a denso system protects the suspension cables on the ...asahimas chemical who chose a seashield...

LEADERS IN CORROSION PREVENTION & SEALING TECHNOLOGY

Volume 28 - Number 4

A Denso System protects the suspension cables on the Ohmishima Great Bridge, Japan - see story page 11.

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WINN & COALES INTERNATIONAL LTD

WINN & COALES (DENSO) LTD Tel: +44 (0) 20 8670 7511Denso House, Chapel Road, London SE27 OTR, England Fax: +44 (0) 20 8761 2456✓ Anti-corrosion and sealing systems Email: [email protected]

Website: www.denso.net

ARCHCO-RIGIDON Tel: +44 (0) 20 8761 6244Denso House, Chapel Road, London SE27 OTR, England Fax: +44 (0) 20 8761 2456✓ Corrosion resistant linings Email: [email protected]


DARTFORD COMPOSITES LTD Tel: +44 (0) 1322 350097Unit 1, Ness Road, Erith, Kent DA8 2LD Fax: +44 (0) 1322 359438✓ Manufacture and repair of FRP panels

for cars and trains Website: www.dartfordcomposites.co.uk

DENSO NORTH AMERICA INC - CANADA Tel: +1 416 291 343590 Ironside Crescent, Unit 12, Toronto, Ontario, M1X 1M3 Fax: +1 416 291 0898Canada Email: [email protected]✓ Anti-corrosion and sealing systems Web site: www.densona.com

DENSO NORTH AMERICA INC - USA Tel: +1 281 821 33559747 Whithorn Drive, Houston, Texas 77095 Fax: +1 281 821 0304United States of America Email: [email protected]✓ Anti-corrosion and sealing systems Web site: www.densona.com

DENSO SOUTH AFRICA (PTY) LTD Tel: +27 31 569 4319 120 Malacca Road, Redhill Industrial Area, Durban North 4051, Fax: +27 31 569 4328Republic of South Africa Email: [email protected]✓ Anti-corrosion and sealing systems Web site: www.denso.co.za

DENSO (AUSTRALIA) PTY LTD Tel: +61 1300 658 590411-413 Victoria Street, Brunswick, Victoria 3056, Fax: +61 1300 655 064Australia Email: [email protected]✓ Anti-corrosion and sealing systems Website: www.densoaustralia.com.au

DENSO (NEW ZEALAND) LTD Tel: +64 9274 1255PO Box 76167, Manakau City, Auckland, Fax: +64 9274 1258New Zealand Email: [email protected]✓ Anti-corrosion and sealing systems Website: www.densoaustralia.com.au

SEASHIELD INTERNATIONAL Tel: +44 (0) 20 8670 7511Denso House, Chapel Road, London SE27 OTR, England Fax: +44 (0) 20 8761 2456✓ Marine corrosion protection systems Email: [email protected]


SEASHIELD INTERNATIONAL Tel: +1 281 821 33559747 Whithorn Drive, Houston, Texas 77095 Fax: +1 281 821 0304United States of America Email: [email protected]✓ Marine corrosion protection systems Web site: www.densona.com

SEASHIELD INTERNATIONAL Tel: +61 1300 658 590411-413 Victoria Street, Brunswick, Victoria 3056, Fax: +61 1300 655 064Australia Email: [email protected]✓ Marine corrosion protection systems Website: www.densoaustralia.com.au

SEASHIELD INTERNATIONAL Tel: +64 9274 1255PO Box 76167, Manakau City, Auckland, Fax: +64 9274 1258New Zealand Email: [email protected]✓ Marine corrosion protection systems Website: www.densoaustralia.com.au

PREMIER COATINGS LTD Tel: +44 (0) 1233 770663Headcord Road, Smarden, near Ashford, Fax: +44 (0) 1233 770633Kent TN27 8PJ, England Email: [email protected]✓ Membranes and corrosion protection systems Website: www.premiercoatings.com

For further information on our products and their suitability for your particular project,please contact any of the Denso companies listed below:

Corrosion Prevention for Welded Pipeline Joints - Republic of South Africa


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For quick identification of the relevantproduct type used in each story we

have used the following colour codes:

BURIED PIPELINES & LPG VESSELS

EXPOSED STEEL & PIPEWORK

STORAGE TANKS, PUMPS ETC

SEALING MASTICS

MEMBRANES & FLASHINGS

INDUSTRIAL TAPES

SUB SEA PIPELINES & JETTY PILES

Protective coatings for......

Protective linings for.....

Sealing & waterproofing.....

