From Alaska to Memphis: The Evolution of Heat Shrink Technology

 

“Long distance information, get me Memphis, Tennessee!”

That’s where this stop takes us—June of 1976. The pipeline industry was in the middle of a quiet but important transition, and once again, innovation was being driven by necessity.

Not long before this, Raychem had made a name for itself by developing coatings used on the Trans-Alaska Pipeline System. One of those key products, Arcticlad, was engineered for extreme conditions—applied with specialized equipment on the unforgiving slopes of Alaska.

But as with most innovations, the next challenge wasn’t invention—it was adaptation.

By the time we arrive in Memphis, Raychem is working to modify that same Arcticlad technology for a much more practical application: coating pipe bends in the field—without the need for large, specialized equipment.

This was a big deal.

Bends have always been tricky. Unlike straight pipe, they introduce geometry that doesn’t cooperate easily with rigid or pre-formed coatings. The goal here was to create something flexible, field-friendly, and reliable—without sacrificing performance.

What we see in these early applications is a product that works… but still has some growing up to do.

Today, that evolution has led us to Flexclad Heat Shrinkable Tape—a far more refined and contractor-friendly solution.

Available in:

• 2", 3", and 4" widths
• 50-foot rolls

Flexclad is designed specifically for applications like these—tight geometries, field installs, and situations where simplicity matters. Even better, it’s readily available and kept in stock at our production facility in Conroe, Texas, just outside The Woodlands.

The photos from that 1976 Memphis job tell a familiar story—one that anyone who has ever worked with a “new” product can appreciate.

It’s a bit clunky.

You’ve got:

Hand application

One person dedicated to running a torch just to keep the pipe preheated

Constant adjustments to get the material to cooperate

And the result?

Functional—but not exactly pretty.

Wrinkles show up throughout the installation. At first glance, you might assume poor adhesion or trapped air. But in reality, those wrinkles are something different: pockets of adhesive that cooled too quickly, before the heat-shrink backing had a chance to fully conform and smooth out the surface.

In other words—it wasn’t a failure. It was a process still being refined.

What makes this moment in Memphis interesting isn’t just the product—it’s the process.

This is what innovation actually looks like in the field:

• Trial and error
• Imperfect installations
• Learning how materials behave outside of controlled environments

Those early “good enough” results laid the groundwork for the solutions we take for granted today.

Modern products like Flexclad eliminate many of those early challenges:

• Easier handling
• More forgiving installation
• Consistent performance across a range of conditions

The jump from Arcticlad on the Alaskan slopes to Flexclad in today’s field applications is a great example of how the industry evolves—not in giant leaps, but in steady, practical improvements.

Memphis, 1976 wasn’t about perfection. It was about progress.

And sometimes, a few wrinkles are just part of getting there.

Enhance Your Pipeline Protection with Henkel’s STOPAQ Composite Wrap

 

When it comes to safeguarding pipelines from environmental stressors and physical damage, Henkel's STOPAQ product line offers an innovative solution: the Outerglass Shield. This composite wrap material, crafted from a robust glass fiber fabric impregnated with a water-curable polyurethane (PU) resin, provides exceptional protection in various challenging conditions. Whether you're dealing with harsh weather, marine environments, or general physical wear, this tough, versatile wrap is designed to offer both long-lasting protection and enhanced durability.

What Makes the STOPAQ Composite Wrap Special?

The STOPAQ Outerglass Shield is engineered to perform in a wide range of demanding applications. Its unique water-curable resin makes it easy to apply, and its glass fiber reinforcement ensures it holds up under stress. As both a physical protective layer and an Anti-Corrosion Coating (ARO), this material is perfect for shielding pipelines from environmental damage while maintaining the integrity of field joint coatings.

