Temporary corrosion protection
Steel tubes from Mannesmann Precision Tubes are provided with a temporary corrosion protection from the plant prior to shipment. If the tubes shall be delivered without oil protection in exceptional cases, this must be indicated in the order. Other or additional corrosion protection measures can be agreed upon.
Corrosion protection oils are mineral oils that contain among other things inhibitors – corrosion-inhibiting organic substances. On request we can provide the safety data sheets of the corrosion protection. The oil can be removed by the customer with appropriate aqueous neutral or alkaline cleaners or solvents. The protective effect of the oil is dependent on the atmospheric conditions and the storage duration.
In the case of water caused by condensation, which occurs on or in the tubes if the temperature drops below the dew point or at highly variable temperatures and high humidity, the oil film can become ineffective. This effect can also occur when stored under roof.
The corrosion protection lasts for about one to five months when stored under roof and in air-conditioned rooms.
The effectiveness of corrosion protection is always connected with the packaging measures. For longer transport and/or storage duration the tubes must be additionally protected. Please contact us for further information.
MW-protect® - Excellent surface protection for HPL tubes
Mannesmann has developed an improved coating system for increased corrosion protection of HPL tubes in particular.
MW-protect® for seamless hydraulic and pneumatic precision steel tubes for according to DIN EN 10305-4 and surface protection with test according to DIN EN ISO 9227 in connection with DIN EN ISO 2081.
The right protection for various applications
We offer coatings and linings that reliably and durably protect steel pipes against corrosion and mechanical impact in difficult terrain, harsh environments and extremely aggressive media.
Cutting-edge coating and lining technology
With the MAPEC® coating technology developed by Mannesmann we are continuing a long tradition at the forefront of the industry. Continuous further development of the coating process and ongoing research into new coating concepts make us a top address in the area of pipe coatings and linings.
Coatings
MAPEC® solutions – for open-trench pipe-laying projects
MAPEC® is the registered trade mark for plastic coating systems consisting of polyethylene and polypropylene (PE/PP). These coatings are made exclusively of proven and approved materials and applied using the blown film extrusion process. It meets all the applicable national and international standards (e.g. DIN, EN, ISO, CAN/CSA) and, of course, the most exacting customer specifications.
There are various types of MAPEC® coating available to suit all types of terrain and service conditions up to operating temperatures of 85 °C (PE)/110 °C (PP). For particularly challenging and complex pipe-laying projects, we offer a range of MAPEC® advanced solutions. In addition, as a complement to plastic coatings, a Fiber cement mortar coating is available.
The plastic-coated pipes are marked in line with the applicable standard. If required, additional markings can be applied to customer specifications. These include colored strip markings. After coating, the pipe ends are usually provided with temporary corrosion protection.
At the customer's request, all coatings can also be supplied to other international standards and individual customer specifications.
MAPEC® polyethylene (HDPE) coating*
Service temperatures up to 85 °C
Description
3-layer coating, consisting of 1) Epoxy resin primer, 2) Adhesive and 3) Polyethylene
Product properties
Standard corrosion protection for line pipe, also in aggressive soils
Range of applications
Pipelines buried in rock-free soils
* "HD" stands for "high density".
MAPEC® polypropylene (PP) coating
with T from 0 °C to 110 °C (higher temperatures on request)
Description
3-layer coating, consisting of 1) Epoxy resin primer, 2) Adhesive and 3) Polypropylene.
Product properties
Efficient corrosion protection for increased service temperatures up to 110 °C (coatings for higher temperatures on request). Also available for pipe with an epoxy resin flow coat lining for significantly reduced friction losses.
Range of applications
Increased (external or internal) thermal loads on the pipe coating. General conditions in pipe-laying, transportation and storage must be observed.
