Protection for offshore splash zones
Ray Aither, ACO-Coatings (U.K.)
Protecting off-shore splash zones from corrosion presents
special problems, not the least of which is the task of applying
coatings in-situ. The hazards include:
1. Wet conditions. 2. Cold environment. 3. Difficult
access. 4. Possible damage by water or wave action
immediately after application. 5. Wind scatter of coating.
Zebron is a solvent-free polyurethane which provides a
thick abrasion and water resistant coating to steel or concrete,
it cures in cold, wet conditions and can be rapidly applied to a
high film thickness in one operation.
Curing is extremely quick, providing rapid protection from
wave or water damage, and during spraying the highly
polymerised particles offer good resistance to wind scatter.
Zebron is also simple to repair.
Application to wet substrates is not possible but priming
systems are available to accommodate damp substrates.
Resistance to damage by wave and water action, however,
rapidly develops and the sprayed film is fully resistant within 15
to 30 minutes.
During 1984, a significant project was carried out on the
splash zone area of the Shell/Esso Brent Alpha platform.
Zebron was successfully applied by spray to all tubular
sections to a film thickness of 2mm in one wet-on-wet process.
The steel was prepared to Swedish Standard S.A. 2.5,
followed by immediate application of the coating.
The rapid setting characteristics of Zebron film allowed blast
preparation of adjacent areas to be carried out in the shortest
possible time.
This rapid blasting and coating operation enables work to be
completed in a time previously not considered possible. The
need to rework previously coated areas, clearly necessary
with a multi-coated system, is eliminated, thus offering
considerable savings in man hours, scaffolding and staging
costs. The problems of intercoat contamination and re-
preparation are also avoided.
The advantages of a one-operation coating system equally
apply to shore-based construction work, as demonstrated on
the Gulf Canada project.
Two drilling rigs fabricated in Japan for Gulf Oil Resources
(Canada) had Zebron applied to the hull areas and moon pool
using the same wet-on-wet high build spray application.
These rigs, designed for operation in the Beaufort Sea and
thus subject to high impact and abrasive forces due to ice
formation and movement, demanded a coating system with
the highest possible abrasion resistance, shear strength and
adhesion.
These physical properties are particularly important when
fabrications and pipework are coated on-shore prior to off-
shore installation. Zebron's resistance to impact damage due
to mechanical handling offers considerable savings in repair
work for the off-shore operation. In the event of localised
damage, repair can be executed quickly and simply using
brush or palette knife application.
Zebron coatings can also be used to repair and overcoat a
wide variety of anti-corrosion systems such as epoxy powder
coatings, liquid epoxy systems, coal tar epoxy, neoprene and
glass-reinforced coatings based on epoxy or polyester resins.
In addition, conventional coating systems can be repaired
and over-coated to enhance service life. There is nothing
conventional about off-shore platforms and conventional
coatings have limited resistance to aggressive off-shore
conditions. Zebron coatings provide long lasting protection
against moisture corrosion and abrasion.
Successful off-shore coating applications using Zebron
have included conductor guard frames, riser pipes, sea water
inlet pipes, boat landings and fenders, valves and fittings, and
non-skid deck coatings.
8 ANTI-CORROSION
Following an agreement between ACO-Coatings (U.K.) and
3M United Kingdom PLC, Zebron is now also available
through the 3M Electrical Products Group distribution network
in pack sizes convenient for on-site handling by customers'
own maintenance crews or their sub-contractors.
Coal tar epoxy applied by diver
Wailes Dove Bitumastic plc., which is part of the Dufay
Bitumastic Group, continues to research and formulate new
coating systems for use in specialised conditions.
'Epimastic' L. 1078 is not an entirely new coating, having
been on the market for some seven years. In 1984, however,
an entirely new application for this moisture-tolerant coal tar
epoxy coating was found. In addition to the capability of
application to steel or concrete in tidal situations, it was found
that 'Epimastic' L. 1078 could be applied by a diver using
specialised equipment in full sea-water immersion conditions.
In April 1984 this coating was applied to approximately 700m2
of the underwater surfaces of an Admiralty floating dock. The
coating cured and hardened satisfactorily, and subsequent
examination of a test panel coated at the same time has shown
that good adhesion was obtained.
Wailes Dove also report that they continue to be active in the
development of coatings for surfaces in contact with drinking
water. The name of 'Bituros' Solution has been well-known in
this field for several generations. Now they are marketing
'Bituros' Super Eleven 16 which is an entirely new concept in
coating surfaces in contact with drinking water, and one which
is listed by the U.K. Water Fittings Bye-laws Scheme operated
by the Water Research Centre. 'Bituros' Super Eleven 16 is a
single component bituminous/epoxy formulation which is
entirely free from coal tar derivatives. It is simple to apply, dries
by the evaporation of solvents only, and is more tolerant of
lower grade surface preparation than conventional epoxy
coatings. It is black in colour, but because of the combination
of a non-tainting bituminous material with epoxy resin it is very
water resistant.
They also report that they are now 'into hot-water' with the
development of the 'Dufon' hot-well system. This is a three-
coat system of primer, intermediate, and finishing coats which,
when applied to a well blast-cleaned surface, is capable ot
withstanding hot-water at temperatures up to 95°C. It is a
two-component system based on selected epoxy resins and
curing agent.
Details: Wailes Dove Bitumastic plc, Hebburn, Tyne & Wear
NE31 1EY.
March 1985