If you’ve been looking for a reliable and tough outer coat, STOPAQ's composite wrap is a great choice. But how exactly does it fit into the broader pipeline protection scheme? Let’s take a look at some of the common applications:

Common Applications for STOPAQ Outerglass Shield

1. Soil to Air Pipeline Transitions
   In areas where pipelines transition from buried soil to exposed air, physical protection is crucial. The STOPAQ Outerglass Shield provides an extra layer of defense in these sensitive areas, helping to prevent wear and tear from external elements. The added strength of the composite wrap ensures long-term protection.
2. Splash Zone Coatings
   When pipelines are exposed to wet/dry cycles, currents, or floating debris—particularly in offshore environments—the coating can quickly degrade. STOPAQ Outerglass Shield is ideal for splash zones, where it’s vital to maintain an effective protective barrier. It’s built to withstand the continuous wear caused by harsh marine conditions.
3. ARO for Field Joint Protection
   Field joints are often the most vulnerable part of a pipeline, prone to corrosion and damage from external elements. STOPAQ's composite wrap serves as an effective ARO to safeguard field joint coatings. By providing extra protection, it helps preserve the integrity of your pipeline and extends its service life.
4. Mechanical Protection for Pipe Saddles
   Adding mechanical protection to pipe saddles is essential to prevent abrasion and physical damage during installation and operation. The Outerglass Shield acts as a durable layer, shielding pipe saddles from wear and enhancing the long-term performance of your pipeline system.
5. Additional Tough Outer Coats for Various Pipeline Components
   From bends and tees to valves, flanges, and other fittings, the STOPAQ Outerglass Shield can be applied to any area requiring extra protection. It’s versatile and designed to perform in various situations, making it a must-have for maintaining the durability of critical pipeline infrastructure.

Henkel's STOPAQ product line, specifically the Outerglass Shield, offers a combination of practical and robust features that make it a go-to choice for pipeline professionals. 

In conclusion, Henkel’s STOPAQ composite wrap offers an excellent solution for protecting pipelines in a wide range of environments. Whether you're dealing with transitions from soil to air, splash zones, or field joint coatings, the Outerglass Shield provides an essential layer of defense. By choosing this high-performance material, you’re ensuring your pipeline's integrity, durability, and longevity.

Have you used STOPAQ’s composite wrap in your pipeline projects? Share your experience or reach out to learn more about how this material can enhance your protective coatings today!

A Look Back at Innovation (and Cigarettes) on the Pipeline Right-of-Way

 

Let’s start with the real question—because you know it crossed your mind too: back in the 1970s, how many packs of cigarettes did a pipeline crew go through in a single day? A carton? More? Honestly… I’d believe it.

Different time, different jobsite culture. And while a lot has changed since then, one thing hasn’t: the constant push to solve problems in the field.

We’re still in Bakersfield, California, in the early days of wrap-around shrink sleeve technology. At this point, the industry was transitioning from tubular sleeves—an important innovation, but one that came with limitations.

This particular project introduces a new challenge: an insulated pipeline.

The original tubular sleeves developed by Raychem were designed to slide over the pipe before welding. That works well—until insulation enters the picture.

With an insulated line, a tubular sleeve would have needed to:

• Be large enough to fit over the insulation during installation
• Still be capable of shrinking tightly down onto the steel pipe

That’s a big ask.

This is where the wrap-around shrink sleeve starts to shine.

Instead of sliding over the pipe, it wraps around the joint after welding—making it far more adaptable, especially in cases like insulated lines or field repairs.

It’s another example of Raychem doing what they did best:

• Thinking ahead
• Solving problems before they became widespread
• Constantly innovating for new applications 

It’s a mindset you still see today from companies like Henkel—always working multiple angles and anticipating what the market will need next.

Now, if you take a closer look at this particular installation… it’s not winning any awards.

There are visible wrinkles in the closure strip—something that would raise eyebrows today. But context matters:

• The technology was brand new
• Installers were still learning the process
• Best practices were being developed in real time

So if you happen to be the installer from 1976 reading this—no disrespect. You were laying the groundwork the rest of the industry would build on.