MAPEC® plastic coating with integrated axial ribbing
Description
3-layer coating (PE or PP), consisting of 1) Epoxy resin primer, 2) Adhesive and 3) Special MAPEC® layer with axial ribbing
Product properties
Pipe coating with increased resistance to mechanical impact and abrasion
Range of application
Buried pipe-laying and pipe relining projects, due to the increased abrasion protection provided by the coating.
MAPEC® Custom Solutions - for specialized installation methods, such as HDD (Horizontal Directional Drilling)
For particularly challenging and complex pipe-laying projects, we offer a range of MAPEC® advanced solutions. These include a variety of options regarding the plastic coating‘s thickness and surface condition. For example, rough coat, T-rib, and S-rib textures are available.
The plastic-coated pipes are marked in line with the relevant standard. If required, additional markings can be applied to customer specifications. This also includes colored paint markings. After coating, the pipe ends are usually provided with temporary corrosion protection.
MAPEC® can be complemented with a fiber cement mortar top coat to DIN 30340-1. Various types are available to match the soil conditions of the project in hand. For pipelines subject to extremely high mechanical loads in stony or rocky terrain, or in subsidence regions. Like plastic coatings, FCM coatings, which are supplied in stone gray as standard, are also available in other colors, indicating the medium transported in the pipeline. Gas line pipe, for example, is given a yellow coating.
In combination with a ribbed structure on the PE corrosion-resistant layer, the fiber-cement mortar (FZM) coating can be supplied in a longitudinally reinforced version (FZM-S). This coating solution is particularly suitable for trenchless pipe installation.
At the customer's request, all coatings can also be supplied to other international standards and individual customer specifications.
MAPEC® plastic coating with Rough Coating (RC) surface
with Tmax = 110 °C (higher temperatures on request)
Description
3-layer plastic coating (PE or PP) consisting of 1) Epoxy resin primer, 2) Adhesive and 3) PE/PP top layer with a special surface treatment in the form of rough coating
Product properties
Pipe coating system with high friction resistance
- Onshore projects: Increased slip resistance when walking on or handling the pipes.
- Offshore projects: Higher sliding friction for increased safety against the pipe string slipping off the stinger.
- Offshore/heavy coat: Increased shear resistance between the concrete and the plastic coating.
PP corrosion protection coating for elevated service temperatures up to 110 °C. Coating for higher temperatures on request.
Range of application
Recommended where high friction resistance of the coating surface is a criterion.
MAPEC® plastic coating with special layer thicknesses and as an ideal substrate for further coatings (rough coat, GFRP, heavy concrete)
(HDPE) for a max. service temperature of 85 °C, or polypropylene for up to 110 °C
Description
MAPEC® 3-layer coating with special layer thicknesses (PE) or with layer thicknesses increased to customer specifications (PP), consisting of 1) Epoxy resin primer, 2) Adhesive and 3) Polyethylene/polypropylene.
Product properties
Special corrosion protection for line pipe (gas/oil, drinking water/waste water/brines, etc.)
Range of application
Buried pipe-laying in rock-free terrain.
MAPEC® plastic coating with color strip marking for all PE coatings to DIN 30670 and all coating thicknesses (standard, greater and special thickness)
Description
3-layer coating consisting of 1) Epoxy resin primer, 2) Adhesive and 3) Polyethylene with 4 or 8 (> DN 355,6 mm) longitudinal strips in the following colors: blue (compressed air), yellow (gas), red (cable), green (water) and brown (flammable liquids); other colors on request.
Product properties
Durable continuous marking according to the intended pipeline medium
Range of application
In line with customer specifications.
Fiber cement mortar coatings
MAPEC® can be complemented with a fiber cement top coat to DIN 30340-1. Various types are available to match the soil conditions of the project in hand. For pipelines subject to extremely high mechanical loads in stony or rocky terrain, or in subsidence regions.
Like plastic coatings, FCM coatings, which are supplied in stone gray as standard, are also available in other colors, indicating the medium transported in the pipeline. Gas line pipe, for example, is given a yellow coating.
