Blocking Composite Bridge Plug | API 11D1 | 10,000 PSI | 97% Composite | Solid Bore | Fast Drill-Out

The Blocking Composite Bridge Plug is a solid-bore, fully drillable downhole zonal isolation tool engineered for efficient and reliable interval isolation in oil and gas drilling, workover, completion, and well abandonment operations. Unlike traditional cast iron or steel bridge plugs that require lengthy milling operations and produce heavy metal cuttings that can cause stuck pipe issues, this plug is constructed from 97% premium composite materials - glass fiber-reinforced epoxy resin or carbon fiber-epoxy matrix - combining exceptional mechanical strength, superior sealing performance, and fast, easy drillability, significantly reducing operational time and costs while ensuring safety and durability in harsh downhole environments. The solid bore design completely blocks fluid flow from both above and below the tool - providing bidirectional zonal isolation that enables targeted operations including multi-stage fracturing, well testing, acidizing, squeeze cementing, formation plugging, and temporary or permanent well abandonment. Equipped with nano-modified rubber sealing sleeves and an adaptive slip anchoring structure, the plug achieves a tight, reliable seal against the casing wall and maintains stable dynamic sealing under extreme conditions up to 300°F (150°C) and 10,000 PSI (70 MPa), with an optional 350°F high-temperature version available for hotter well environments. Compatible with casing sizes from 4½" to 7" (custom sizes available) and casing grades up to P110/Q125, the plug can be set via wireline - compatible with Baker E-4/E-5 setting assemblies - coiled tubing, or hydraulic setting methods, with running speeds up to 500 ft/min and a smooth mold-made sealing sleeve that minimizes the risk of premature setting, expansion, or jamming during deployment. After operations are complete, the composite plug drills out in just 10–20 minutes per plug using conventional drilling tools or coiled tubing-deployed motors, producing small, lightweight cuttings that circulate out of the wellbore easily without causing stuck pipe or casing damage - reducing milling time by up to 50% compared to traditional metal bridge plugs and enabling efficient one-trip milling. With total lengths of 26" (660mm) or 39.4" (1000mm), release force of 26,000–55,000 lbs (customizable), and excellent corrosion resistance against downhole fluids including oil, gas, and water, the blocking composite bridge plug is widely applied in shale gas and unconventional oil multi-stage fracturing, well testing and acidizing, temporary and permanent well abandonment, vertical/devitated/horizontal well operations, underbalanced drilling and completion, and squeeze cementing and formation plugging tasks - delivering reliable performance and significant cost savings for operators worldwide.

1. Superior Bidirectional Blocking and Sealing with Nano-Modified Rubber

Equipped with nano-modified rubber sealing sleeves and an adaptive slip anchoring structure, the plug achieves tight, reliable zonal isolation - effectively blocking fluid flow from both above and below the tool thanks to its solid bore design. It maintains stable dynamic sealing under extreme conditions up to 300°F (150°C) and 10,000 PSI (70 MPa), with an optional 350°F high-temperature version, preventing cross-zone contamination and ensuring operational safety during fracturing, testing, acidizing, and abandonment operations. The nano-modified rubber compound provides superior elasticity, compression set resistance, and fluid compatibility compared to conventional rubber seals.

2. High-Efficiency Drillability - 10–20 Minutes per Plug

Made of 97% premium composite materials (glass fiber-reinforced epoxy resin or carbon fiber-epoxy matrix), the plug can be easily milled with conventional drilling tools or coiled tubing-deployed motors. Average milling time is just 10–20 minutes per plug - reduced by up to 50% compared to cast iron bridge plugs - producing small, lightweight cuttings that can be quickly circulated out of the wellbore without causing stuck pipe issues or casing damage. The non-metallic composite construction eliminates the long, stringy metal cuttings typical of steel plug mill-out, enabling efficient one-trip milling and faster well turnaround.

