Flex Fabric Mold Encapsulation

Flexible Fabric Encapsulation (FFE) is a technique commonly used for repairing leaking joints or pipes in situations where traditional methods may not be feasible. The process works by utilizing a mold and a two-part polyurethane sealant, which together create a flexible, durable repair.

Here’s a breakdown of how the process works:

1. Mold Encapsulation:

   • The leaking joint is first encased in a mold, which is typically made of a flexible fabric material that can conform to the shape of the joint. This mold effectively isolates the leaking area to prevent further leakage during the repair process.

2. Polyurethane Sealant:

   • A two-part polyurethane sealant is then injected into the mold. Polyurethane is commonly used for such applications because it is a strong, durable material that can form a watertight seal when fully cured.

3. Pressurization:

   • After the sealant is applied, the mold is pressurized to above mains pressure. This is typically done by twisting or tightening the mold neck, which helps the polyurethane sealant to spread evenly and fill any gaps, cracks, or voids in the leaking joint.
   • The pressurization ensures that the sealant is pushed into all the areas of the joint, forming a tight, waterproof barrier that prevents further leakage.

4. Curing:

   • After the sealant has been applied and the mold is pressurized, the two-part polyurethane mixture begins to cure (harden), bonding to the surfaces and creating a robust, flexible repair. The curing time can vary depending on the type of sealant used and environmental conditions.

5. Result:

   • Once the sealant has fully cured, the mold is removed, leaving behind a durable, flexible repair that effectively stops the leak. The repair is designed to withstand the pressures of the pipeline and provide a long-lasting solution without requiring the complete replacement of the joint or pipe.

This method is especially useful for pipeline repairs, such as in water distribution systems or oil and gas pipelines, where immediate, efficient, and minimally invasive repairs are necessary. It’s also popular because it can be done with minimal downtime, keeping the system operational while repairs are made.