UNIQUE POLYMER SYSTEMS offers advanced solutions for the protection and repair of critical infrastructure. This case study details the successful refurbishment of a 5km seawater intake pipeline using UPS 405 EPC EPOXY PROTECTIVE COATING and UPS 19003 THISTLEBOND A&B CEMENT.

A 5km long, 24-inch diameter seawater intake pipeline was showing extensive signs of corrosion. Over time, the pipeline had become vulnerable to degradation, with several sections exhibiting heavy pitting and damage. To ensure the continued integrity and performance of the pipeline, a thorough cleaning, repair, and re-coating process was required.

The primary challenge was to repair the heavily corroded and damaged sections of the pipeline and apply a protective coating that would prevent future corrosion. The solution needed to be robust enough to withstand the harsh marine environment and ensure the long-term durability of the pipeline.

UNIQUE POLYMER SYSTEMS provided a comprehensive repair and protection strategy using UPS 405 EPC and UPS 19003 A&B. The application process involved the following steps:

Surface Preparation

The steel substrate of the pipeline was abrasive grit blasted to a cleanliness level of Sa 2.5 with a 75-micron profile, in accordance with ISO 8501/4 Standard Sa2.5 (SSPCSP10/NACE2). This preparation was essential to remove contaminants and ensure optimal adhesion of the repair materials and protective coating. 

Repair with UPS 19003 THISTLEBOND A&B CEMENT

- Sections of the pipeline that were heavily pitted or damaged were rebuilt using UPS 19003 A&B.This step restored the integrity of the corroded sections, providing a solid foundation for the protective coating.

Application of UPS405 EPC EPOXY PROTECTIVE COATING

- The internal surfaces of the pipeline were lined with UPS 405 EPC to an average dry film thickness of 500 microns. The coating was applied using an airless spray, ensuring an even and durable protective layer across the entire length of the pipeline.

The application of UPS 405 EPC, combined with the repair of damaged sections using UPS 19003 A&B, successfully restored the integrity of the seawater intake pipeline. The comprehensive repair and re-coating process provided a durable solution that protected the pipeline from future corrosion, extending its service life and ensuring reliable operation.

This case study demonstrates the effectiveness of UNIQUE POLYMER SYSTEMS' protective coatings and repair solutions in maintaining the integrity of critical infrastructure in harsh environments. Our advanced materials and precise application process delivered a reliable solution that ensured the long-term durability of the seawater intake pipeline.