CCS Weave: The High-Shrink Material That’s Changing the Game

 

When it comes to high-performance sealing solutions, Covalence has engineered something truly remarkable: CCS Weave. This innovative material is used to create Casing Seals, Flange Seals, and other applications where a high-shrink product is essential. But what makes CCS Weave stand out in a crowded market? Let’s dive in.

1. Unmatched Shrink Ratio
CCS Weave boasts an impressive 66% shrink ratio. To put that into perspective: a 24-inch casing pipe could see the Caseal shrink all the way down to just 8.5 inches if allowed. This dramatic shrink capability ensures a tight, secure fit, even on irregular surfaces.

2. Durable, Multi-Layer Construction
At the heart of CCS Weave is a fiber-reinforced sheet laminated between two layers of polyethylene. This construction delivers exceptional performance in key areas:

• Penetration resistance – tough enough to withstand challenging environments
• Abrasion resistance – maintains integrity over time
• Elongation – flexible enough to handle complex applications

3. Hyper-Aggressive Mastic Sealant
A seal is only as good as the bond it creates. CCS Weave utilizes a hyper-aggressive mastic sealant that adheres well to a variety of substrates—even when surface preparation isn’t perfect. This ensures reliable sealing performance across diverse field conditions.

High-shrink materials can introduce a unique problem: how to keep the material intact during the shrinking process. Covalence tackled this challenge by borrowing a brilliant technique from Raychem, developed decades ago. Since 1995, we’ve been sewing a nylon zipper into the sleeve using Kevlar thread.

When the ends of the sleeve are zipped together, even the extreme 66% shrink ratio isn’t enough to break the threads. This simple yet ingenious solution allows CCS Weave to deliver maximum shrink performance without compromising structural integrity.

CCS Weave isn’t just another sealing material—it’s a high-performance solution designed to meet the demands of today’s toughest applications. With its impressive shrink ratio, multi-layer durability, and clever engineering, it’s a product that engineers and field teams alike can rely on.

It’s more than cool—it’s next-level material innovation.

Seal for Life Casing Seals & Flange Seals: Proven Protection for Challenging Applications

    

When it comes to protecting critical pipeline components, some applications simply refuse to cooperate. Off-center carriers. Large sizing disparities.

That’s where Seal for Life (formerly Raychem) Casing Seals and Flange Seals truly shine.

These aren’t just “wraps.” They’re engineered sealing systems designed to solve real-world field challenges.

Key Advantages:

• Fiber-reinforced, multi-layer heat shrink backing

• Integrated fiber mesh layer for enhanced penetration resistance

• Coated with a very aggressive mastic sealant

• Works even when the carrier pipe is not centered inside the casing

• Approximate 66% shrink ratio

That high shrink ratio is critical. It allows the material to conform across a wide range of casing-to-carrier pipe diameter ratios — without sacrificing seal integrity.

The aggressive mastic flows into irregularities, filling voids and creating a durable moisture barrier. The fiber reinforcement provides mechanical strength to resist damage and environmental stress.

The result? A reliable seal in one of the most challenging spots on a pipeline.

Sizing for Sealing a Flange with Flangeseal

 How do I Know What Size to Order: FS-Flangeseal and AQW-FPK (Flange Protection Kit)

An installed Covalence FS (Flangeseal)

     Coating a flange can be tricky.  You've typically got a significant size difference between the outside diameter of the flange - and the diameter of the pipeline.  You've also got a number of bolts that could have sharp edges.  You've got a gasket of some kind that you'd likely don't want to covered in anything permanently (that would prevent you from re-entering that flange if it was necessary.  You've also likely got some amount of uncoated pipe where the flange is welded in.  There are a lot of important data points there.  Let's try and break it down so it is a bit simpler.

     Typical flangeseal nomenclature will be something like this (I'll give a few examples):  

FS 24000-24 -- this is for a flange with an ACTUAL OD of 24.0".  This FS is supplied 24" wide (we'll get more into that below).

FS 36000-36 -- an FS for a 36" OD Flange that is supplied at 36" wide.  

FS 12750-24 -- an FS for a 12.75" OD Flange that is supplied at 24" wide.

     So, the first number is VERY important!  That tells us how to make the Flangeseal so that is long enough to wrap all the way around the flange and meet back up with itself.  An FS 12750 would never work on a 24" OD flange --- it would be like someone with a 36" waist trying to button up jeans that are made for a 22" waist.  

     The second number is the width of the flange as supplied.  That is slightly trickier to figure out.  Let's say you are working with a 24" OD Flange and a 12.75" OD Pipe.  In addition, let's say that flange is 4 inches wide itself and there are 4 inches of uncoated pipe where the pipe and flange connect.