MAPEC® plastic coating with FCM-N fiber cement mortar top coat
Description
3-layer coating to (PE or PP), consisting of 1) Epoxy resin primer, 2) Adhesive, 3) PE/PP layer, plus FCM-N top coat to DIN 30340-1.
Product properties
The FCM-N top coat provides for very high mechanical strength and integrated protection against buoyancy. In addition, there is no need for sand bedding (no landfill charges), the spoil can be re-used, and the coated pipes can be bent on site.
Range of application
Pipe-laying in stony and rocky terrain.
MAPEC® plastic coating with T-ribbing and FCM-S fiber cement mortar top coat
Description
3-layer coating (PE or PP), consisting of 1) Epoxy resin primer, 2) Adhesive, 3) PE/PP with co-extruded T-ribbing plus fused-on PE particles (rough coat) and FCM-S top coat to DIN 30340-1.
Product properties
The interlocking effect between the 3-layer coating and the integrated T-profile with rough-coat surface on the one hand and the FCM top coat on the other generates an extremely strong adhesive bond. The advantages: fractures and cracks are reduced to a minimum because excessive stresses are avoided; increased shear resistance between the concrete and the plastic coating.
Range of application
The combination of mechanical protection and shear force transmission makes this coating type specially suited to trenchless pipe-laying projects.
MAPEC® plastic coating with thick-layer FCM top coat (FCM-N / FCM-S)
Description
3-layer coating (PE or PP), consisting of 1) Epoxy resin primer, 2) Adhesive and 3) PE/PP layer, plus FCM top coat to customer specifications.
Product properties
The thick-layer FCM top coat generates high mechanical strength and integrated protection against buoyancy.
Range of application
The MAPEC® + FCM coating system is particularly well suited as a heavy coat against buoyancy.
Fusion-bonded epoxy – for onshore and offshore projects
For many years now, Mannesmann Line Pipe has supplied steel pipes with a single- or two-layer fusion-bonded epoxy (FBE) coating to offshore and onshore projects. This coating offers efficient corrosion protection and is suitable for the most varied pipe-laying methods and difficult soil conditions, including mechanical loads.
Mannesmann Line Pipe supplies FBE coatings to all relevant standards and specifications, such as CAN CSA Z245.20, ISO 21809-2, AS 3862, API RP 5L2 and NACE RP 0394, or according to GBE/CW 6.
FBE coatings can be applied in layer thicknesses of between 350 µm and 1000 μm. The maximum permissible service temperature in continuous operation is 90°C.
At Mannesmann Line Pipe, FBE coatings (single- or two-layer) are made exclusively from proven and approved materials and applied using an electrostatic spraying technique.
Thanks to its outstanding mechanical properties and adhesion, FBE is highly resistant to cathodic tunneling, which helps to limit the operating costs of cathodic corrosion protection systems.
Single-layer FBE coating
Single-layer FBE coatings protect buried pipelines against corrosion and mechanical damage. The average layer thickness of this coating variant is 400 to 500 μm.
Two-layer FBE coating
The first layer of this coating type serves mainly for corrosion protection, while the second layer serves as mechanical protection in the case of increased external loads.
For the second layer, either the same material as for the first layer may be used or, in the case of applications involving increased service loads, an abrasion-resistant overlay (ARO). The second layer is particularly designed to provide protection against mechanical impact and abrasion. It is applied using the same technique as for the first layer (wet-on-wet) to an average minimum thickness of about 400 to 500 μm.
The second layer for non-buried pipelines, such as pipe bridges, consists of an UV-resistant polyester. It is also applied to a thickness of 400 to 500 μm.
In offshore projects, FBE is frequently combined with a ballast coat of cement mortar. In this case, the second FBE layer is usually applied as a so-called rough coat, which provides increased shearing resistance to prevent the cement mortar coat from slipping off as the heavy pipe string is lowered to the seafloor.
