Working with pipelines, especially large-diameter ones, is rarely straightforward. Access can be limited, trenching can be expensive, and full pipe replacement is often unnecessary. When only a short section of a pipe is damaged, a point repair using a packer can save both time and budget.
This is where Pillow Packers come into play, a versatile, trenchless repair tool developed for just such challenges. PlugCo, an industry leader in pipe testing and rehabilitation tools, has designed a line of Pillow Packers that are built to solve one of the toughest problems in utility maintenance: how to repair pipes efficiently and effectively without digging them up.
What Is a Pillow Packer and How Does It Work?
A Pillow Packer is an inflatable bladder used for point repair inside pipes. The design is simple, but the execution is anything but basic. The packer is inserted into the pipe with a patch of repair material, typically a resin-impregnated fiberglass, wrapped around its body.
Once the packer is in place, it is inflated, pressing the patch firmly against the damaged area of the pipe wall. After the resin cures (usually within a few hours), the packer is deflated and removed, leaving behind a sealed, reinforced section of pipe.
Why Choose PlugCo Pillow Packers?
PlugCo’s Pillow Packers are known for their durability, flexibility, and ease of use. Made of double-layer reinforced rubber, PlugCo’s Pillow Packers can withstand internal pressures while maintaining enough flexibility to navigate into hard-to-reach pipe sections. Their flat and foldable design also means they can fit through manholes and tight entry points with minimal effort.
PlugCo offers a wide range of Pillow Packers to suit various pipe diameters and project needs. The different models PlugCo produces are multi-sized which means that you can use the same Pipe Pillow Packer for different Pipe Diameters.
- PlugCo offers also Flow Through Pillow Packer Models which are equipped with a bypass feature, allowing fluid to pass through the packer during the repair. This is perfect for live systems where shutting down the flow is not an option.
All models are available in different lengths to match specific repair zones.
When to Use the Pillow Packers?
Pillow Packers are particularly effective in the following cases:
- Large-diameter pipes where standard packers won’t fit
- Access-restricted zones, when the manhole is way smaller than the pipe diameter
- Emergency repairs, where speed and minimal disruption are essential
- Trenchless projects, reducing the need for excavation and restoration
Utilities and contractors frequently rely on Pillow Packers when rapid mobilization is required. Because of their lightweight, foldable construction, these packers can be transported and set up by a small team, even in remote or confined environments.
Installation: Simple, Yet Precise
One of the reasons maintenance crews like PlugCo’s packers is their simplicity. Positioning the packer is straightforward with the use of pull ropes or robotic equipment. Inflation is done via a standard compressor or pump, PlugCo’s Air Control Device allows for accurate pressure monitoring during the curing process.
Because the patch bonds permanently to the pipe wall, the resulting repair is strong, smooth, and often more corrosion-resistant than the original pipe material.