Introduction

Global pipeline infrastructure is under increasing strain, with many systems reaching or exceeding their intended service life. Corrosion, infiltration, and material degradation continue to threaten water, sewer, and industrial pipelines, prompting a shift toward smarter, less disruptive repair technologies.

According to the Global Energy Monitor (October 2023), over 800 operational oil pipelines are worldwide, with 25 more under construction, each representing a significant maintenance challenge over time. In the United States alone, trenchless technologies such as Cured-in-Place Pipe (CIPP) account for nearly half of the $3.4 billion sewer line rehabilitation market and 12.9% of the $1.5 billion spent on potable water pipe repairs, as reported by Geosynthetics Magazine (January 2024).

Ilium Composites plays a critical role in this transformation. With an advanced portfolio of high-performance composites developed specifically for CIPP applications, Ilium helps contractors and pipeline owners around the world reinforce and rehabilitate aging infrastructure efficiently, sustainably, and reliably.

Overview of Ilium Composites

Ilium Composites is a global leader in engineered reinforcements, supplying high-performance composite materials for a range of industries including infrastructure, construction, and transportation. Within the CIPP sector, Ilium’s materials are designed to challenge the real-world demands of structural pipe renewal, offering enhanced durability, flexibility, chemical resistance, and installation efficiency.

The company’s focus on innovation and robust R&D and customer collaboration ensure each product delivers long-term performance under diverse and often aggressive environmental conditions. Ilium’s expertise helps contractors streamline operations, meet strict performance specifications, and reduce total lifecycle costs.

Project Background

Pipeline degradation is a widespread issue that stems from the historic use of materials like clay, cast iron, and early-generation plastics. Many of these materials were not designed for the pressure, chemical exposure, or joint fatigue they now face. Failures often arise from joint infiltration, corrosion, and erosion, particularly in aging municipal sewer and water systems and vertical installations in buildings.

Cured-in-Place Pipe technology has emerged as a proven alternative to traditional “dig and replace” methods. By creating a new pipe within the old one, CIPP restores structural integrity without the need for extensive excavation. Ilium’s materials are essential to this method, providing reinforcement, chemical resistance, and dimensional stability.

These advantages are especially critical in densely populated areas and vertical applications, where digging is impractical or impossible. Ilium’s tailored reinforcements provide consistent performance across diverse installation environments, from corrosive wastewater systems to high-rise building stacks.

CIPP Lining Methodology

CIPP involves inserting a resin-saturated liner into an existing pipe, inflating it to conform to the host structure, and curing it (usually with steam, hot water, or UV light) to create a rigid, fully bonded pipe-within-a-pipe. Ilium’s role in this process is to supply the reinforcement material within the liner, typically a glass or composite mat that provides structural strength and shapes the performance of the cured system.

Key contributions of Ilium’s materials include:

  • Structural Performance engineered to deliver optimal wall thickness and hoop strength, Ilium materials ensure the cured pipe meets or exceeds design loads.
  • Resistance to a wide range of aggressive sewer and industrial effluents, as well as elevated cure and service temperatures.
  • Ease of Processing as materials are optimized for compatibility with different resin systems and cure techniques, helping contractors improve handling and reduce waste.
  • The reinforcement allows for adaptation to bends, diameter changes, and transitions without compromising performance.

Together, these qualities help reduce installation time, minimize errors, and ensure long-term structural reliability.

Results and Outcomes

Contractors and system owners using Ilium’s materials report significant improvements in project outcomes:

  • Time Savings: The use of pre-optimized reinforcement materials reduces installation and cure times. In some municipal projects, the total duration was cut by up to 40%.
  • Cost Efficiency: Trenchless installation combined with Ilium’s ease-of-handling materials results in less equipment use, reduced labour hours, and minimal site disruption, delivering cost savings of 20–30% compared to traditional methods.
  • Extended Lifespan: Ilium’s reinforcements’ structural and chemical performance contributes to a 50+ year design life for rehabilitated pipelines, even in aggressive conditions.
  • Environmental Impact: CIPP using Ilium’s materials drastically reduces excavation and disposal waste, helping asset owners meet sustainability targets and reduce carbon emissions.

In one vertical retrofit, contractors were able to restore corroded stacks in a 20-story building within days, without disrupting occupants or accessing hidden pipework, an achievement made possible by Ilium’s materials’ flexibility and curing reliability.

Conclusion and Future Implications

Cured-in-place pipe technology has transformed the landscape of pipeline rehabilitation, offering a non-invasive, fast, and cost-effective solution to aging infrastructure. Ilium Composites is proud to be at the forefront of this evolution, supplying advanced materials that underpin the performance, sustainability, and scalability of modern CIPP systems.

As global infrastructure ages and regulatory, environmental, and economic pressures mount, Ilium’s mission remains clear: to deliver smarter materials that help engineers build safer, longer-lasting pipeline systems for the future.