CCS Weave: The High-Shrink Material That’s Changing the Game

 

When it comes to high-performance sealing solutions, Covalence has engineered something truly remarkable: CCS Weave. This innovative material is used to create Casing Seals, Flange Seals, and other applications where a high-shrink product is essential. But what makes CCS Weave stand out in a crowded market? Let’s dive in.

1. Unmatched Shrink Ratio
CCS Weave boasts an impressive 66% shrink ratio. To put that into perspective: a 24-inch casing pipe could see the Caseal shrink all the way down to just 8.5 inches if allowed. This dramatic shrink capability ensures a tight, secure fit, even on irregular surfaces.

2. Durable, Multi-Layer Construction
At the heart of CCS Weave is a fiber-reinforced sheet laminated between two layers of polyethylene. This construction delivers exceptional performance in key areas:

• Penetration resistance – tough enough to withstand challenging environments
• Abrasion resistance – maintains integrity over time
• Elongation – flexible enough to handle complex applications

3. Hyper-Aggressive Mastic Sealant
A seal is only as good as the bond it creates. CCS Weave utilizes a hyper-aggressive mastic sealant that adheres well to a variety of substrates—even when surface preparation isn’t perfect. This ensures reliable sealing performance across diverse field conditions.

High-shrink materials can introduce a unique problem: how to keep the material intact during the shrinking process. Covalence tackled this challenge by borrowing a brilliant technique from Raychem, developed decades ago. Since 1995, we’ve been sewing a nylon zipper into the sleeve using Kevlar thread.

When the ends of the sleeve are zipped together, even the extreme 66% shrink ratio isn’t enough to break the threads. This simple yet ingenious solution allows CCS Weave to deliver maximum shrink performance without compromising structural integrity.

CCS Weave isn’t just another sealing material—it’s a high-performance solution designed to meet the demands of today’s toughest applications. With its impressive shrink ratio, multi-layer durability, and clever engineering, it’s a product that engineers and field teams alike can rely on.

It’s more than cool—it’s next-level material innovation.

Stopaq: The Common Sense Tank Chime Repair Solution

If you’ve followed some of my previous posts on Stopaq visco-elastic coating systems, you’ve likely seen how effective they can be when it comes to repairing and recoating tank chimes. Today, I want to walk through the application process—and highlight a few key advantages that really set this system apart in the field.

One of the first things that stands out is the minimal surface preparation required. Unlike traditional coating systems that often demand abrasive blasting and extensive prep work, this process eliminates the need for sandblasting altogether. That alone can significantly reduce both project complexity and cost.

Another major benefit is the simplicity of the application. There’s no need for specialized spray equipment or complex tooling. The system is designed to be straightforward and user-friendly, allowing crews to get the job done efficiently without a steep learning curve.

And perhaps most importantly, the time savings are substantial. Because of the streamlined process, you can complete projects with fewer crew members and in far fewer hours compared to conventional methods. In today’s environment—where labor availability and project timelines are constant challenges—that’s a game changer.

If you’re looking for a faster, simpler, and more efficient way to handle tank chime repairs and recoating, this is definitely a system worth considering.

Feel free to reach out if you’d like more information or want to discuss how it could fit into your next project.

Powercrete J: The Go-To Field Joint Coating for HDD and Tough Pipeline Applications

 

When it comes to protecting pipeline field joints—especially in demanding environments like horizontal directional drilling (HDD) and bores—you need a coating system that can handle more than just the basics. That’s where Powercrete J continues to stand out as a premier solution in the industry.

Backed by Seal for Life Industries, Powercrete J has built a reputation for delivering exceptional performance in some of the most challenging pipeline conditions out there.

Let’s start with where Powercrete J really shines: directional drills, bores, and high-stress installations.

These applications demand:

• Extreme abrasion resistance

• Strong Shore-D

• Durability in wet dry pipeline cycles

Powercrete J checks all those boxes.

This ceramic-modified, 100% solids epoxy is specifically engineered to provide corrosion and abrasion protection for both mainline pipe and field joints. Whether you're pulling through rocky soil during an HDD or dealing with difficult right-of-way conditions, this coating is designed to hold up.