3. Fast and Safe Running-In with Baker E-4/E-5 Compatibility

The smooth mold-made sealing sleeve and optimized structural design allow a running speed of up to 500 ft/min, minimizing the risk of expansion, jamming, or premature setting during deployment. The plug can be set via wireline - fully compatible with Baker E-4/E-5 setting assemblies - coiled tubing, or hydraulic setting methods, adapting to different operational requirements with high flexibility. The guide shoe ensures smooth movement through the wellbore, and the anti-preset design provides reliable, accurate depth placement in deviated and horizontal sections.

4. Solid Bore Design for Complete Blocking

The solid bore (non-through-bore) design completely blocks fluid flow through the plug - unlike through-bore frac plugs that allow limited flowback. This makes the plug ideal for applications requiring full zonal isolation including well testing, acidizing, squeeze cementing, formation plugging, and well abandonment, where no fluid communication across the plug is acceptable. The bidirectional anchoring and sealing system contains pressure from both directions, ensuring reliable isolation regardless of pressure differential orientation.

5. Durable, Lightweight, and Corrosion-Resistant

The composite material boasts excellent high-temperature and high-pressure resistance, as well as strong corrosion resistance against downhole fluids (oil, gas, water, and stimulation fluids). It avoids the wear, galling, and mechanical damage issues common with brittle metal components, ensuring long-term reliability in diverse well conditions including vertical, deviated, and horizontal wells. The lightweight composite construction - significantly lighter than equivalent cast iron plugs - also reduces transportation, handling, and deployment costs, and minimizes strain on running equipment.

6. Cost-Saving Operation with Wide Casing Compatibility

By reducing running-in time, milling time (up to 50% faster), and the need for multiple trips, the blocking composite bridge plug lowers overall rig costs and operational expenses. Compatible with casing sizes from 4½" to 7" (custom sizes available) and casing grades up to P110/Q125, with release force of 26,000–55,000 lbs (customizable) and total lengths of 26" (660mm) or 39.4" (1000mm), the plug covers a wide range of wellbore configurations. Its lightweight design reduces transportation and handling costs, delivering greater economic benefits for oilfield projects of all scales.

The Blocking Composite Bridge Plug operates in four phases - running-in, setting, blocking and operation, and milling and removal:

Phase 1: Running-In

The plug is delivered to the target wellbore interval via wireline, coiled tubing, or hydraulic running string, with running speeds up to 500 ft/min. The guide shoe at the lower end ensures smooth movement through the casing and prevents jamming or hang-up on casing joints, perforations, or debris. The smooth mold-made sealing sleeve and anti-preset design minimize the risk of premature expansion, setting, or damage during deployment, even in deviated and horizontal well sections.

Phase 2: Setting

Once on depth, hydraulic or mechanical force is applied to activate the setting tool - wireline setting is compatible with Baker E-4/E-5 assemblies, while coiled tubing and hydraulic setting methods are also available. The setting force pushes the cones to expand the adaptive slips, which anchor firmly to the casing wall with bidirectional grip. Simultaneously, the nano-modified rubber sealing sleeve compresses and expands radially to form a tight, pressure-tight seal between the plug body and the casing ID. After setting, the setting tool releases and is retrieved to surface.

Phase 3: Blocking and Operation

The solid bore design of the plug completely blocks fluid flow through the tool - with no through-bore passage - providing full bidirectional zonal isolation. The adaptive slips maintain anchoring against pressure from both above and below, while the nano-modified rubber seals contain differential pressure up to 10,000 PSI. This enables targeted operations on the isolated interval including multi-stage fracturing, well testing, acidizing, squeeze cementing, formation plugging, or well abandonment, with no fluid communication across the plug.