Country: South Africa

Location: Pietermaritzburg to Durban

Object: Welded pipe joints, bends and specials

Problem: Corrosion prevention

Product Denso Ultraflex andsolution: S.T. Epoxy

Project Summary

Product type:Buried Steel Coating

The project consists of 20km ofcontinuously welded 1.60m diaand 1.40m dia pipes of 18mlengths. The protection systemspecified consists of Denso MasticSealing Tape to protect the weldbead and then a fullcircumferential wrap of DensoUltraflex 1250/300 with a 55%overlap to protect the weldedfield joints.

Other Denso products specifiedwere Denso ST Epoxy andDensotherm HD. Denso STEpoxy is used for the corrosionprotection of the internals of thewelded pipe as well as theprotection to the exposedcompensation plates. DensothermHD is used for the protection ofthe pipe interface betweenthe epoxy coated steel andpolyethylene shopcoat(Sinterkote).

Denso Ultraflex TapeSystem protects PipeWeld JointsUmgeni Water in Pietermaritzburg and eThekwini Water inDurban have funded a R800m project to provide for the everincreasing demand for potable water to the communitiesbetween the two cities. WK Pipelines were awarded phase1 of the project which is currently under way.

Photos:Left: The new pipeline in progress.

Below: Application of Denso S.T. Epoxy

Bottom: Denso Ultraflex 1250/300 Tape protecting a pipe bend.

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Corrosion Prevention of Steel Air Shafts - Canada

When completed, the tunnel willmeasure over 33,000 feetin length.

The project called for 5 x 36”diameter fresh air shafts to bebored vertically from the surfaceinto the tunnel.

These vertical shafts will alsoprovide equipment access andpump access for emergencywater evacuation.

Denso Canada was chosen tosupply Protal 7250 and Protal7125 to all the exterior surfaces ofthe vertical steel pipes, each shaftcovering a distance of nearly 500ʼvertically, linking to the horizontaltunnel beneath. Each of the 5

Protal 7125/7250 StandingUp to Cold Canadian WintersAfter beginning one of North America’s largest hydro-electrictunneling projects at Niagara Falls, the Ontario PowerGeneration company needed to supply vertical access to a47.2 foot diameter tunnel being bored 459 feet belowthe surface.

Using a collar arrangement toprevent the pipe length fromslipping down the shaft, eachhoisted pipe section was weldedin place and lowered into theground. The girth weld area wasthen coated with Protal 7125 andthe entire process was repeateduntil all the sectionswere finished.

shafts was spaced approximately13 feet apart along a specificsection of the tunnel.

Each pipe section was coated inplant with Protal 7250 and shippedto site where it was hoisted bycrane and lowered into the shaft.

Country: Canada

Location: Niagra Falls

Object: Steel air shafts


Product Protal 7250 andsolution: Protal 7125

Project Summary


The vertical shaft work wascompleted in the winter monthsat sub-zero temperatures, hencethe use of Protal 7125 on thefield applied girth welds.

Denso Protal products -growing in different directions!!!

Photos:Left: Girth weld area being coated with Protal 7125 in sub-zero temperaturtes.Below & inset: A steel air shaft is welded to a tunnel section prior to the Protal application.


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Corrosion and Abrasion Protection in Directional Drilling - United States of America

Liquid epoxy overcoatingfor the maximum protectionof Fusion Bonded Epoxy(FBE) in directionaldrilling applications.

The new Protal ARO is a VOCfree, 100% solids liquid epoxycoating formulated to be appliedover FBE as an ARO coating(abrasion resistant overcoating).It is a 3:1 ratio compatible formost plural component sprayunits coating that can be spray orhand applied in the field or shop.Protal ARO is used to protectFBE mainline coatings and overProtal 7200 on girth welds duringdirectional drilling, bores, rivercrossings and other rough terrainapplications. Protal ARO can alsobe used to provide additionalprotection to the coating onbends, fittings and fabricationwhen severe handling or roughterrain exists.

Protal ARO offers excellentgouge and abrasion resistance,fast touch dry and set times, high

Denso North America OffersNew Protal ARO - AbrasionResistant Overcoating

Photos:Above: Directional drill application with

Protal ARO coated pipe.

Below: Protal ARO being spray applied in the shop

temperature resistance (up to150°F), and high build (up to 60mils in one coat). In addition, ithas excellent adhesion to FBEand Protal 7200 and is safe andenvironmentally friendly.

Denso manufactures a full line

of Protal liquid coatings to meetthe demand of the pipelineindustry. Protal liquid coatingsare the coatings of choice byowners, oil and gas specifiersand contractors acrossNorth America.