While Powercrete J is a go-to for HDD contractors, it’s not limited to specialty applications.

Many contractors are using it for:

• Standard girth weld field joints

• Rehabilitation work

• Tie-ins and fittings

Why? Because it offers:

• Excellent adhesion to FBE, liquid epoxies, and even coal tar epoxy (CTE)

• Strong mechanical properties

• The flexibility to be hand applied depending on the jobsite needs

One of the biggest advantages of Powercrete J is how adaptable it is in real-world conditions.

• Steel: SSPC-SP10 (Sa 2½) abrasive blast recommended

• FBE: SSPC-SP7 (Sa 1) sweep blast to remove gloss

• Handles situations where full blasting isn’t feasible

As long as the substrate temperature is at least 5°F above dew point, you're good to go.

• Can be applied up to 20 mils (500 microns) per layer

• Multi-coat builds up to 60 mils (1500 microns) depending on requirements

Powercrete J is designed to be user-friendly and efficient.

From the Product Data Sheet, a few highlights worth calling out:

• 100% solids, no VOCs

• Meets AWWA C210, EN 10289, and CSA Z245.30 standards

• Excellent soil stress resistance

• Operating temperature up to 140°F (60°C)

And for those tracking coverage:

• ~81.5 ft² per gallon at 20 mils

• ~40.1 ft² per gallon at 40 mils

Another area where Powercrete J really delivers is availability and logistics.

• Offered in 2 lb, 4 lb, 10 lb, or custom kits

• Orders typically ship within 1 day (often same day)

• Common order sizes range from 8 kits to 20–30 kits

Bottom line: no order is too small, and you won’t be waiting around when the job is ready to move.

If you’re working in HDD, bores, or any application where coatings take a beating, Powercrete J has proven itself time and time again. But its versatility also makes it a strong candidate for standard field joints and rehabilitation work.

It’s that combination of performance, flexibility, and availability that keeps contractors coming back to it.

If you haven’t looked at Powercrete J recently—or only think of it as an HDD coating—it might be time to take another look.

Recoating a Condensating Pipeline in Chicago: When Conditions Leave Few Options

 Pipeline rehabilitation projects are rarely simple—but every now and then a job comes along that checks nearly every “difficult application” box imaginable.

Today’s example takes us to Chicago, where a client needed to rehabilitate a 36-inch pipeline that had originally been coated with coal tar epoxy. Over time, the coating had begun to fail, and the operating conditions were creating continuous condensation on the pipe surface.

Recoating a sweating pipeline is already challenging. Add tight working conditions and limited surface preparation, and suddenly the list of viable coating systems becomes very short.

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A Challenging Environment

The pipeline in question included both horizontal and vertical sections, and the working space around the pipe was extremely limited.

Just as importantly, the environment did not allow abrasive blasting, which meant achieving the typical high-level surface preparation required by many coatings simply wasn’t possible.

That left the client with a very demanding checklist for any potential coating system:

• Minimal surface preparation requirements

• Ability to be applied in tight spaces

• High flexibility

• Tolerance for high humidity

• Capability to be applied to a sweating (condensating) pipe

• A system capable of extending asset life by at least 25 years

In other words—no big deal, right?

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When the Checklist Seems Impossible

Many conventional coating systems would immediately struggle with these conditions.

Most coatings require abrasive blasting to achieve proper adhesion. Others simply cannot tolerate moisture during application, let alone a pipe that is actively condensating.

And when a pipe is constantly expanding, contracting, and exposed to humidity, flexibility becomes critical to long-term performance.

Fortunately, there are systems specifically designed for these kinds of environments.

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The Stopaq Solution

For this project, the solution centered around Stopaq Wrappingband WSH from Stopaq (Seal For Life Industries).

One of the key advantages of the WSH system is its ability to displace surface moisture during application. That makes it uniquely suited for situations where condensation is unavoidable.

Instead of requiring abrasive blasting, the pipe surface can be prepared to ST2/ST3, which can typically be achieved using hand tools to remove loose, disbonded coating and rust.

