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analysis

review

THE SUCCESS
OF GLASS FLAKE
EPOXIES
Epoxy glass flake technology
has been used in the offshore
industry for over 30 years
to protect the splash zone of
offshore assets and heavy duty
areas including heli-decks
Dr Toby Stein, from International
Paint, explains why.

poxy glass flake technology rapidly


grew favour during the North Sea
oil boom in the 1980s encouraged
by UK yards, which saw the ease of
application compared to other technologies. At
the time they had to apply low solids coatings.
By switching to high solids glass flake epoxies,
productivity was increased as fewer coats
were needed. Oil majors also began to see the
performance benefits of choosing epoxy glass
flake coatings. Today many projects still rely on
such products for corrosion protection. Epoxy
glass flake coatings can deliver outstanding
performance, which is well documented. Recent
inspections of offshore assets demonstrate the
excellent long term performance of this coating
technology.
Epoxy glass flake coatings have been
extensively tested to offshore standards including
Norsok M-501 System 7A and 7B, and perform
very well against them. The inspection of the
now decommissioned Hutton TLP demonstrates
a good correlation between performance in the
Norsok M-501 tests and what is seen in the field.
It is clear after almost 30 years offshore, the
glass flake epoxy selected on the Hutton TLP
is still performing very well, says Chris Jordan
(former Coatings Manager for ConocoPhillips,
Hutton TLP)
The particular epoxy glass flake used for the
Hutton TLP possesses unique features and is
still widely used today. It is a high solids epoxy
with the addition of >30% lamellar glass flake
present within the dry film. Not only does this
type of formulation clearly provide outstanding
corrosion protection but it also boasts benefits
for yards too, who are responsible for applying
such coatings.
The fabrication yards favour application of
glass flake epoxies, such as that used on the
Hutton TLP, as they give excellent resistance
to damage during construction. This was a key
reason for glass flake epoxy selection on the
Hutton TLP. Glass flake epoxies such as this
have damage and abrasion resistance, which
enable heavy lift equipment to be used during
construction, with minimal repairs to the coating
afterwards. In addition, the high build of the
coating minimises the damage that penetrates
to steel. This in turn speeds up any repairs and
helps sustain high productivity levels. The epoxy
technology also provides easy application and a
good over coating window for multiple coats or
the use of other topcoats or foul release coatings.
All of these factors are reasons why yards still
favour glass flake epoxies such as that applied to
the Hutton TLP.
Glass flake epoxy differences
Selecting a glass flake epoxy can be confusing
with such an apparent large choice available
in the market. Broadly speaking these can be
categorised into those with low levels of glass
flake and those with high levels present in the
dry film. It is the high level glass flake coatings

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with a high aspect ratio (or lamellar glass flake)


which are used for long term protection. The
purpose of the glass flake is to add to the mean
path distance of ion migration through the dry
film. So the higher the aspect ratio, the greater
the ion migration distance is through the coating.
Thus it is clear that an optimum level of high
aspect ratio glass flake is required to afford
ultimate anticorrosion levels of performance. At
too low a level, the anti corrosion properties will
be diminished and at too high a level of glass
flake, the coating will become brittle. Examples
of offshore assets protected with this technology,
are numerous, (table 1).
Year

Owner

Project

Platform Type

1979

ConocoPhillips

Murchison

Offshore platform

1983

ConocoPhillips

Hutton

TLP

1985

Marathon

Brae B

Offshore platform

1989

BP

Arbroath

Offshore platform

1993

BP

Amethyst

Offshore platform

1995

Perenco

Trent & Tyne

Offshore platform

2000

BP

Lomond

Offshore platform

2007

Statoil

Gjoa

Semisubmersible

2010

Statoil

Valemon

Offshore platform

2012

ConocoPhillips

Jasmine

Offshore platform

Table 1 Glass flake epoxy coatings with high levels of


lamellar glass flake in their dry film have proved very
popular for splash zone protection in the North Sea.

