Understanding Composite Repairs: Expert Insights from Brad Whelan, HJ3’s Senior Application Engineer

Composite repairs are becoming a go-to solution for many industrial applications. They offer a reliable way to keep systems running without shutting down operations, making them ideal for addressing pipeline defects like anomalies, dents, and other irregularities. To get a deeper understanding of this technology, we sat down with Brad Whelan, HJ3’s Senior Composites Application Engineer, who shared his experience, the benefits, and what makes composite fiber repairs unique.

Can you tell us about your background and experience in composite fiber repairs?

I'm Brad Whelan, a Senior Applications Engineer at HJ3 with over 10 years of experience in composite repair design. My work primarily involves piping systems—whether it's process piping in plants or refineries, transmission pipelines, or pressure vessels. I also play a key role in developing our design calculators, which help engineers quickly assess and apply the right solutions. At HJ3, we don’t just sell materials—we provide real, effective solutions that meet the needs of our clients and ensure long-term reliability.

What type of pipe repairs do composite fiber products typically address?

Composite fiber repairs are used across various types of piping systems. In process piping, we often deal with elbows, tees, and pressure vessels, especially in the petrochemical industry where a wide range of chemicals are handled under lower pressures and temperatures. We collaborate with contractors globally to create custom solutions that fit complex geometries and operational challenges. For transmission pipelines, the focus is on long-term durability. These pipelines span thousands of miles, so the goal is to classify repairs as permanent. The designs must be sustainable for decades, and sometimes they need to be adjusted based on final inspections, requiring quick responses.

What defects can be addressed with composite fiber repairs?

One of the most common issues we tackle is corrosion. For example, Corrosion Under Insulation (CUI) occurs when moisture forms under insulation, especially in petrochemical facilities. Another issue is coating failure, which can lead to rusting. Internal corrosion can also occur in lines that should be made of stainless steel but may degrade due to chemical exposure. Dents are another major concern, particularly in oil and gas transmission pipelines. While these are well-regulated, they're still vulnerable to third-party damage, manufacturing flaws, or natural events. Repairing dents involves evaluating the cyclic profile of the pipeline and calculating the best repair method, considering fluctuating pressures.

What are the advantages of using composite repairs over traditional methods?

The main advantage is minimized downtime. Shutting down equipment can cost millions per day, so extending asset life with carbon fiber is a smart choice. Composites are also much lighter than alternatives like steel clamps or closures—often weighing just 10% of their counterparts. Another benefit is speed. Traditional repair sleeves can take hours to install, while complex replacements might take months and involve overseas shipping. With composites, we can deploy solutions on the same day, reducing lead times and improving efficiency.

How does HJ3’s CarbonSeal™ stand out in the market?

HJ3’s CarbonSeal™ is known for its Speed To Solution™ approach. We can ship materials anywhere, same day, and even offer zero-cost inventory plans to keep supplies on-site. Our system also delivers unmatched strength per ply, using higher density materials that require fewer layers, leading to faster installations and lower costs. We’ve tested our systems extensively, including full-scale testing for ASME PCC-2 compliance. Over the past 20 years, HJ3 has delivered engineered composite solutions for tanks, vessels, and more, proving our commitment to quality and innovation.

Can you share a notable project where composite repairs made a significant impact?

A few years ago, we helped repair a pressure vessel that had cracks near the weld seam of the head. The leak was discovered during a scheduled outage, and there was no time for replacement. Working with a nested contractor, we wrapped the entire vessel head and a 4-foot section of the shell within 48 hours. The repair restored integrity without affecting the turnaround schedule. The design is expected to last until 2029 and has been performing well for several years now. At HJ3, we pride ourselves on providing engineered solutions that meet industry standards and ensure long-term performance. We work closely with operators to find viable, compliant, and durable repair options. It's not just about the material—it's about delivering real value and support.

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