Overcoming challenges in marine buoyancy with specialist foams

Dunlop Oil and Marine (DOM), part of Continental AG, is recognised as the leading supplier of offshore loading hoses to all major oil, gas and petrochemical companies worldwide.  As a pioneer in offshore oil hose technology, they faced significant challenges in ensuring the durability and reliability of their floating hose products, Selflote and Saflote.  They turned to Zotefoams who engaged Kewell Converters to collaborate on the manufacture of advanced foam solutions.  Selflote and Saflote required state of the art foam solutions that provided exceptional mechanical and chemical properties suitable for harsh marine environments. The collaboration resulted in the development of the world’s first integrally floated offshore oil hose, setting a new industry standard for flexibility, strength, and resistance to tough conditions.

The problem

DOM faced a significant challenge in looking for specialist manufactured foams for marine buoyancy, particularly for ship-to-shore pipelines. The marine environment, characterised by salt water, chemical exposure, and physical stress, demanded materials that could withstand these conditions while maintaining performance integrity. Traditional materials failed to provide the necessary combination of low mass, high flexibility, and durability, leading to frequent maintenance issues and operational inefficiencies.

The solution

DOM consulted with Zotefoams who collaborated with Kewell Converters to create bespoke designs for the floating hoses. After in-depth consultations, we supplied high density foams using Azote product, Plastazote, which offered the perfect blend of characteristics required for marine buoyancy applications including:

• Mechanical strength: These foams manufactured by Zotefoams and then fabricated by Kewell Converters, provided exceptional durability and energy absorption, essential for withstanding physical stress.
• Low mass and high flexibility: The properties in the foams ensured the products could perform efficiently in dynamic marine environments.
• Chemical resistance: The inherent hydrophobic nature and inertness of the foams made them resistant to salt water and chemical degradation.
• Flame retardancy: This was crucial for safety in offshore installations.

Results

The partnership between Zotefoams and Kewell Converters led to remarkable outcomes, establishing a new benchmark in the marine industry. The Selflote offshore oil hose product became the industry standard which others are compared, thanks to its unique design and superior performance.  The innovative use of specialist foams and complex conversion of these foams resulted in products that offer unmatched performance, durability, and reliability even in the harshest marine environments including:

• Proven design: The Selflote hose demonstrated exceptional reliability and performance in the most exposed offshore installations
• Highly flexible: Capable of withstanding dynamic marine conditions
• Specialised fitting design: Enhancing ease of installation and maintenance
• Floatation bonding system: Resisting sea water ingress and maintaining performance integrity

Setting a new standard in marine buoyancy

This unique and complex project not only addressed the critical challenges faced by DOM but also set new industry standards for marine buoyancy solutions.

The ongoing collaboration promises to drive more innovations, ensuring Selflote remains at the forefront of the offshore oil and gas industry.

For manufacturing businesses looking to achieve similar results, read more of our case studies to learn how our foam solutions can elevate your product performance and reliability.

To find out more about our robust foam solutions and how we work in diverse sectors serving the industrial sector and construction industry, please email enquiries@kewell-converters.co.uk