Splash zone protection


Glass flake epoxy coatings are most commonly
used to protect splash zone areas of offshore
assets. This area is subjected to the highest
rates of corrosion due to its alternating wet and
dry atmosphere (figure 1). In addition, splash
zones and heavy duty decks also experience
high impact and abrasion which can easily wear,
penetrate or rupture a coating that does not
contain glass flake.

Figure 1 Steel loss on offshore assets is at its greatest


in the splash zone area.

Performance testing support


With so many glass flake coatings on offer,
its often unclear how to choose between them.
In some instances, people turn to Norsok M-501
(based on ISO20340) for guidance, which

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review
analysis

under system 7A, uses a set of prequalified tests


specifically for splash zone areas and system
4, which is for heavy duty decks. Norsok M-501
does not offer a coatings lifetime performance
guarantee; it merely provides a performance
standard. Thus, whilst glass flake coatings may
pass this standard, it is also useful to turn to
in-service performance before making a coating
selection. The 30 year in service track record of
International Paints Interzone 1000, as applied
to the Hutton TLP, is a perfect example of a
coating meeting the requirements of Norsok
M-501 and of proven performance in the field.
Norsok M-501 testing induces stress in a
coating. This helps us to understand whether the
coatings properties are likely to change during
its service lifetime. Therefore, we should look
for coatings which show little change in internal
stress or show a good resistance to ageing
(see graph 1).

To meet both of the options listed above,


coatings manufacturers may choose between
different types of glass. For instance, lamellar
glass flake will add a long tortuous path for
ions and for water to migrate through the dry
film (see figure 2) providing an excellent barrier.
It is important to realise that a high aspect ratio
lamellar glass flake is expensive, as the material
itself is costly. Alternative glass flake epoxies
can use micronized glass, but this may not
significantly improve anticorrosion performance.
Micronized glass flake has a low aspect ratio
and this is why such coatings perform poorly in
comparison to some lamellar glass flakes such as
that on the Hutton TLP.

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Figure 2 For the best anticorrosive performance


lamellar glass flake is required with a high aspect ratio

Graph 1 Internal stress graph of Interzone 1000


compared to other glass flake epoxy coatings

Poorly formulated fast cure, high solids epoxies


may lead to in-service cracking. This can often
be attributed to the quick curing mechanism that
leads to solvent entrapment which can over time,
result in coating shrinkage. Slower curing epoxies
allow the solvent to escape. This reduces the
chance of solvent getting trapped in the dense
epoxy amine network needed for long term
corrosion protection.
Type and level of glass flake
A coating will always require careful
formulation to ensure it meets high end
performance needs. Coating manufacturers have
two options available to them in formulating
epoxies with glass flake:
1) Add glass flake to increase the coatings
performance
2) Add glass flake to ensure the coating meets
the requirements of a specification phrase such
as glass flake epoxy.
There is a big difference between the two
options. Screening of commercial glass flake
epoxies can reveal a 30% variance in the levels of
glass flake present within the dry film.

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Surface preparation
It is well known that the level of surface
preparation undertaken prior to the application
of a coating can have a profound impact on
the coatings lifetime. Therefore, it is always
recommended that carbon steel is prepared to a
Sa2.5 level of cleanliness with an angular surface
profile of 50-75 microns. This allows a good
mechanical lock to take place between the steel
substrate and the newly applied coating. The
same is true of glass flake epoxies: maximum
performance is achieved from a Sa2.5 surface
preparation with an angular profile. If this surface
preparation level cannot be achieved then
coating lifetime will be reduced.
Coating performance
In summary, it is no surprise the glass flake
epoxy on the Hutton TLP has performed so
well after almost 30 years. It is high build with a
high level of lamellar glass flake in the dry film
(>30%) that provides excellent damage and
corrosion resistance. This makes it ideal for both
use in heavy duty yards where coating impact
is common and for long term anti corrosion
performance. It is no wonder coatings such as
International Paints Interzone 1000 still prove
popular today and are sure to do so for many
years to come.

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