Country: USA

Location: Dallas, Texas

Object: FBE coated pipe

Problem: Protection during directional drilling

Productsolution: Protal ARO

Project Summary


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Corrosion Prevention for Marine Piles - Indonesia

SeaShield System Selected for Repairs toIndonesian Chemical JettyTo provide a tailor made solution to meet specific siterequirements a number of Jetty piles, all with a damaged PElayer and showing the inevitable corrosion as a consequence,were recently repaired with a Denso SeaShield system. The jetty in Cilegon, Banten,Indonesia is owned by PT.Asahimas Chemical who chosea SeaShield system due to itsenviable reputation as aneffective, long term solution tomarine corrosion problems.

The system was installed byour agent PT. Imbema PacificIndonesia. After removing all of

the PE layer material around thedamaged area and all loose andflaky rust ect, the surface wascoated with Denso S105 Paste.Strips of Densyl Tape were thenapplied over the paste to bringthe repair level up to thesurrounding ʻsoundʼ PE layer. Asingle sheet of Denso Hi-TackTape was then applied over the

Country: Indonesia

Location: Cilegon, Banten

Object: Jetty Piles


Product Denso solution: SeaShield

Project Summary

Product type:Sub Sea / Splash Zone Coating

1. All loose PE layer, rust and debris is removed from the damaged area using scrapers and wire brushes.

2. Denso S105 paste is then applied to the cleaned area only.

4. A single sheet of Denso Hi-Tack Tape is then positioned as a band, over the Densyl Tape and around the whole pile.

5. Finally SeaShield 2000 FD Jackets are attached using a hydralic pump to compress the joint to enable easy bolting.

6. The finished application, a durable andneat repair for the damaged piles.

Densyl Tape followed by theHDPE Jackets which wereattached using a hydraulic pumpto compress the joints together.This enabled the fixing bolts tobe tightened securely.

The work was all completedto schedule.

3. Strips of Densyl Tape are then placed over the Denso S105 Paste to bring therepair area up to the surrounding level.


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Corrosion Prevention for Tank Bases - Korea

Country: Korea

Location: Onsan, Ulsan

Object: Toluene Tanks


Product Denso KF Tape solution: System

Project Summary

Product type:Exposed Surface Coating

Denso KF Tape SolvesStorage Tank ProblemThe engineers at a large oil company situated in Onsan, Ulsanneeded a cost effective and commercially proven repair solutionfor some tanks that were used to store toluene because thebottom plate of the tanks were showing signs of corrosion.

There are always gaps presentbetween the steel bottom plateand the concrete plinth that it sitson and consequently air andwater penetrates into them andthe bottom plate starts to corrode.

K-Cotech Co. Ltd engineerslooked at the problem andrecommended to the oil companythat all of the corroded platesshould be repaired with a Densoanti-corrosion system utilisingDenso Hi-Tack Primer,Denso Primer D, Densyl Masticand Densyl KF Tape. This systemwould seal all of the gaps andstop the bottom plate fromcorroding any further.

The chosen system waseventually applied by K-Cotechand the oil company engineerswere very pleased withthe results.

1. Corroded/damaged tank base. 2. Preparation - cleaning the area ready for the Denso system.

3. Priming the steel surfaces with Denso Hi-Tack Primer.

4. Priming the concrete surfaces with Denso Primer D.

5. Applying Densyl Mastic to fill all voids. 6. Applying the Densyl KF Tape to complete the system.

Right: The oil companyʼs tanks on site atOnsan, Ulsan.

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Corrosion Prevention for Sea Outfall Pipeline Joints - Australia

The project is part of theAlkimos Wastewater TreatmentScheme and is an alliancebetween the Water Corporationand the private sector, beingnamed The AlkimosWater Alliance.

The outfall pipeline is a 3.7kmlong 1270 Diameter MSCL Pipe,comprising 294 joints tobe protected.

The Sintakote pipe supplied byTyco Water is delivered to siteand then a concrete weightcoating is applied.

At the cutback area DensoPrimer ʻDʼ is first applied bybrush/roller, followed by TheDenso Densopol 80 Tape,spirally wrapped incorporatinga 55% overlap.

This effectively gives aprotective coating of 4mm (4000microns) prior to the cutback

The Denso Densopol 80 Tape System has been selected toprotect the field joints on The Alkimos Outfall Pipelinesituated 40km North of Perth Western Australia.