Once the loose material is removed, the process is straightforward:

1. Apply Wrappingband WSH, which conforms to the pipe and displaces moisture.

2. Install a protective outerwrap to provide additional mechanical protection.

3. The pipeline is once again protected from corrosion.

Simple, but extremely effective.

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Checking Every Box

What makes this project particularly interesting is how many difficult requirements had to be satisfied simultaneously.

The coating system needed to:

• Perform with minimal surface preparation

• Be installed in tight working conditions

• Handle high humidity

• Be applied to a condensating pipe

• Deliver long-term asset protection

In this case, the Stopaq system checked every box—allowing the operator to rehabilitate the pipeline and extend its service life without the need for blasting or major operational disruptions.

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The Big Lesson

Pipeline rehabilitation isn’t always about finding the “strongest” coating. Often it’s about finding the coating that can actually be installed under the real-world conditions you’re facing.

In environments where traditional surface prep and dry conditions simply aren’t possible, visco-elastic coating systems like Stopaq can make the difference between a project that stalls—and one that succeeds.

And in Chicago, that made all the difference for this 36-inch line.

ScarGuard: The New ARO

In recent years, one of the fastest-growing products in the pipeline industry has been ScarGuard from Seal For Life Industries.

If you want the informal description?

Think of it as a field-applied ARO… on steroids, testosterone, and nine cups of coffee.

If you prefer the technical version:

A fiber-reinforced composite mechanical protection system designed for HDD and other demanding applications.

 ScarGuard is a moisture-curable, fiber-reinforced wrap engineered to deliver serious mechanical protection. Once cured, it forms a tough composite shell around the pipeline — dramatically increasing resistance to:

• Abrasion

• Impact

• Gouging

• Shear forces during pullback

• Damage from sharp or rocky backfill

And in today’s environment, that matters more than ever.

As more pipelines are installed via horizontal directional drilling (HDD) and routed through rocky or unforgiving soil conditions, owners are becoming less comfortable relying solely on traditional ARO systems.

We’re seeing a growing trend:

• End users adding ScarGuard over field joints

• Owners specifying it as added protection over factory-applied coatings

• Projects in rocky terrain incorporating it as a risk-reduction strategy

Because when you’re pulling thousands of feet of pipe through abrasive conditions, the cost of extra protection is small compared to the cost of failure.

ScarGuard doesn’t replace your corrosion coating system — it enhances it.

It acts as a mechanical armor layer, giving your pipeline a fighting chance in conditions where standard protection may be pushed to its limits.

In challenging soils, HDD crossings, or projects where downtime simply isn’t acceptable, that added durability can make all the difference.

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If you’d like more information on how ScarGuard can fit into your next project — or whether it makes sense for your soil conditions — reach out. I’m happy to help.

Powercrete J: The Premier Two-Part Epoxy for Field Joint Protection

When it comes to protecting pipeline weld joints, not all coatings are created equal. In demanding applications like directional drills and road bores, the stakes are even higher. Abrasion resistance, adhesion, and long-term corrosion protection aren’t optional — they’re essential.

That’s where Powercrete J stands apart.  It was built for Directional Drills and Road Bores

In HDD (horizontal directional drilling) and road bore installations, pipelines are subjected to:

• Extreme abrasion during pullback

• High soil stress and friction

• Challenging environmental conditions

Powercrete J has earned its reputation as a premier two-part epoxy field joint coating specifically because it performs under these exact conditions. Its abrasion resistance and bond strength make it a go-to solution when the weld joint cannot be the weak link.

When you’re pulling thousands of feet through a bore, the last thing you want is coating failure at the weld.

Here’s something many people don’t realize:  Powercrete J isn’t just for HDD and road bores.

It’s also an excellent solution for standard field joints. Even in conventional installations, weld areas deserve the same level of protection as the factory-applied coating. Using a high-performance epoxy ensures continuity of corrosion protection across the entire pipeline.

