Sarpol-e Zahab Polyethylene Gas Pipeline Repair Project

Manshoor Composite Sanat Asia Company successfully repaired 225mm polyethylene pipelines in Sarpol-e Zahab County. The project solved the problem of composite adhesion to polyethylene pipes and fixed leaks caused by coupler defects and an 8mm hole. The project’s rigorous testing was conducted by Jahad Zamzam Plastic Industries Company, and it received final approval.

Due to their unique chemical structure, polyethylene pipelines typically have poor adhesion with composite materials. This makes their repair a complex challenge, especially in cases of leaks caused by coupler defects or small holes. In this project, the Kermanshah Gas Company provided a sample of polyethylene pipelines with a “specifically designed groove” and an “8mm hole,” which required an innovative solution to fix the leak.

To overcome this challenge, the technical team at Manshoor Composite Sanat Asia Company designed a special composite formulation. By optimizing its chemical composition, it enabled the creation of an effective bond with the polyethylene surface. This process included the following stages:

Pipeline Surface Preparation: Using cleaning and chemical modification methods, the pipeline surface was prepared to increase adhesion.
Application of the Composite Coating: The composite layers were precisely installed on the damaged points to ensure no leaks remained.

After the repair, the pipelines were subjected to rigorous tests to ensure quality and performance. These tests were conducted by Jahad Zamzam Plastic Industries Company and included the following:

Quality and performance testing under the supervision of Jahad Zamzam Plastic Industries Company

Project Results

Complete Leak Sealing

In both 63mm and 90mm pipes.

Cost Reduction

Preventing the need for complete pipeline replacement and saving time and resources.

Standard Compliance

Compliance with standards ISO 1167-1,2, ASTM D1599, and INSO 11233-2 and receiving the ISO/IEC 17025 certificate from Jahad Zamzam laboratory.

Conclusion

The Sarpol-e Zahab Gas Supply Polyethylene Pipeline Repair Project is not only a technical success for Manshoor Composite Sanat Asia Company but also a significant step toward enhancing the safety and stability of the country’s gas network. This project proved that by using innovative technologies and specialized material design, even seemingly impossible challenges, such as the adhesion of composites to polyethylene, can be solved.

The key achievements of this project are:

Enhanced safety of the gas network by completely fixing dangerous leaks.
Reduced maintenance and repair costs by preventing the need for full pipeline replacement.
Confirmed the company’s technical competence by passing rigorous international tests.

This success paves the way for the use of this technology in future projects and even in other industries, and it demonstrates the company’s commitment to innovation and the development of sustainable infrastructure.