Offshore CompoSol® Flat
Composite flat surface coatings are beneficial as they both protect steel substrates from corrosion deterioration and also reinforce the plate to reinstate load bearing capacity lost through deterioration. Composites are light weight, flexible and strong. High quality fibre reinforced polymer composites also have good impact resistance, as the fibre-matrix interfaces act as crack stoppers and crack deflectors. Below is a cast study of CompoSol® Flat application to a pipe deck container loading bay on a platform in the North Sea.
Stage 1 - Initial Inspection
Initial inspection highlighted various through wall defects across the operational area of the loading bay. Approx. 80% of the deck area had severe wall thinning, measuring between 0 and 3 mm in certain areas. This conformed to inspection information. Existing anti slip patched were noted to be in a very poor condition and required to be uplifted for further investigation.Upon removal of the anti slip tiles, additional defects were exposed beneath.
Stage 2 - Surface Preparation
The substrate was prepared toST 3 standard – Power Tool Cleaning – to remove all rust scale, loose paint and loose rust using wire brushes and air driven grinders with non-sparking abrasives. Upon completion of the surface preparation the substrate was inspected to ensure it was free from oil, grease, dirt and any other contaminants. The application area was treated by applying IMG Composites Ferroblock to convert the rust to a stable compound and seal the metal from moisture. Once Ferroblock had reached full cure, the through wall defects were addressed by the application of patch repairs utilising IMG Composites Reinforced Epoxy Paste and CompoSol® Flat.
Stage 3 - Self Levelling Compound
Quality checks were carried out on to ensure the IMG Composites Ferroblock together with the patch repairs were adequately cured. Temperature readings were taken and the minimum application temperature of 10°C was achieved. After recording the temperature rating, IMG Composites Self-Levelling Compound was applied over the complete surface area of the loading bay and left to dissipate. Once cured, the self-levelling compound provides a level area on which to commence application of the complete composite repair.
Stage 4 - Composite Reinforcement
Initial quality checks were conducted to ensure the IMG Composite Self Levelling Compound had achieved full cure. The first application of the IMG Composites Reinforced Epoxy Paste and CompoSol® Flat was then applied in accordance with the repair design. All materials applied are batch coded and documented within the quality documentation so that they are traceable. This application is allowed to cure before continuing to build up with CompoSol® Flat.
Stage 5 - Composite Build-up
Quality checks were conducted and recorded throughout the layer build up. The continuous build up of the IMG Epoxy and Laminate increases the strength characteristics of the composite, whilst giving the repair the flexibility to dissipate any impact forces from normal operational conditions. Once the full build-up of the complete composite system has been achieved, the repair was left to cure before the final anti slip coating was applied.
Timetable of Repair
The entire 52m2 Repair Area took 15 days to complete:
- Day 1: Arrive Platform, Check Worksite, Habitat, Progress Permits
- Day 2: Prep Deck Area using air powered tools and non sparking disks, ensuring compliance with HAVS and Platform regulations, to a ST2/ST3 standard. Apply deck levelling compound.
- Days 3-11: Apply Lightweight Kevlar Reinforcement Compound / Lay Up Kevlar Laminate
- Days 12-13: Lay Anti Slip Coating
- Day 14: Tidy Site, Final Inspection, Complete Documentation, Pass Back to Platform
- Day 15: Depart Platform