Performance of Different Protection Technologies Under Demanding Installation Conditions

Conventional corrosion barrier coatings such as Fusion Bonded Epoxy (FBE) and liquid epoxy field-joint coatings are very effective for corrosion prevention. However HDD pull back operations can pose significant challenges. They can often struggle to withstand the severe mechanical stresses encountered.

Coatings can suffer damage from abrasion, impact, gouging, shearing, tearing, and cracking when exposed to aggressive ground conditions such as granite and cobble. Even when abrasion-resistant over coatings (AROs) are added, the protection is often insufficient for the most demanding HDD crossings. As a result, coating failures, rework, and costly reinstallation efforts can still occur.

Composite protection technology is the best alternative. Extensive laboratory testing routinely demonstrates that composite coatings significantly outperform traditional epoxy coatings:

  • Glass composites were found to be approximately eight times stronger than epoxy coatings.
  • Composites achieved stiffness values of around 4,000 ksi, compared with 250 ksi for epoxy coatings.
  • Fracture toughness testing showed composites outperformed conventional coating materials by a factor of 20 to 60 times, making them much more resistant to cracking, peeling, chipping, and other forms of mechanical failure.

With an extensive track record, composite protection from Scar-Guard successfully protects pipelines during HDD installations through difficult formations including granite and cobble. In these cases, inspections after pullback found abrasion on the sacrificial composite layer but no damage to the underlying corrosion barrier coating, allowing the projects to proceed without costly repairs or re-pulls.

Key takeaway: Traditional corrosion barrier coatings provide essential corrosion resistance but may not withstand the mechanical demands of HDD installations. Composite protection technologies demonstrate superior strength, stiffness, fracture toughness, and real-world performance, providing enhanced protection in challenging installation environments and helping to ensure successful pipeline installation and long-term integrity.

Related Solution

Field-proven composite protection systems such as ScarGuard are designed to provide enhanced mechanical protection in demanding HDD installations where conventional coating systems may be exposed to severe installation stresses.

Learn more about ScarGuard →