A leaking cooling water pipe at a major Mid-Atlantic power generation facility escalated into a catastrophic rupture prior to a scheduled site visit, forcing a cooling tower shutdown. Banks Industrial Group (BIG) rapidly mobilized and completed an engineered composite repair within the plant’s outage window—restoring reliability to infrastructure supporting 1,193 MW of generation capacity, enough to power approximately 1.2 million homes.
The Pain Point
Plant personnel initially contacted Banks Industrial Group to evaluate and stop a leaking cement-mortar lined steel cooling water pipe. Before the scheduled site visit could occur, the pipe failed catastrophically, creating a large through-wall opening and forcing an immediate shutdown of a multi-cell cooling tower essential to turbine operation.
Without adequate cooling, steam turbine exhaust pressure and temperatures rise quickly, triggering protective trips and disconnecting generators from the electrical grid. For a natural-gas combined-cycle plant, every hour offline represents significant lost revenue and risk to customers relying on uninterrupted power—especially during a holiday period.
Why the Repair Was Challenging
The failed pipe included multiple layers requiring different repair methods:
• A damaged cement inner liner
• A ruptured steel pressure boundary
• Deteriorated external concrete (primary driver of the corrosion)
Repairing a large sidewall defect on a round pipe is difficult because gravity causes traditional repair materials to slump, particularly without interior access. Cold conditions further complicated curing timelines, while the sudden escalation from leak to full rupture required immediate redesign of the repair approach.
The BIG Solution
BIG technicians adapted quickly to the changed scope. To rebuild the internal liner, they engineered a temporary backer using reinforced paperboard that could be installed externally and would safely deteriorate once normal operation resumed, eliminating the risk of debris obstructing cooling water flow.
This allowed application of Belzona 4141 Magma‑Build, a uniquely capable lightweight epoxy mortar specifically suited for vertical and overhead concrete rebuilding where conventional materials fail. Unlike traditional concrete—which may require up to 28 days to cure—Belzona 4141 achieves mechanical cure in approximately 12 hours, enabling significantly faster restoration of service.
To restore pipe strength, BIG then installed an engineered carbon-fiber composite repair using Belzona SuperWrap II, designed and applied in accordance with ISO 24817 and ASME PCC-2 Article 4.1 composite repair standards. The composite effectively became the new pressure-containing wall, eliminating the need for welding or pipe replacement. Heated enclosures ensured proper curing despite cold ambient conditions.
Results & Business Impact
• Rapid mobilization and repair completed within the plant’s outage schedule
• Approximately 48 hours of total hands-on repair time
• Structural integrity restored and cooling water service returned
• Power generation reinstated for a facility producing 1,193 MW
• Extended asset life without replacement or hot work
By adapting to a rapidly changing failure and deploying fast-curing, engineered repair technology, BIG helped the plant minimize downtime, reduce financial exposure, and safely return critical infrastructure to service.
Key Takeaways
• Unique vertical/overhead epoxy technology enabled rapid liner restoration
• ASME- and ISO-compliant composite wrap restored full pipe strength
• Emergency response prevented prolonged outage
• Engineered repair extended service life without replacement
For power producers facing unplanned outages, this case demonstrates how engineered composite repairs—executed by experienced specialty contractors—can restore critical systems quickly while protecting reliability, safety, and operational continuity.
Read more about our composite wrap repair service here.
Read about fiberglass beetle pipe repair here.
