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REINFORCEKiT® STRUCTURE, Corroded metallic structures – Europe
Composite solution for structural repair

Overview

In April 2025, 3X ENGINEERING (3X) specialists carried out reinforcement works on 16Insulator Support Frames that were severely corroded. These structures, designed to support insulators, are critical components for ensuring the electrical insulation of overhead catenary lines. To restore their structural integrity, the REINFORCEKiT® STRUCTURE composite repair system was applied.

Results

The repair work was successfully completed by 3X ENGINEERING specialists, with all 16 Insulator Support Frames reinforced using REINFORCEKiT® STRUCTURE solution. The restored structures are now fully operational and able to perform their original function.These reinforcements ensure continued safety for both railway operations and personnel by preventing potential electrical hazards.

Defect type
 Corroded metallic structures
Details
 Insulator Support Frames / beams
Location
 EUROPE, Transportation/Railway Industry
3X Product type
 REINFORCEKiT® STRUCTURE

SCOPE OF WORK


REINFORCEKiT® STRUCTURE is a tailor-made composite repair system designed to rehabilitate corroded structures and restore their original mechanical integrity. For this project, repair designs were developed using finite element analysis (FEA) to ensure optimal structural performance.

Prior to the composite application, the initial step was to break the concrete base of the beams and thoroughly clean the surrounding area. This preparation was essential to ensure a proper seal between the beam supports and their bases. Additionally, sufficient space around the supports was required for effective composite wrapping.

Repair process executed by 3X specialists was performed following below stages:

  1. SURFACE PREPARATION & HYGROMETRIC CONDITIONS CONTROL
    Surface preparation was carried out via sandblasting to achieve adequate roughness (minimum60-micron surface profile). Before applying the resin, hygrometric conditions were checked to confirm compliance with application standards, and surfaces were cleaned with acetone to remove any contaminants.
  2. 3X RESIN & METAL INSERTS INSTALLATION
    3X epoxy resin was first applied at the base of the structures to seal the interface between the concrete and the beam. Custom-designed metal inserts, tailored to match the specific geometry of the structures, were then installed. These inserts were fixed using 3X filler and secured with ratchet belts until the filler cured completely.
  3. COMPOSITE WRAPPING REINFORCEMENT
    A first layer of 3X resin was applied on the entire surface to be wrapped to ensure optimal adhesion and impregnation. The composite reinforcement was then performed using eight layers of Kevlar® tape impregnated with epoxy resin, to restore the mechanical performance of the structures.
  4. IMPACTS & UV PROTECTION
    To ensure long-term durability, all repaired areas were covered with a specific coating to protect against UV exposure and mechanical impacts.
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