Oleg:

Back then, we were focused on shipbuilding and how to make SPS panels faster, safer and more efficient to fabricate. I was exploring how to eliminate the challenges of welding inside the narrow cavity between the two steel plates. Welding ‘spacers’ —what we now call perimeter bars —between plates was difficult and time-consuming, especially when access was limited.

So, my idea was to replace some of that welding with adhesive bonding, which would maintain the strength and precision needed, reduce heat input, avoid warping and simplify assembly, even in hard-to-reach spaces.

Jonny:

Traditionally, structural repairs rely on hot work such as cutting and welding, which are both costly and present significant safety risks. For seagoing vessels, these activities are typically performed during scheduled dry-docking cycles. However, for offshore assets such as FPSOs and similar installations, this approach poses serious challenges.

Conducting hot work offshore involves extensive hazard assessments leading up to preparation activities, including gas-freeing, tank cleaning, and, occasionally, diving operations, each introducing additional risks and complexity. These requirements demand substantial resources, resulting in high operational costs for the client.

Ian:

This was a direct response to a client requirement. SPS Technology has always been an engineering solutions company, and Cold Work was developed to solve a very real operational challenge. SPST and its partner network perform safe structural steel repairs globally without the need for any hot work or shutdowns.

Oleg:

Since the first application, the SPS Cold Work process has advanced in several key ways. Firstly, the concept of ‘development length’ for the determination of the extent of SPS required (with the calculation formulas/equations derived). We also added bolted connections to restore local strength. We later expanded them to provide structural continuity between adjacent top plates in larger areas that needed strengthening for global loads.

Although the 3-step installation process in general remains the same for any SPS project (with or without hot works, for reinstatement of the existing structure or for newly built SPS panels), the procedures for SPS Cold Work are still evolving to make them more streamlined and robust, reducing complexity for greater efficiency and adaptability.

Jonny:

A technical paper was presented and published by ABS at the Offshore Technology Conference (OTC) in 2003, highlighting this breakthrough cold-work repair method and its technical details. The project involved repairing a single-hull bottom plate in a crude oil tank, successfully eliminating the need for hot work and diving operations.

Following this publication, SPS Technology gained significant attention across the offshore industry, leading to a surge of inquiries for its application on various structural areas such as main decks, side shells, and bulkheads, and across different asset types, including semi-submersibles, jack-ups, FSOs, and fixed platforms.

Ian:

The first project satisfied the design intent and proved the concept, but, like every pioneering solution, SPS Cold Work has undergone more than two decades of refinement. The process has become more innovative, more predictable, and more adaptable to different environments, from FPSOs and FSOs to LNGs and semi-subs. Each project has helped evolve procedures, equipment, and training to deliver consistent quality and efficiency in the field.

Jonny:

The approach to structural repair has evolved significantly — welding and cutting are no longer the only options. SPS Cold Work offers a low-risk, controlled, and predictable solution that has become a preferred method across the industry.

With advancements such as 3D scanning during surveys and 3D modelling for design and fit-up, SPS faceplates can now be fabricated onshore with high precision. This development further reduces overall costs by shifting work from offshore to onshore, minimising the need for offshore personnel (POB) and shortening repair durations.

Ian:

SPS Cold Work has completely changed how operators think about structural repairs. It’s taken an idea from the SPS drawing board and proven it in service, offshore, under live conditions. What started as an innovative alternative is now a trusted, class-approved method —the original and most established Cold Work solution in the industry.

Jonny:

The key advantage of this method lies in eliminating the need for welding and cutting in hazardous environments. The approach to repair is fundamentally different from traditional hot-work methods. In conventional welding and cutting repairs, most of the work is carried out on site — including material preparation, trimming to fit the damaged area, and re-welding new plates into place.

