News - Marine & Offshore

Metalock Brasil has completed a cold structural repair on the upper deck of a cargo oil tank onboard an FPSO unit operating in the Campos Basin, using SPS (Sandwich Plate System) technology.

The key differentiator of the project was the engineering developed by SPS Technology (SPST), responsible for the complete technical detailing of the solution, including 3D modelling, definition of the cavity arrangement, material specification, preparation of detailed fabrication drawings and management of the approval process with the Classification Society.

The adopted solution was engineered to restore and exceed the original structural capacity of the area affected by localized pitting corrosion, while maintaining structural integrity without the need for hot work. The project included:

• Structural assessment and thickness measurements in accordance with Classification Society requirements;
  
• Definition of surface preparation parameters;
  
• Specification of perimeter bars, top plates and structural adhesives;
  
• Strict control of cavity air tightness;
  
• Environmental control procedures (temperature and humidity);
  
• A comprehensive QA/QC plan and full traceability of injection data.

The construction process involved bonding perimeter bars to the existing plating, installing a new 10 mm top plate and forming a 25 mm cavity, which was subsequently filled with structural elastomer injected under controlled conditions. After curing, the solid core formed a composite panel permanently bonded to the steel plates, restoring the structural strength of the deck plating.

All processes were carried out without hot work, a decisive factor for operational safety in the offshore environment and for maintaining the unit’s operational continuity. Each cavity underwent air tightness testing, post-injection inspection and full recording of application parameters in accordance with Class-approved procedures.

With the SPS installed, the upper surface of the existing plating was fully encapsulated by the elastomer core, preventing further corrosion progression and increasing the fatigue resistance of the structure.

The service was completed within four days by Metalock Brasil’s specialized team, under SPST’s technical guidelines, reinforcing the company’s capability to execute highly complex structural solutions with technical rigor, traceability and regulatory compliance in the Offshore sector.