Anti-Corrosion Methods and Materials

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

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Protection for offshore splash zones

Ray Aither, ACO-Coatings (U.K.)

8 ANTI-CORROSION March 1985

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