     First thing I look at:  24" OD flange down to a 12.75" OD pipe.  Picture the sleeve installed.  The sleeve is going to 'step down' from the peak of the flange down to the pipe surface and nearly 6" of the sleeve "width" is going to be lost on that vertical of the sleeve shrinking.  Does that make sense?  Simplify it by picturing yourself cutting a strip of duct tape that spans from your kitchen island down to the floor and across to the wall.  You would have to measure - the number of inches you want it to be attached to your kitchen island -- and the distance from island to floor -- and the distance across floor to wall.  In this paragraph - the step down from outermost flange to pipe is like the distance from the kitchen island to the floor.  

     So right there - with this 24" to 12.75" dimension we know we are going to lose 6" of our sleeve width TWO TIMES (have to figure this step down will happen on both sides of the flange.  So that is 12" of our width "used" already.  In addition - the flange is 4" across (which includes where the bolts are, etc).  We've now used 16" of our sleeve width (12+4).

     Now let's add in that there are 3" of bare steel adjacent to the flange on both sides.  That is 6" of bare steel (total - we have to add them together) AND we still need to overlap onto good pipe coating by at least 3" per side (another 6").

     That leaves us (in terms of sleeve width) with:

• 12" of width used to bridge the gap between flange and pipe
• 4" of width used to cover the flange itself
• 6" of width used to cover bare steel
• 6" of width used to overlap onto good coating

12 + 4 + 6 + 6 = 28"

     The minimum FS width that could work on this configuration is 28".  Our standards are 24" and 35.5" --- so the only option here is to use a 36" wide Flangeseal (24" would not properly seal).  

 Flangeseal: An Excellent Option for Protecting Flanges from Corrosion

Flanges play a crucial role in connecting pipes and ensuring the integrity of industrial systems. However, these vital components are susceptible to corrosion, which can compromise their performance and lead to costly repairs. To prevent this issue, a reliable solution is needed, and Flangeseal emerges as an excellent option for protecting flanges from corrosion while offering easy installation.

One of the key advantages of Flangeseal is its backing with integrated fiberglass reinforcement. This feature gives the product toughness and long-lasting durability, allowing it to withstand harsh environments and demanding conditions. Additionally, the high recovery capacity of Flangeseal, combined with its impressive 65% shrinkage ratio, enables it to conform to high transitions smoothly. This versatility reduces inventory and logistics costs, making it a cost-effective choice for protecting flanges.

The mechanical resistance backing of Flangeseal is another noteworthy feature. It is designed to resist abrasion, impact, and penetration, providing reliable protection for flanges against various forms of damage. Moreover, the sealant used in Flangeseal is specially formulated to ensure a strong bond and a tight seal to virtually any substrate. This ensures that the seal remains intact, even when exposed to a wide range of temperatures, maintaining its elasticity and sealing characteristics over time.

One of the standout features of Flangeseal is its self-healing effect. The sealing adhesive has the ability to automatically flow and repair minor mechanical damages. This capability not only enhances the longevity of the product but also saves money by reducing the need for frequent maintenance or replacement. Additionally, Flangeseal does not require a primer, eliminating the need for drying time and making the application process quick and easy.

Installation of Flangeseal is made even more convenient by its zipper closure system. This system simplifies and accelerates the installation process, ensuring a secure fit around the flanges. Moreover, Flangeseal does not require any special equipment for installation, making it accessible to a wide range of users. This not only saves time but also keeps installation costs low.

The excellent performance of Flangeseal is further supported by its impressive properties. The bursting strength of the backing, tested according to DIN 30672, is measured at 3500 N, demonstrating its ability to withstand significant pressure. The adhesive's softening point, tested per ASTM E-28, is 92°C (198°F), indicating its high-temperature resistance. Additionally, the shear strength and peel strength of the adhesive, tested according to EN12068, are 8 N/cm² and 9 N/cm, respectively, confirming its strong bonding capabilities.

Flangeseal is a heat shrinkable corrosion protection sleeve specifically developed for installation on flanges or mechanical couplings that are already in place. It consists of two layers: a visco-elastic sealant and a fiberglass-reinforced, radiation cross-linked, polyethylene backing. The product comes in pre-cut sleeves with a zipper closure system, allowing for fast and simple installation. Additionally, each kit includes a corrugated cardboard sheet to keep the flange nuts and bolts clean, facilitating easy re-entry and disassembly when necessary.