Linings
Epoxy flow coat – Lining for the reduction of friction resistance in gas line pipe
An epoxy flow lining is applied as a thin layer to pipes intended for the transportation of non-corrosive gases. Its purpose is to provide for a smooth pipe inside surface with minimum friction for the medium to be transported. This means the flow rate is improved and energy requirements are reduced.
Epoxy-lined pipes facilitate visual inspection and pig passage. The flow lining also acts as corrosion protection during pipe storage.
Epoxy lining is applied in accordance with API RP 5L2 or EN 10311 to a thickness of about 60 μm.
Cement mortar linings – for the prevention of incrustations and optimization of the pipeline's hydraulic properties
The standard lining for drinking water pipes prevents incrustation and ensures good hydraulic properties of the pipelines. The lining provides active corrosion protection, not only through its barrier effect on the steel substrate but also through its ability to self-heal cracks and fissures, depending on the water composition. The mortar components promote the formation of passive layers on exposed steel surfaces in the immediate vicinity of the lining.
Special linings are used for specific applications such as wastewater, salt water, brine, or media containing water in gas and oil exploration.
Cement mortar lining CM-S
| Description | Lining according to DIN 2880, EN 10298 Based on CEM I (Portland cement) |
|---|---|
| Properties | Excellent hygienic characteristics, optimally suited to drinking water through the use of CEM I, resistance to sulfate (variety S) |
| Application example | Standard lining for drinking water line pipe |
During a service life extending over many decades, large-diameter pipes are frequently exposed to environmental extremes. Therefore, reliable coatings for protection against corrosion and mechanical damage are indispensable in most cases. Besides passive corrosion protection, an epoxy lining reduces the surface roughness on the pipe inside surface – and thus the flow resistance – to a minimum, which is particularly beneficial in the case of gas pipelines.
We can provide our pipes with the coatings and/or linings listed below to customer requirements and/or in line with applicable standards. Other coatings and linings are available on request.
Before coating, our pipes can be subjected to a high-pressure water scrub.
Coatings
Polyethylene (PE) coating
Before coating, the pipe is dried, externally shot-blasted to SA 2.5 requirements and then inductively heated to about 220 °C. This is followed by a primer coat of electrostatically applied epoxy resin (EP) powder with a thickness of 60 to 255 µm. Then a single layer of an approximately 125 to 400 µm thick adhesive foil is wound over the EP. Finally, a PE foil is wound over the adhesive. The pipe ends are left uncoated and, if required, provided with temporary corrosion protection. As added protection against rust creep during extended on-site storage, the transition area from the PE chamfer to the bare pipe end can be provided with a bituminous coat.
Polypropylene (PP) coating
At service temperatures above 80 °C, a coating's indentation resistance becomes increasingly critical. In such cases, we recommend a 3-layer coating system in which the third layer consists of polypropylene. In all other respects the build-up of the 3-layer PP coating system is the same as of the 3-layer PE coating system. Here too, the pipe ends are left uncoated and can be provided with temporary corrosion protection. A bituminous coat can be applied to the transition area from the PP-chamfer to the bare pipe end.
Lining
Epoxy lining
Epoxy resin lining to API RP 5L2 is mainly used on gas line pipe. Its purpose is to reduce the pipe's surface roughness and thus flow resistance inside the pipeline for increased transportation efficiency.
At our coating facility, the airless spray technique is used to apply a low-solvent 2-component epoxy resin lining to a dry thickness of at least 60 µm.
Clear coat
Our clear coat for direct application provides an environmentally friendly and low-odor protective layer for steel tubes, preserving their metallic appearance.
The coat is applied on an automated continuous system at approximately 55°C using four spray nozzles arranged radially around the tube at 90° intervals. The resulting evenly and continuous coat layer is at least 25 µm thick.
Once completely dry, the coat is waterproof, lightfast, and provides temporary corrosion protection (maximum 6 months) against atmospheric corrosion. It acts as a barrier against moisture and oxygen to prevent surface rust while allowing the metal to remain visible.