If your pipe has been factory coated with Powercrete-DD, the recommendation is simple:

Pair it with Powercrete J for the field joints.

Powercrete-DD is widely recognized as one of the best abrasion resistant overcoats (ARO) on the market. And if your pipeline deserves that level of factory protection, it only makes sense to extend that same standard to the weld joints.

Powercrete J is available as a standard in:

• 2-pound kits

• 4-pound kits

Custom kit sizes are also available upon request, giving contractors flexibility depending on pipe diameter and project scope.

Want to See It for Yourself?

If you’re in the United States and would like to get your hands on a sample, let’s talk. There’s no substitute for seeing how a product handles in real-world conditions.

When it comes to protecting weld joints — whether in a challenging directional drill or a standard pipeline installation — Powercrete J delivers performance you can trust.

Because your pipeline deserves more than “good enough.”

STOPAQ Offshore Success in the Arabian Gulf: Speed Without Sacrificing Performance

 

When it comes to offshore pipeline construction, time truly is money. Every hour on a barge carries significant cost, and any process that slows production can quickly turn into a major financial setback.

That was exactly the concern for a major project in the Arabian Gulf, where a client was searching for a better way to handle offshore field joint coatings on pipe sizes ranging from 4” to 18”. The project spanned from 2012 to 2014 — and the mission was clear:

Field joint coating could not be the bottleneck.

The Challenge: Fast, Reliable, Offshore-Ready

The client’s requirements were straightforward — but demanding:

• A system that was quick and easy to apply

• Proven, robust, and reliable performance offshore

• Ready to hit the rollers and face the sea in a very short timeframe

• Minimal HSE concerns

• No unnecessary equipment or complicated prep procedures

If you’ve spent any time offshore, you know how difficult it can be to balance speed with long-term corrosion protection. Many coating systems look good on paper but slow down production with cure times, blasting requirements, or complex heating procedures.

This client wasn’t willing to take that risk again.

The STOPAQ Solution

The winning system centered around STOPAQ, combining:

• Wrappingband CZHT

• Outerwrap

• High Impact Shield HT

• Rockshield

Together, these components delivered exactly what the project demanded.

One of the biggest advantages of the STOPAQ Wrappingband CZHT system is its surface prep requirements.

Instead of full abrasive blasting, surface preparation could be achieved with simple power tools. Offshore, this is a game changer. Less equipment, less logistical complexity, and less downtime.

Speed was critical.

With STOPAQ Wrappingband, there is no cure time required before applying the Outerwrap and High Impact Shield HT. Application can proceed immediately.

That dramatically reduced the cycle time per joint compared to other technologies under consideration — especially those requiring primer cure times or complex heating sequences.

On a barge, shaving minutes off each joint adds up quickly.

The system required:

• Less heating equipment

• No hazardous primers

That means fewer HSE risks, simplified compliance, and a safer working environment for crews — all while maintaining coating integrity.

In offshore environments, fewer variables often equal fewer problems.

The coating system was ready to see rollers and seawater within a very short time frame. There was no waiting around for cure development or strength build-up.

For offshore contractors, that kind of reliability isn’t a luxury — it’s essential.

Checking Every Box

The client essentially submitted a checklist. The STOPAQ system checked every one:

Quick and easy to apply

Proven offshore performance

Reduced cycle time

Minimal surface prep requirements

Lower equipment demands

Improved HSE profile

Ready for immediate handling

From 2012 through 2014, this project demonstrated that STOPAQ isn’t just a corrosion solution — it’s a production solution.

Revisiting a Milestone in Raychem History: The Great Trans-Alaskan Pipeline Challenge (August 1975)

 

In August of 1975, Raychem found itself at the center of a historic moment in the oil and gas industry. The Trans-Alaskan Pipeline, a massive undertaking that would transport oil from the Alaskan wilderness to the rest of the world, was facing significant delays. One of the primary challenges? A substantial amount of pipe coated with Fusion Bond Epoxy (FBE) had been left exposed to the harsh UV rays of the Alaskan sun for far too long. As a result, the FBE began to degrade, jeopardizing the integrity of the entire pipeline.