The installation process of Flangeseal is straightforward. After cleaning and preparing the pipe surface and flange, the corrugated cardboard sheet is wrapped around the flange to be sealed. The heat-shrinkable sleeve is then positioned centrally over the flange and closed using the zipper closure. As the sleeve is heated above 125°C (257°F), it shrinks tightly around the substrate. During the recovery process, the adhesive softens and flows, forming a tight bond. The bond strength further develops during cool down and remains fully intact upon completion of the installation process.

How To Seal a Flange

How Do I Seal A Flange?

An Installed FlangeSeal

     Raychem / Covalence's (same company) is designed to prevent corrosion of flanges and mechanical couplers.  The Flange Seal system consists of a precoated, heat shrinkable fiberglass reinforced wraparound sleeve that provides a smooth transition from flange to pipe surface.
     Flangeseal products are available in a variety of sizes that accomodate 4" to 62" (or larger) flanges and a wide range of pipe diameters.  After wrapping the sleeve around the pipe and flange, it is easily closed with the preattached zipper and then the sleeve is torch shrunk in place.  The Flangeseal system provides a moisture seal that resists heat, cold, vibration, impact, abrasion and corrosive gases and fluids.
     It is important when calling for pricing that you know both the actual OD of the Flange and the actual OD of the pipe.  With those two bits of information we can have price and delivery information for you in seconds.
   

The products features and benefits of Flangeseal (sometimes images don't show up well on phones):

• Heat shrink backing with integrated fiberglass reinforcement that is tough and long lasting.  FS backing provides a high recovery capacity.
• 65% shrink ratio conforms to high transitions; reduces inventory and logistics costs and ultimately saves money.
• High mechanical resistance backing resists abrasion, impact and penetration.
• No primer is required.  There is also no cure time. 
• Specially formulated sealant ensures a strong bond and a tight seal to virtually any substrate.  Flange seal maintains its elasticity and sealing characteristics over a wide temperature range.
• Sealing adhesive automatically flows and repairs minor mechanical damage if there is any.  Flangeseal is self healing which saves money on repairs and CP systems.
• Low preheat sensitivity and proven functionality leads to faster application, saving labor costs and time.
• Zipper closure system if simple and fast.
• No special equipment is needed.

Examples of a few of the sizing options.

     With its 65% shrink ratio, Flangeseal is able to cover nearly any Flange OD / Pipe OD transition.  Please have Flange OD and Pipe OD handy before contacting us for a quote at 936/321-3333.

Flange Protection

Heat Shrinkable Corrosion Protection for Flanges

     Flangeseals are a niche product that we manufacture and sell.  Though the volume isn't yet tremendous, this is a fantastic product with a long, successful use history.  Flange Protection is a fairly common need out in the world.  There can be plenty of confusion as well though, as flange protection sleeves very often are specified on different criteria than we see field joint coatings specified.  Coincidentally, I've recently been in a position to have a few different discussions about our specific flange protection solution.

     Being that these are separate projects, there is an interesting opportunity here to evaluate our product (Flange Seal) from a couple of different angles:  Technically and cost.  

     First let's look at coating thickness:

Flangeseal is supplied with a backing thickness of 51 mils.  It is supplied with an adhesive thickness of 47 mils.  So we have a total supplied thickness of 98 mils.  This is a product that will shrink 67% if allowed to shrink that much (unrestricted by a pipe diameter, etc).  In such a case where there was going to be a full unrestricted recovery, this product backing thickness would be 127 mils.  Just like the backing, the adhesive thickness will increase during the shrink process (volume of the adhesive does not change, while the area of sleeve backing is reduced, resulting in a thicker adhesive even with the consideration that some small amount of adhesive will flow at the edges of the sleeve by design to form a seal.

That would mean a total, full unrestricted recovery of something in the neighborhood of 180 mils.  This may answer the question as many spec writers would see a number like this on a data sheet - and would copy it over to a spec - not realizing that they may have made a mistake.  If they meant to include the "full unrestricted recovery" dimensions (which are certainly are directly tied to the installed dimensions) then they have succeeded.  If, on the other hand, they have included a number which is the 'full unrestricted recovery' dimension but what they really want is the installed thickness - they may have inadvertently caused themselves an issue. 

Determining installed thickness can very often be a difficult task (as evidenced by the fact that no shrink sleeve manufacturer anywhere in the world reports an installed thickness).  Why is it difficult?  Because there are a number of very important factors.  How much 'slack' was in the shrink sleeve prior to shrinking?  What was the exact temperature of the preheated steel?  How much longitudinal shrink occurred during the shrink process?  What were weather, humidity and wind conditions during the shrink process?  What was the exact thickness of the adhesive during the manufacturing process (this can vary a great deal for mastic products, though the plant is always certain to guarantee a minimum thickness). 

