Innovative Field Joint Coating Enhances Offshore Pipeline Protection: A Collaborative Success Story

Abstract This paper presents the development and qualification of an alternative Field Joint Coating (FJC) system for offshore pipelay that replaces a manual process with semi-mechanised, highly automated polypropylene sheet wrapping method using the same 3-Layer Polypropylene (3LPP) materials as the parent line pipe factory-applied coating. Co-developed by the Operator and EPC Contractor and validated through a structured program aligned with industry and operator standards, the system underwent short- and long-term testing to assess the anti-corrosion integrity, mechanical impact resistance, and durability. Results showed anti-corrosion and mechanical performance comparable to the parent line pipe factory-applied coatings, with markedly improved impact resistance and application consistency versus the previously established manual FJC. Field observations during offshore pipelay demonstrated reduced manual labor, enhanced safety, and higher operational efficiency through lower manual handling. Overall, the new FJC solution streamlines execution and delivers robust, long-term protection of welded joints in demanding offshore subsea environments.