Phase 4: Milling and Removal

After completion of operations, the composite plug is quickly milled using conventional drilling tools or coiled tubing-deployed motors. The 97% composite construction drills out in an average of 10–20 minutes per plug - significantly faster than cast iron or steel plugs - producing small, lightweight, non-metallic cuttings that are easily circulated out of the wellbore without stuck pipe risk or casing damage. The efficient drillability enables one-trip milling, reducing rig time and accelerating well turnaround for production or subsequent operations.

Every Blocking Composite Bridge Plug is manufactured under an ISO 9001:2015 certified quality management system and designed in accordance with API 11D1 specifications for downhole packers and bridge plugs. Our quality assurance process covers the full product lifecycle:

Raw Material Control

Composite materials - glass fiber-reinforced epoxy resin and carbon fiber-epoxy matrix - are sourced from approved suppliers and accompanied by material test reports (MTR) verifying fiber content, resin matrix composition, tensile strength, compressive strength, and heat deflection temperature. Each batch undergoes composite material verification testing. Nano-modified rubber sealing materials are tested for hardness, tensile strength, compression set, and fluid compatibility before release to production.

In-Process Manufacturing Control

Composite components are molded and machined under controlled temperature and pressure conditions with documented process parameters. Critical dimensions - outer diameter, inner bore, seal groove dimensions, slip tooth geometry, cone angle, and guide shoe fit - are inspected at first-article, in-process, and final inspection stages using calibrated micrometers, bore gauges, and coordinate measuring machines. The adaptive slip assembly is tested for uniform expansion and release force within the 26,000–55,000 lbs specification range.

Performance Testing (100% of production)

• Hydrostatic Pressure Seal Test: Each assembled plug is tested at rated differential pressure (10,000 PSI) with zero visible leakage as the pass criterion

• Setting Function Test: Sample plugs from each production lot are set in test casing to verify slip expansion, seal compression, and anti-preset function for all setting methods (wireline Baker E-4/E-5, coiled tubing, hydraulic)

• Drill-Out Verification Test: Representative samples are milled with conventional tools to confirm drill-out time within the 10–20 minute specification and cutting size/weight characteristics

• Release Force Test: Slip release force verified within 26,000–55,000 lbs range

• Dimensional Inspection: 100% verification of critical mating dimensions against engineering drawings

Warranty and Support

We provide a 12-month warranty from the date of shipment against manufacturing defects in materials and workmanship. Our engineering team provides 24-hour online technical support for product selection, running procedures, drill-out optimization, and field troubleshooting.

1. Multi-Stage Fracturing in Shale Gas and Unconventional Oil Reservoirs

The core application scenario - suitable for large-scale multi-stage fracturing of horizontal and deviated wells in shale gas, tight oil, and other unconventional reservoirs. The solid bore design provides reliable zonal isolation between fracturing stages, while the fast drill-out (10–20 minutes per plug) reduces post-frac rig time and accelerates well turnaround. The 500 ft/min running speed and Baker E-4/E-5 compatibility ensure efficient deployment in long-lateral wells.

2. Zonal Isolation for Well Testing, Acidizing, and Stimulation

The solid bore completely blocks fluid flow, making it ideal for well testing, matrix acidizing, and stimulation treatments where full isolation of the target zone is required. The bidirectional sealing contains pressure from both directions, and the nano-modified rubber seals are compatible with acid and stimulation fluids. After operations, the plug drills out quickly without damaging the tested or treated interval.

3. Temporary and Permanent Well Abandonment

Suitable for both temporary and permanent well abandonment operations. The solid bore design provides reliable long-term zonal isolation, and the composite material's corrosion resistance ensures durability during the abandonment period. For temporary abandonment, the plug can be drilled out quickly when the well is re-entered; for permanent abandonment, it provides a cost-effective isolation barrier compared to cement plugs or cast iron bridge plugs.

4. Vertical, Deviated, and Horizontal Well Operations

Compatible with all wellbore trajectories including vertical, deviated, and horizontal wells. The anti-preset design and smooth sealing sleeve ensure reliable deployment and setting in high-angle and horizontal sections where conventional plugs may experience slippage or premature setting. The guide shoe prevents hang-up on casing joints and perforations in deviated wellbores.