Enter Raychem: a company known for its innovative solutions, but this time, the task ahead was nothing short of extraordinary. Raychem was given a daunting proposition: find a way to re-coat thousands of feet of exposed pipe without needing to ship it anywhere. The clock was ticking, and the stakes were high.

Raychem’s team immediately sprang into action. They understood that solving this issue wasn’t just about fixing a problem; it was about developing a solution that could be deployed quickly and effectively in some of the most remote and challenging conditions on Earth.

The result? Arcticlad. A revolutionary product—a spiral-wrapped, heat-shrinkable tape—was born. This tape could coat long lengths of pipe with precision, effectively protecting the pipeline and preventing further damage from UV exposure. But there was one more hurdle to overcome: the installation. Raychem didn’t just create a new product; they also engineered the machinery needed to apply the Arcticlad tape in the field.

This was a true engineering marvel. The teams worked tirelessly, and within an incredibly short amount of time, they had a solution that was both effective and scalable.

The success of Arcticlad wasn’t just a technical win. It was a business triumph that would have lasting implications for Raychem’s future. The ability to offer a cost-effective, field-deployable solution allowed the company to generate significant revenue while cementing its reputation as a leader in pipeline coatings. This success didn’t just solve a problem—it set the stage for Raychem’s pipeline division to thrive in the years to come, establishing a legacy that would last for decades.

Thanks to the ingenuity, quick thinking, and relentless dedication of the Raychem team, the Trans-Alaskan Pipeline project became more than just a milestone—it was a defining moment that helped Raychem’s pipeline division flourish and remain a leader in the industry for many years.

This remarkable chapter in Raychem’s history shows how, with the right combination of innovation, determination, and teamwork, a challenge can be transformed into an opportunity that reshapes the future.

Stopaq Splash Zone Success: An Italian Case Study in Long-Term Pile Rehabilitation

Today we’re looking at a fascinating long-term case study from Italy involving the rehabilitation and recoating of marine piles. (I’ve only had the chance to visit Italy once—but it is one of my favorite places!)

This project began in 2012 and continued for years, ultimately rehabilitating hundreds upon hundreds of pilings. What makes this story especially compelling is not just the scale—but the environment.

Anyone who works around marine infrastructure knows the splash zone is one of the most punishing environments a coating system can face.

Constant wet-dry cycling.

Salt exposure.

UV radiation.

Mechanical impact.

Cathodic protection influence.

In this case, the client was experiencing coating failures within just six weeks of application. The primary culprits were:

• Impressed current interference

• Salt entrapment

• Coating cracking

That kind of rapid failure doesn’t just create maintenance headaches—it drives up lifecycle costs and undermines confidence in the entire protection system.

Before any new coating system was installed, the piles were prepared using high-pressure waterjetting.

This step is critical in marine rehabilitation. Proper surface prep removes salts and contaminants without embedding additional debris into the steel surface—an essential factor when previous failures were partially attributed to salt entrapment.

The rehabilitation utilized products from Stopaq, specifically:

• Wrappingband WSH

• Outerwrap

• Wrappingband CZH

• Outerglass Shield XT

One particularly noteworthy detail: Wrappingband WSH can be applied underwater. That capability dramatically increases installation flexibility and reduces downtime in tidal or continuously wet environments.

Because the project extended over many years, the client had the opportunity to inspect performance across multiple seasons and service cycles.

What stood out?

Flexibility.

In the splash zone, rigid coatings often fail because they cannot tolerate movement, thermal cycling, or mechanical stress. A system that maintains flexibility while continuing to seal against moisture ingress has a significant advantage.

Over time—and across hundreds of rehabilitated pilings—the system demonstrated durability in an environment where previous coatings had failed in weeks.

That kind of field validation speaks louder than any datasheet.

This wasn’t a short-term test patch. It was an ongoing rehabilitation program. The ability to observe performance over years provided meaningful confidence in the system’s durability.

