Metalock Brasil completes structural repair on FPSO in Campos Basin

Metalock Brasil has completed a class-approved cold structural repair on the upper deck of a cargo oil tank aboard an FPSO operating in Brazil’s Campos Basin, using Sandwich Plate System (SPS) technology to restore structural integrity without hot work.
Engineering for the repair was developed by SPS Technology, which produced the full technical design package including 3D modelling, cavity configuration, material specifications, fabrication drawings and management of the classification society approval process.
The solution addressed localised pitting corrosion on the deck plating and was designed to restore and exceed the original structural capacity of the affected area while maintaining the unit’s operational continuity. The project included structural assessment and thickness measurements in line with classification society requirements, along with detailed specifications covering surface preparation, perimeter bars, top plates and structural adhesives.
During installation, technicians bonded perimeter bars to the existing plating before fitting a 10-mm top plate, creating a 25-mm cavity that was subsequently filled with injected structural elastomer. After curing, the elastomer formed a solid composite core permanently bonded to the steel plates.
Metalock Brasil said all works were conducted under strict environmental and quality control procedures, including cavity air-tightness testing, injection monitoring and full traceability of application data, with the repair completed within four days.