In contrast, the SPS Cold-Work method requires greater engineering input. Detailed drawings, 3D modelling, and engineering studies are performed in advance to verify the suitability and strength of the repair before any fabrication begins. The SPS panels are then prefabricated onshore, ensuring precision and quality control. Offshore, the work primarily involves surface preparation and the installation of prefabricated SPS panels, significantly reducing hot-work risks, exposure hours, and offshore manning requirements.

Ian:

SPS can be installed safely in hazardous (HazEx) environments. The key advantage is that the vessel or asset can remain fully operational during the repair. Hot work risks, such as heat transfer that damages coatings, insulation, or underdeck systems, are eliminated. SPS is clean, controlled and predictable, making it ideally suited for in-service assets.

Jonny:

From a safety perspective, the SPS Cold-Work method is significantly safer than conventional welding-based repairs. It completely removes the risks associated with hot work, such as fire, explosion, and exposure to fumes, making it a far safer alternative for offshore and confined-space environments.

From an environmental standpoint, the SPS solution offers further advantages. It does not require cutting or scraping corroded structures, resulting in substantially less material waste than traditional repairs. In addition, because the process involves no welding, cutting, or grinding, it eliminates the release of fumes, particulates, and greenhouse gases typically produced during hot-work activities.

Ian:

Most offshore assets operate under strict safety protocols due to the risk of hydrocarbons. SPS Cold Work removes the ignition source entirely. There is no flame and no spark, eliminating some of the most hazardous installation activities and reducing overall environmental impact. SPS cold work was even installed on the roof of a live Above Ground Storage Tank with 750K barrels of oil inside in 2010.

Jonny:

SPS Cold-Work extends asset life while using less steel material. The system uses thinner faceplates and generates no scrap steel during the repair process, making it a more efficient and sustainable solution compared to conventional methods.

Classification rules require that any corrosion exceeding 20% of the original thickness be repaired. In a traditional repair, up to 80% of the affected steel is typically scrapped and replaced. In contrast, with SPS Cold-Work, approximately 80% of the existing structure is retained and reused, significantly reducing material waste and supporting sustainable asset management.

Ian:

SPS Cold Work preserves the original structure. There’s no cutting out or scraping of steel. The original plate remains in place, and a thin faceplate is added, creating a sandwich system that restores strength without waste. It’s a repair method that extends asset life and reduces material consumption in a single step.

Oleg:

I think our Brent Charlie project stands out. If all the repairs on the FPSOs, semi-subs, etc., where SPS Cold Work was utilised, still could be carried out using traditional C&R methods (of course, with greater amounts of time and financial resources spent), I have no idea what Shell would do without Cold Work SPS to reinstate the corroded gas-tight floor plating and peripheral seal.

As I understand, even during the decommissioning of this platform, it was decided not to clean the contents of the GBS cells (120 meters below the surface), which included hydrocarbons, but to leave them in place because removal would be technically challenging and dangerous, posing significant safety and environmental risks. Nevertheless, the use of SPS offshore repair enabled safe, unhindered work to continue while the operations continued.

Jonny:

One notable example is the FPSO Capixaba project, carried out offshore Brazil during the COVID-19 period, when operations faced strict limitations on personnel on board (POB). The repair involved the main deck area above a live tank, making conventional hot-work methods impractical due to safety and operational constraints. All SPS components were fabricated onshore, allowing precise preassembly and greatly reducing the need for offshore manpower. This approach enabled the repair to be completed safely, efficiently, and in full compliance with pandemic-related restrictions.

Ian:

FSO Africa, Brent Charlie, FPSO Espoir Ivoirien, FPSO Sendje Ceiba, Bohai Shi Ji, and Arcadia all demonstrated the system’s capability and longevity. These were Cold Work repairs performed years ago that remain in service today, a testament to the durability and integrity of the SPS system.

Jonny:

The SPS Cold Work system is a mature and proven innovation with an extensive track record of successful applications across various asset types.

Ian:

A trusted repair solution with a proven in-service track record, SPS Cold Work repairs are still performing decades after installation. Accept no substitute!