The Densopol Tape SystemProtects Outfall Pipeline

Country: Australia

Location: Perth

Object: Outfall pipeline


Product Densopol Tapesolution:

Project Summary


area being in-filled with concrete.The 3.7km long ocean outfall

pipeline will be buried up to 4metres below the beach and willsit in a trench on the seabedsome 8-12 metres belowsea-level. Towards the end ofthe pipeline the depth of wateris between 25-30 metres.

Photos:

Top: A joint protected with the Densopol Tape sytem

Middle: Concrete weight coat pipelengths.

Bottom: The outfall pipeline under construction.

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Waterproofing Reservoir Roof - United Kingdom

Premseal Membrane usedto Waterproof HullReservoir RoofApproximately 11,000m2 of self amalgamating PremierPremseal 100 blue cold applied waterproofing, adhesivemembrane has been used to waterproof the roof of YorkshireWater’s Keldgate No.1 reservoir that supplies Hull’spotable water system.

It is part of an ongoingmaintenance scheme to maintainwater quality for Yorkshire Waterʼscustomers. The work was carriedout by the term contractors,Stonebury Ltd of Beverley, Yorksand Cranfield, Bedfordshire.

The 100-year-old KeldgateNo. 1 reservoir is of vaulted roofconstruction. To ensure maximumwaterproofing effectiveness,Stonbury engineers applied thePremseal 100 in full strip lengthsstarting along the roof ʻvalleysʼthen working up to the ʻpeaksʼ, sogoing with the flow of rain water.

Premseal 100 prevents theingress of water and water-borneaggressive salts such aschlorides and sulphatespenetrating concrete structures.It is approved by the WaterResearch Council and is UKWFBS Listed for use in potablewater situations as well ashaving BBA Certification.

Premseal 100 is constructedfrom orient cross laminated highdensity polyethylene sheetingand bitumen-polymer compound.The product is a tough, durable,cold applied self-adhesive sheet

Country: United Kingdom

Location: Keldgate

Object: Reservoir roof

Problem: Waterproofing

Product Premseal 100solution: (Blue)

Project Summary

Product type:Waterproofing Membrane

with an overall thickness of1.5mm. A unique feature is theselvedge that enables a fast andsecure seal on all side edge laps.The blue HDPE film enablesinspection for consultants andclients to be made easier andquicker. Where buried, thewaterproofing layer is easilyidentified during any subsequentexcavation, allowing greatercare to be taken to avoidunnecessary damage.

Keldgate No.1 reservoir roof after a storm, demonstrating the rain water flow from the Premseal 100 protected vaulted ceiling roof design.

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Corrosion Prevention for Oil Intake Pipeline - Japan

Country: Japan

Location: Unspecified

Object: Oil intake pipeline


Product Densyl KF Tapesolution: System

Project Summary


Oil Intake PipelineInspected After 21 Years ofDenso ProtectionAn oil intake pipeline in Japan which was originally protectedin 1985 with a Denso system combining Densyl KF Tape andDenso Profiling Mastic, was inspected in March 2006 to seehow it was performing.

The original Denso coatingsystem was removed from partof the pipeline to check itscondition. The pipe, flange, nutsand bolts below were all foundbe in excellent condition.

After the inspection wasfinished the removed section oftape and mastic was replaced.

All of the engineers involvedhad to agree that the inspectionprovided a very impressivedemonstration of the long-termcorrosion prevention capabilitiesof the Densyl KF Tape system.

Photos:

Left: The Denso system removed after 21 years for inspection.

Below: Close up of nut, thread and flange in excellent condition.


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Corrosion Prevention for Bridge Suspension Cables - Japan

Denso System ProtectsBridge Suspension CablesEngineers in charge of the Ohmishima Great Bridge thatcrosses the Setonaikai Inland Sea in Japan, wanted to protectthe base of the 160 bridge suspension cables against corrosion.

A Denso system was chosencomprising Densyl Mastic Stripsthen a coating of Denso Pasteoverwrapped with Densyl KF

Country: Japan

Location: Setonaikai Sea

Object: Bridge suspensioncables


Product Denso Tapesolution: System

Project Summary

Product type:Exposed Surface Coating

Tape with a final outer layer ofself-adhesive tape to protectagainst mechanical damage.

1. Densyl Mastic Strips used to smooth the cable contour prior to wrapping.

2. After applying a coating of Denso Paste, over the Densyl Mastic Strips and cable strands,Densyl KF Tape is spiraly wrapped with a 55% overlap.

3. A final wrap of self-adhesive tape completes the protection system.

Cable protection work in progress on the Ohmishima Great Bridge.

a denso system protects the suspension cables on the ...asahimas chemical who chose a seashield...

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