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A 2026 Skolkovo Institute of Science and Technology study describes a potentially portable way to join and repair thermoplastic pultruded profiles: heat the joint locally with hot air, place the parts in formwork, and press them together while the material fuses. The laboratory work used a hot-air blower and a press. Researchers suggest that a field crew might substitute a compact hydraulic device, such as a car scissor jack, for the laboratory press. The method is not a general fix for rusted steel, concrete, or thermoset composites, and the report does not document repairs on operating infrastructure. It is a proposed field option whose engineering performance still requires verification.
What did the 2026 study actually demonstrate?
The paper, “Hot-gas welding of thermoplastic pultruded profiles,” by Nikita Lyashenko and colleagues, was published in the Journal of Materials Research and Technology in 2026 (DOI 10.1016/j.jmrt.2026.09.210). A Tech Xplore report based on Skoltech research describes laboratory joining of thermoplastic, fiber-reinforced pultruded profiles.
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Outbyte Driver Updater FREEFix the driver behind crashes, sound loss and screen glitchesFind Drivers →Outbyte PC Repair FREEClear out junk files and repair common Windows errorsFree Scan →The process locally heats the thermoplastic matrix until the mating surfaces can fuse. The parts are then aligned in formwork and compressed. Unlike a mechanical fastener or adhesive repair, the joint is formed by remelting and consolidating the thermoplastic itself.
That distinction matters: thermoplastics can be melted and rejoined locally, whereas thermoset composites cannot be remelted without degrading their properties. The method therefore applies to suitable thermoplastic composite profiles, not to arbitrary plastics or existing thermoset structures.
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How does the hot-gas welding sequence work?
- Prepare and align the profiles. The sections are positioned so their joint surfaces meet in the intended geometry.
- Heat the joint locally. A hot-air blower directs heat at the thermoplastic surfaces.
- Use formwork. The heated parts are held in a fixture that helps preserve the profile shape during joining.
- Apply compression. In the reported experiments, a laboratory press brought the softened surfaces together for a controlled period.
- Allow the joint to consolidate. Pressure and cooling must be managed so the fused area remains aligned rather than distorted.
The report identifies four variables that must be balanced: hot-air temperature, heating exposure time, pressing force, and pressing duration. Alexander Safonov, an associate professor at Skoltech and principal investigator, summarized the control problem by saying, “There are just four parameters.” The report does not publish optimized numeric settings, material grades, profile dimensions, or a field procedure.
Could a crew use portable equipment instead of a laboratory press?
Possibly, but this remains a proposal rather than a demonstrated deployment. The researchers describe a small blower paired with a hydraulic device similar to a car scissor jack as a potential field arrangement. A real repair system would also need a rigid, accurately fitting fixture, a way to monitor temperature, controlled force application, safe access to the damaged member, and inspection criteria for accepting the joint.
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How does this approach compare with other composite-welding methods?
The news report gives a qualitative comparison, not a numerical benchmark. It says the resulting joint strength was comparable to ultrasonic and resistance welding and not critically inferior to induction welding. It supplies no measured strength values, sample counts, test methods, confidence intervals, or service-life data.
| Joining approach | What the report says | Field implication described in the report |
|---|---|---|
| Hot-gas welding | Uses local hot air and pressure; the study identifies four adjustable process variables. | Potentially portable with a small blower and hydraulic compression, but not field-validated. |
| Ultrasonic welding | Reported as a qualitative strength comparison point. | Described as requiring more complex equipment than the hot-gas concept. |
| Resistance welding | Reported as a qualitative strength comparison point. | Described as requiring more complex equipment than the hot-gas concept. |
| Induction welding | Hot-gas joint strength was described as not critically inferior. | Induction equipment is described as bulkier, more expensive, and more energy-intensive. |
Those statements establish direction, not a design value. Engineers would need the underlying journal paper and project-specific testing before selecting a joining method for a load-bearing member.
Where might the method be useful?
The Skoltech report discusses assembly and repair of bridges, cell towers, warehouses, wind-turbine and transmission towers, and pedestrian overpasses. These are possible application areas, not evidence that the process has been used on operating assets. Before adoption, owners would need to confirm the profile’s resin and fiber system, damage limits, environmental exposure, load path, inspection method, and applicable approval requirements.
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Thermoplastic composite infrastructure is attractive because it does not rust and can potentially be reheated for joining or recycling. However, this report does not quantify corrosion savings, recyclability rates, maintenance costs, emissions, durability, or service life. Those benefits remain rationale for investigating the material system, not measured outcomes of this welding study.
What is still missing before a repair can be specified?
- Thermoplastic grade, fiber architecture, profile dimensions, and surface-preparation requirements.
- Numeric temperature, heating-time, force, and pressing-duration windows.
- Measured joint strength, failure modes, specimen counts, and test standards.
- Effects of moisture, wind, contamination, thermal gradients, and field access.
- Fatigue, impact, creep, fire, ultraviolet, and long-term environmental performance.
- Inspection, quality-assurance, and acceptance criteria for installed repairs.
- Code, certification, and owner approval for each infrastructure type.
Until those details are available and independently checked, the method should be viewed as a promising laboratory process for thermoplastic pultruded profiles—not as a ready-made structural repair specification.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.Frequently Asked Questions
Can hot-gas welding repair steel that has started to rust?
No. The reported process is for thermoplastic pultruded composite profiles. It does not remove corrosion from steel or create a weld in metal.
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Can this method join thermoset fiberglass components?
Not on the evidence reported. Thermoset composites cannot be remelted for fusion joining without degrading their properties, so compatibility must be established for a thermoplastic matrix.
Is there a published temperature or pressure recipe for field crews?
The report names temperature, heating time, pressing force, and pressing duration as the four variables, but it does not provide optimized numeric settings. A field recipe should not be inferred from the news summary.
Has a bridge or tower already been repaired with this portable system?
The report presents bridges, towers, warehouses, and overpasses as possible applications. It does not document a completed repair on operating infrastructure.
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