The cost
was much lower than with
traditional methods as there
were no process stops, no
deviations or modifications of
other auxiliary services near
the action area (gas pipelines,
water, electrical wiring, fibre
optics, telephone...), as well
as no interference with the
facility's operations.

Fig. 5: The finished carbon fibre pipe
before nanoceramic coating

This innovative system for the
industrial sector is a versatile
solution that can be applied to
other substrates such as steel,
inside or outside, and not only
to pipes, but also equipment and
pressure vessels in compliance
with the ASME and ISO international standards. The greatest
advantage is found in buried
systems where logistical access
difficulties and auxiliary means
can be an impediment to repair
or replacement processes.
More information:
www.gruponavec.com
www.saertex.com

/ jec composites magazine

67


http://www.gruponavec.com http://www.saertex.com

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #119 - March 2018

Cover
Edito
Opinion: Aeronautics
Contents
NEWS
In brief
Agenda
BUSINESS
KPIs - Up-to-date key performance indicators for the fibre-reinforced plastics market
Opportunities - Advanced plastics and composites break through the automotive sector
EV - China: driving the whole car supply chain, electric vehicles are in full swing
MANUFACTURING
Surface - New machine system takes surface finishing to a new level
3D printing - Additive manufacturing of highperformance composite structures
Automotive - Body in black versus body in white
Automotive - Sheet moulding compression of prepreg sheets for a composite subframe
Simulation - High-quality sound-absorbing automotive carpets
Curing - GRP composite manufacturing optimization: opportunities with UV curing
FEATURE Materials: pushing boundaries - Do materials have their limits?
Fastener - High-resistance fastener for structural composite parts
Recycling - Applications of recycled carbon fibre in high volume manufacturing
Resin - High-performance epoxy/carbon fibre SM
Honeycomb - High-performance polypropylene honeycomb boards at minimal cost
CFRTP - Beautiful, lightweight, and tunable
SOLUTIONS
Aeronautics - A demountable composite wing box for private planes
Civil engineering - Repair and replacement of concrete pipes with carbon composites
Sports - Sustainable composite manufacturing kicks into high gear
Medical - lmproving lives with carbon composites
TECHNOLOGY
NDT - NDT in-line inspection using the NIDIT procedure
Assembly - Ensuring the durability of adhesive-bonded assemblies
Index
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JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 84
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Cover
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Ad1
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 1
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 2
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Edito
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Opinion: Aeronautics
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 5
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Ad2
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Ad3
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Contents
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 7
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - In brief
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 9
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 10
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 11
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Agenda
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 13
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 14
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 15
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 16
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - KPIs - Up-to-date key performance indicators for the fibre-reinforced plastics market
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 18
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 19
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Opportunities - Advanced plastics and composites break through the automotive sector
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 21
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 22
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - EV - China: driving the whole car supply chain, electric vehicles are in full swing
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 24
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 25
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Ad4
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Ad5
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Surface - New machine system takes surface finishing to a new level
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 27
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 28
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 3D printing - Additive manufacturing of highperformance composite structures
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 30
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 31
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 32
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 33
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 34
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Automotive - Body in black versus body in white
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 36
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 37
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 38
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Automotive - Sheet moulding compression of prepreg sheets for a composite subframe
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 40
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 41
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Simulation - High-quality sound-absorbing automotive carpets
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 43
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Curing - GRP composite manufacturing optimization: opportunities with UV curing
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 45
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 46
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 47
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Fastener - High-resistance fastener for structural composite parts
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 49
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 50
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Recycling - Applications of recycled carbon fibre in high volume manufacturing
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 52
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Resin - High-performance epoxy/carbon fibre SM
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 54
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 55
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 56
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Honeycomb - High-performance polypropylene honeycomb boards at minimal cost
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 58
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - CFRTP - Beautiful, lightweight, and tunable
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 60
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 61
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 62
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Aeronautics - A demountable composite wing box for private planes
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 64
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 65
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Civil engineering - Repair and replacement of concrete pipes with carbon composites
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 67
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 68
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Sports - Sustainable composite manufacturing kicks into high gear
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 70
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Medical - lmproving lives with carbon composites
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 72
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 73
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - NDT - NDT in-line inspection using the NIDIT procedure
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 75
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 76
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Assembly - Ensuring the durability of adhesive-bonded assemblies
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 78
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 79
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 80
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 81
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Advertisers
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