Wil-Cor’s crack arrestors for pipe line repair consist of two shells larger than the damaged pipe. A shell thickness and grade equal to the damaged pipe used. These two shells are placed around the damaged area and welded together. The void between the outside of the pipe and inside of the shell is then pressure-injected with Armor Plate 999 epoxy grout, providing permanent pipe repair without interrupting the product flow.


Epoxy filled crack arrestors prevent a damaged area from bulging radially, reducing the stress near the damaged area and preventing subsequent cracks and line failure. Repaired areas are stronger than the original undamaged line pipe.


Epoxy filled crack arrestors repair pipelines above ground, at ground level, underground or underwater. Epoxy filled crack arrestors eliminate damage caused by leaks and cracks, corrosion loss to 85% of material inside or outside the pipe, dents, gouges and distortions up to 12% of line diameter and fatigued sections of the pipe.


Epoxy filled crack arrestor injection uses equipment that is portable and simple to operate, tolerant of site conditions and able to operate with the available power supply. Epoxy filled crack arrestors provide a permanent repair without cutting, fitting and welding to an in-service pipeline. Repair components are not welded on a live line, so there is no doubt about weld integrity. Epoxy filled crack arrestors tolerate a wide variance in the annular gap. This tolerance eliminates fitting problems and allows the use of standard shell sizes.


Epoxy filled crack arrestors are a less expensive alternative to cutout repair of pipeline. The actual repair of the line requires less time and material. In addition, there is no loss due to pipeline down time. Epoxy filled crack arrestors are a must for pipelines, such as those on the North Slope of Prudhoe Bay, Alaska, which cannot be shut down for repairs.

The Wil-Cor Injection Process

Armor Plate 999 epoxy is injected at reduced pressure. When the line pressure is restored, the repair restrains the damage. This method is used where the pressure has been reduced as a safety precaution because of the pipe line damage. Reduced pressure injection uses a simple grout injection technique, a simple sealing arrangement, requires no knowledge of actual line pressure and is suitable for large or small annular gaps.

The Armor Plate 999 Epoxy Grout

  • High Strength
  • Quick cure time and long pot life
  • Packaged in pre-measured components of epoxy resin and catalyst
  • Sets in temperatures as low as 45 °F Can be stored and pumped at sub-zero temperatures
  • Resistant to water, steam, salts, solvents, grong caustics, mild acids, oils and grease
  • High, non-volatile flashpoint – ship by air
  • Excellent bonding properties eliminate contamination

Installation of Wil-Cor’s Crack Arrestors

Choose a crack arrestor to fit the size of the pipe needing repair. Allow a minimum annulus of 1/8″ to 1/4″. Wipe the crack arrestor interior and pipe exterior with a degreasing solvent.

  • 1If crack arrestors abut each other, fill the gap between with Armor Plate 990 Epoxy Putty.
  • 2As the annulus fills, epoxy will begin to flow from the vent holes and tapped injection holes on the crack arrestor. Seal these holes as the epoxy hardens.
  • 3Apply Armor Plate 990 Epoxy Putty to each interior and of the crack arrestor. Place the top and bottom halves of the crack arrestor over the repair site. Use weld straps to join the top bottom halves.
  • 4Attach the epoxy injection equipment to the tapped injector hole at the bottom of the crack arrestor.
  • 5Seal the ends of the crack arrestor with additional AP 990. Wrap the ends of the crack arrestor with fiberglass if necessary.
  • 6Pump the epoxy through the injection ports located at the bottom of the crack.

Wil-Cor has 25 years of field experience providing permanent on-line pipe repair for many industries. The most challenging project has been repairs to the pipelines on the North Slope of Prudhoe Bay, Alaska. Working in harsh climates and sometimes remote locations, Wil-Cor understands the necessity to make the repairs right the first time so expensive call backs are not required. In Alaska, as well as other locations around the world, Wil-Cor has met every challenge and set new standards for pipeline repair. Your system may not be as extensive as the Alaska pipelines, but if preventative maintenance and repair is important, call on Wil-Cor to keep your pipeline flowing smoothly with epoxy.