Fyfe - 100-Year-Old Penstock Given New Lease Of Life By Tyfo System

Hydroelectric facilities with century-old riveted steel penstocks face unique maintenance challenges as corrosion leads to wall loss and structural deficiencies. When traditional "remove-and-replace" methods are deemed too disruptive or costly, advanced composite systems offer a way to restore full structural capacity without altering the footprint of the existing infrastructure. In high-head environments, these systems are designed to act as standalone structures, capable of managing working pressures, vacuum forces, and extreme temperature gradients without relying on the host pipe for strength.

The rehabilitation process involves applying high-performance carbon fiber layers in specific hoop and longitudinal orientations to create a watertight, high-strength liner. This approach is particularly effective for navigating complex geometries, such as protruding rivet heads and air vent interfaces. Even in extreme climates with sub-freezing temperatures, specialized heating and hoarding plans ensure the composite material cures properly, achieving maximum durability. This trenchless solution significantly reduces downtime, allowing power generation to resume in a fraction of the time required for traditional steel repairs. Read the full case study to see how composite technology revitalizes aging hydroelectric assets.