Looking at this through my own 15 years of experience, exclusively with this product line, here are my opinions.

This product would be ~180 mils with a full recovery.

This product is 98 mils supplied. 

I believe it is reasonable to assume that the shrink sleeve thickness at the pipe will reach the 130+ mil thickness. 

This raises another difficult aspect of trying to define 'installed thickness' (which your client may not have even intended to do).  Because the sleeve will shrink a great deal when it bonds to the pipe surface; while not shrinking nearly as much as it bonds to the Flange surface (which is much larger) - the installed sleeve will be thicker at the pipe surface than it is at the flange surface; because shrink sleeve recovery has such a significant bearing on installed product thickness.

I'm sorry I could answer that one with fewer words.  I'm sure that is more than you ever wanted to know about installed shrink sleeve thicknesses.

 Now, when considering specifically my product (FlangeSeal) against a competitors heat shrinkable option:

Competitors product: 

Backing thickness supplied:  31 mils

Backing fully recovered:  not reported

Flangeseal:

Backing thickness supplied: 51 mils

Backing thickness fully recovered:  128 mils

So right there - we are looking at ~62% thicker backing as supplied.  I expect there will be a similar disparity with fully recovered dimensions.  So 62% thicker backing.  That is pretty significant when considering the weight these sleeves will bear on larger flanges. 

An important note:  our backing is comprised of three layers:

1 layer of radiation cross linked polyolefin

1 layer of a fiber mesh material specifically designed to improve penetration resistance and abrasion resistance (critical for sealing a flange in my opinion)

a 2nd layer of radiation cross linked polyolefin

From all I can see - my competitors product is comprised of a single layer of polyethylene.

Looking at adhesive thicknesses (which aren't as important in my opinion) - Competitor is at 44 mils and our Flangeseal is at 47 mils. 

I really think the fiber mesh laminated in the backing of our product is the most important difference though.  Truly, I think it is the difference between a product that works...and a product that doesn't.

FLANGESEAL Heat Shrinkable Corrosion Protection Sleeve

 

FLANGESEAL

 Heat shrinkable corrosion protection sleeve specifically developed for installation on flanges or mechanical couplings that are already in place.

Product Description: FCWS-F/Flangeseal (US) flange/pipe sealing and protection.

• Construction: Two-layer system
• First layer: Visco-elastic sealant.
• Second layer: Fiberglass reinforced, radiation cross-linked, polyethylene backing.

The FCWS-F/Flangeseal (US) - is a wrap-around heat-shrinkable sleeve, with a specially designed zipper closing system, allowing a fast and simple installation. The fiberglass-reinforce woven backing gives the FCWS-F/Flangeseal (US) a high mechanical resistance as well as a high recovery capacity. In addition to the sleeve, a cardboard sheet is supplied to keep the flange nuts & bolts clean, allowing easy re-entry and disassembly when necessary.

FCWS-F/Flangeseal (US) is installed using standard gas torches. The installation is carried out directly on the cleaned and prepared pipe surface and flange. After preheating, the corrugated cardboard sheet is wrapped around the flange to be sealed. The heat-shrinkable sleeve is positioned centrally over the flange
and closed, using the zipper closure. When heated above 125°C (257°F), the sleeve shrinks tightly around the substrate. During recovery, the adhesive softens and flows to form a tight bond. The bond strength builds up during cool down and is fully retained after completion of the job.

Product Features/Benefits:

• Backing with integrated fiberglass reinforcement making it tough and long lasting. Provides a high recovery capacity.
• 65% shrinkage ratio – conforms to high transitions. Reduces inventory & logistics costs allowing to save money.
• High mechanical resistance backing resists abrasion, impact and penetration.
• No primer required, no drying time and easy application.
• Specially formulated sealant ensures a strong bond & tight seal to virtually any substrate. Maintains its elasticity and sealing characteristics over a wide temperature range.
• Sealing adhesive automatically flows and repairs minor mechanical damages "Self-healing effect."saves money.
• Low preheat sensitivity & proven functionality for faster application, this saving time.
• Zipper closure system for simple & fast installation.
• No special equipment required makes installation fast, easy and keeps installation costs low.

Product Selection Guide:

Max operating temperature:   30°C (86°F)
Compatible line coatings:   PE, PP, FBE, Tape, Coal tar, Asphalt, Plastics
Min preheat temperature:   60°C (140°F)
Recommended pipe preparation:   ST3

FCWS-F/Flangeseal (US) type products are available as a kit containing:
- a sleeve (pre-cut sleeve with zipper closure)
- a corrugated cardboard sheet