Marine pile rehabilitation is expensive, disruptive, and complex. When a solution proves itself in the splash zone, that’s worth sharing.

If anyone from Stopaq Italy would like to add technical insights or additional field details, please feel free—real-world case studies like this are invaluable to the industry.

 

A Trip Back to 1975: Raychem LTPS in Corpus Christi, Texas

This week, we’re heading back in time—December 1975, to be exact—to beautiful Corpus Christi, Texas. The project? A pipeline installation featuring one of Raychem’s now-retired products: LTPS.

Based on old Raychem nomenclature (which, let’s be honest, was usually more practical than poetic), LTPS likely stood for “Large Tubular Pipe Sleeve.” I’ve said it before and I’ll say it again—Raychem was incredibly creative when it came to products, backings, and sealants. When it came to naming them? Not so much!

This particular job involved 18-inch and 20-inch pipe, which meant these LTPS sleeves had to be installed before the pipe joints were welded. The process would have looked something like this:

1. Sleeve Placement (Pre-Weld)
   The shrink sleeve was slipped onto the pipe before welding took place.

2. Weld Completion
   Once the joint was welded, the crew prepared the weld area.

3. Surface Prep & Preheat
   The weld zone was cleaned thoroughly and preheated to at least 140°F—critical for proper adhesion and shrink performance.

4. Positioning the Sleeve
   The LTPS sleeve was then slid into place over the weld area.

5. Release Liner Removal
   The liner was removed to expose the adhesive.

6. Shrink It!
   Using a propane torch, the installer shrank the sleeve tightly over the joint, creating a protective, sealed coating.

LTPS has been a dead product for as long as I’ve been around. However, its smaller sibling—TPS—is still very much alive and well. Today, TPS sleeves are regularly sold for 2", 2.5", 3.5", 4.5", 6" and 8".

While product lines evolve, it’s always fascinating to see the roots of today’s solutions in these legacy installations.

What really makes this project memorable are the photos. In one shot, the installer is casually smoking a cigarette through the entire application process—while operating a propane torch.

Different times, indeed.

It’s wild to think that 1975 was 51 years ago. The industry has changed. Safety standards have changed. Product technology has changed. But there’s something timeless about looking back at these projects and appreciating the craftsmanship and ingenuity that laid the groundwork for where we are today.

Here’s to the legacy of LTPS—and to the crews who made it work in Corpus Christi, December 1975.

 

Norway: Stopaq Case Study

 Another STOPAQ Case Study: Norway 

This latest STOPAQ® case study, completed by the good people of Norway, is a perfect example.

The project site presented a uniquely challenging set of conditions. Noise levels were so extreme that workers could only be exposed for 15 minutes at a time without proper hearing protection. In an environment like that, speed of installation wasn’t just a convenience, it was a necessity.

As if the noise alone weren’t enough, the operating conditions raised the bar even higher. Several of the lines were running at temperatures above 95°C (203°F), while also being subjected to significant vibration and pipe flexing. To make matters more complicated, sand blasting was not an option for surface preparation.

In short, this was not a job for an ordinary coating system.

The solution needed to be:

• Fast and easy to install

• Capable of handling high operating temperatures

• Flexible enough to withstand vibration and pipe movement

• Effective without blasting surface preparation

• Durable, reliable, and cost effective

For those new to STOPAQ, the answer might come as a surprise. For those with experience, it won’t.

The solution was Wrappingband CZHT combined with an HTPP Outerwrap. Simple.

This system delivered exactly what the project demanded: excellent corrosion protection under extreme conditions, quick installation in a high-risk environment, and reliable performance at elevated temperatures—all without the need for sand blasting.

And as an added bonus?
The system also provided a noticeable noise-dampening effect, which turned out to be the cherry on top of an already cost-effective, high-performance coating solution.

This project is another reminder that when conditions get tough, simplicity and proven technology often win. STOPAQ once again delivered a solution that met every requirement—and then some.

Sometimes, the best answer really is the simplest one.