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Tech-Bond Global | How to Repair a Cracked HDPE Pipe (Permanent Polymer-to-Polymer Bond)

When a high-density polyethylene (HDPE) pipe cracks, most repair methods fail — epoxies won’t hold, adhesives peel, and welding often weakens the material. Tech-Bond’s Polymer Bonding Process, used in our Tech Patch Repair System (TPRS™), solves that problem permanently.
This video shows step-by-step how to repair a cracked HDPE pipe in minutes using Tech-Bond’s molecular bonding technology. The repair creates a true polymer-to-polymer bond, restoring full strength, flexibility, and service life without heat fusion or replacement.

The Challenge
HDPE is chemically inert, low in surface energy, and extremely difficult to bond. Traditional glues and epoxies simply “sit on top.” In water, slurry, or industrial systems, those repairs fail quickly. Downtime is costly — and pipe replacement means excavation, welding, and lost productivity.

The Tech-Bond Solution
The Tech Patch Repair System (TPRS™) uses a combination of Poly Prep, Accelerator (catalyst), and our SI-series Bonding Agents to permanently join polymers.
The Process creates an exothermic reaction that chemically cross-links the HDPE surface with the adhesive and the PTFE-coated e-glass reinforcement. The result: a permanent molecular bond that remains flexible and pressure-resistant.

Step-by-Step Process
1. Surface Prep:
Rough the HDPE pipe surface with sandpaper or a rotary tool to below the sheen — removing all oxidation and contaminants. Then remove all residue.
2. Apply Poly Prep:
Sauturate the HDPE surface with the Poly Prep. This step permanently alters the HDPE surface energy. Allow to dry.
3. Apply Accelerator:
Spray a light mist of the Acceleator (the catalyst) which is one component of preparing the surface for the critical Exothermic Chemical Reaction. Let the Accelerator flash off (~15–60 seconds max).

4. Apply Bonding Agent to the Patch:
Apply a minimal, controlled amount of Bonding Agent over the entire area of the Tech Patch/Tech Wrap (the PTFE-coated e-glass fabric) using small concentric circles. Run a bead of the Bonding Agent all the way around the perimeter of the patch/wrap.

5. Pick up the Tech Patch, apply it to the pipe by starting on one end and working toward the other end. Make sure that the patch/wrap is absolute smooth.

6. Use a glue squeegee on a slant and apply pressure from the center out. Your objective is to squeeze every excess drop of the Bonding Agent from between the pipe and the patch/wrap. CRITICAL | FAIL POINT. Excess adhesive means that the surfaces are not bended together.

7. Gentle Heat Activation:
Warm the area to 120 °F (49 °C) — this initiates the exothermic reaction. Stop heating when temperature rises on its own. When the surface turns HOT, STOP. Within minutes, the patch will be permanently bonded to the HDPE substrate.

8. Inspect and correct any issues.

Performance Results

Bonds withstand pressure, vibration, and immersion.

No heat welding or special tools required.

Proven success rate: 99%+ across thousands of field applications.

Material Science Behind It

PTFE-coated e-glass fabric provides a chemically inert, high-strength reinforcement layer.

Excellent chemical resistance: Unaffected by acids, bases, fuels, oils, and solvents.

Thermal range: –200 °C to +260 °C (–328 °F to +500 °F).

UV & weatherproof: Non-yellowing, non-wetting, and non-stick.

Mechanical: Durable, abrasion-resistant.

Combined with Tech-Bond’s cross-linked polymer adhesive, the patch becomes an integral part of the pipe — not a surface cover.

The Result

The crack disappears under a permanent bond that can handle, in most cases, the flow, impact, and environmental stress that occurs.

It’s not glued. It’s Tech-Bonded.

Applications

Mining slurry lines

Water mains and irrigation systems

Chemical, oil, and gas transfer lines

Underground utilities and poly storage tanks

Verified Performance

A study conducted in the Borouge Compandy, according to ISO 1167 and 13479 guidelines, found that 4" diameter, SDR 11 pipe, found that the HDPE pipes withstood 1800 psi for over 100 hours (test reports available). In addition, there will be independent testing at the Indian Institute of Technology (ISM Dhanbad) to confirm the strength and permanence of TPRS™ repairs under pressure and moisture. Results will be presented during the upcoming Tech-Bond Global Event at IIT-ISM.

Precision • Performance • Permanence
That’s the Tech-Bond difference.
www.techbondglobal.com