We helped deliver a first-of-class composite repair to the primary hull structure of an Australian FPSO – approved by Lloyd’s Register and executed offshore without dry docking. Our independent, technically advanced approach enabled the operator to restore structural integrity, reduce downtime, and avoid hot work, while setting a precedent for future hull repairs using composites.
The challenge
The operator of an ageing Australian FPSO needed to address hull anomalies without resorting to traditional steel crop-and-renew repairs. They sought a permanent solution that could be executed offshore, maintain Class compliance, and avoid operational disruption.
Key challenges included:
- No published precedent for Class-approved composite repairs to primary hull structure.
- Lack of LR-specific guidance for bonded composite repairs.
- Need to maintain watertight integrity and structural capacity.
- Complex approval process involving international Class materials specialists.
- Operational constraints including remote location, cyclone demobilisation, and simultaneous hot work.
Our solution
We partnered with IC Integrity to deliver a Class-approved composite repair using Technowrap™ SRS-HA carbon/epoxy laminate. FSC led the naval architecture, structural analysis, and Class engagement, while ICI managed material qualification and installation.
Key activities included:
- Developed a Basis of Design and composite repair booklet aligned with ABS and DNV standards.
- Conducted analytical calculations and FEA to validate strength, buckling, and bondline performance.
- Delivered rope-access installation using pre-wet layup and vacuum consolidation.
- Managed QA using INSONO™ NDT to inspect laminate, bondline, and underlying steel.
- Completed Class-witnessed material testing and ageing validation for epoxy systems.
The outcome
The repair reinstated structural integrity and was approved by Lloyd’s Register. It demonstrated that composite repairs can be safely and effectively executed offshore, offering a viable alternative to steel renewal.
Key outcomes delivered:
- First-of-class composite repair to primary hull structure.
- Avoided hot work, reducing HSE risk and downtime.
- Maintained watertight integrity and structural capacity.
- Enabled stop/start flexibility during cyclone demobilisation.
- Set a precedent for future composite repairs on floating assets