5. Underbalanced Drilling and Completion Operations

The lightweight composite construction and fast drill-out make the plug suitable for underbalanced drilling and completion operations where minimizing formation damage and rig time is critical. The non-metallic composite material is compatible with underbalanced fluid systems, and the small cuttings produced during mill-out circulate out easily without disrupting underbalanced conditions.

6. Squeeze Cementing and Formation Plugging Tasks

The solid bore design provides a reliable barrier for squeeze cementing operations - containing cement slurry pressure and preventing fluid loss into unwanted zones. After cementing, the plug can be drilled out quickly along with the cement, leaving a clean wellbore. Also suitable for formation plugging and water shut-off operations where temporary zonal isolation is required.

Q: What is the difference between a blocking composite bridge plug and a composite frac plug?

A: A blocking composite bridge plug has a solid bore (no through-passage) that completely blocks fluid flow in both directions, making it suitable for well testing, acidizing, squeeze cementing, well abandonment, and applications requiring full isolation. A composite frac plug typically has a through-bore design that allows limited flowback or ball-drop activation, optimized specifically for multi-stage fracturing operations. Both are made from composite materials and drill out quickly - the choice depends on whether you need complete blocking (solid bore) or flow-through capability (through-bore).

Q: How long does it take to drill out a composite bridge plug compared to a cast iron bridge plug?

A: A composite bridge plug typically drills out in 10–20 minutes per plug using conventional or coiled tubing tools, while a cast iron bridge plug typically requires 30–60 minutes or more per plug. Composite plugs produce small, lightweight, non-metallic cuttings that circulate out easily, whereas cast iron plugs produce heavy metal cuttings that can cause stuck pipe issues. Overall, composite plugs reduce milling time by up to 50% and enable one-trip milling.

Q: What is the maximum pressure and temperature rating?

A: The rated differential pressure is up to 10,000 PSI (70 MPa). The standard operating temperature is up to 300°F (150°C), with an optional 350°F (177°C) high-temperature version available for hotter well environments. The plug maintains bidirectional sealing at rated conditions, as verified by 100% hydrostatic pressure testing.

Q: What casing sizes and grades are compatible?

A: Standard sizes include 4½" (114.3mm), 5½" (139.7mm), and 7" (177.8mm), with custom sizes available on request. The plug is compatible with casing grades up to P110 and Q125. Total length options are 26" (660mm) or 39.4" (1000mm), and release force is 26,000–55,000 lbs (customizable). Contact our engineering team for size-specific OD/ID dimensions and setting tool compatibility.

Q: What setting methods are available?

A: The plug can be set via three methods: (1) Wireline - fully compatible with Baker E-4/E-5 setting assemblies; (2) Coiled tubing - with coiled tubing-deployed setting tools; (3) Hydraulic setting - with hydraulic setting tools on tubing or work string. Running speed is up to 500 ft/min. The anti-preset design ensures reliable deployment in vertical, deviated, and horizontal wells.

Q: What are the composite materials used, and what percentage is composite?

A: The plug is constructed from 97% premium composite materials - either glass fiber-reinforced epoxy resin or carbon fiber-epoxy matrix - with the remaining 3% consisting of nano-modified rubber sealing elements and small metallic fasteners. The high composite content ensures fast, easy drill-out with no long metal cuttings, while maintaining mechanical strength and pressure containment capability.

Q: What is the MOQ, delivery time, and payment method?

A: The MOQ is 1 piece for standard models. Standard products ship within 7–15 working days after deposit; custom sizes or configurations require 20–30 working days. We ship from Shanghai or Ningbo port. Payment terms include T/T (30% deposit, 70% before shipment), L/C at sight, and Western Union. Packaging is individual plastic tube plus export wooden crate.

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