Why you should choose Non-Metallic Solutions for the Subsea Industry

Subsea composite solutions have multiple advantages, making them one of the best alternatives for underwater operations.

An introduction to Non-Metallic Solutions

CSUB specializes in producing non-metallic subsea support structures and protection systems using Glass Fibre Reinforced Polymer (GRP), which offers significant advantages for subsea applications.

GRP is highly resistant to corrosion, lightweight, and durable, making it a cost-effective alternative to traditional steel and concrete solutions. The material has become popular in industries such as oil and gas, offshore wind, and aquaculture due to its ability to withstand harsh underwater environments without suffering from galvanic corrosion or requiring extensive maintenance.

CSUB offers a variety of products. Such as pipeline sleepers, subsea crossings, subsea bridges, pipeline freespan correction and foundations. In addition, we provide a variety of subsea protection systems.

– Our Non-Metallic Subsea systems are designed for easy installation, high resistance to ocean conditions, and minimal environmental impact, with GRP materials providing improved energy efficiency through weight reduction. Additionally, CSUB’s solutions are customizable, allowing clients to tailor them to specific project requirements, says CTO, Jon Inge Brattekås. 

The environmentally friendly aspect of our non-metallic solution, combined with its durability and cost-effectiveness, makes it an ideal choice for industries moving toward more sustainable operations.

The environmental aspect

Non-metallic solutions are beneficial on several levels. Compared to traditional wet lay-up methods, vacuum infusion produces fewer emissions and waste. It is a cleaner and more environmentally friendly manufacturing process for subsea solutions.

In addition, you will save emissions by the reduced need of campaigns during shipping due to our products being lightweight and stackable.

Multiple studies and publications show that non-metallic solutions have proven to be more sustainable and environmentally friendly in the long run compared to more traditional solutions. EuCIA (European Composites Industry Association) has stated that composites are essential for realizing renewable energy targets.

– Composite components provide more sustainable products than alternative materials by offering high performance, long-lasting solutions leading to lower maintenance and reduced energy use. Composite play an essential role in key markets, from lightweight structures for cars and aircraft. To wind turbine rotor blades, pipes for corrosive environments, PCBs for electronic equipment, and numerous construction and infrastructure applications. Without composites, our renewable energy targets will not be realized, they state.

They are not alone. The European Comission has also identified advanced materials, including composites, as a key family of materials to achieve the objectives of the Green Deal.

In July EuCIA released a series of publications explaining why composites are genuinely circular. Not only does solutions in composite make a substantial contribution to decarbonization while they are still being used for their intended use. At the end of their intended use they can be reused, repaired, refurbished, remanufactured, repurposed or recycled, and therefor fulfilling the last six R’s of circular economy.

– There are many options for extending the lifetime of composite components. For example, the product might be used as it is for the same purpose in a different application (reuse), or its use can be extended by applying conventional maintenance techniques both in situ (repair) and through industrial processes (refurbish and remanufacture). If repair is not possible, the product can often be used for a different function (repurpose). When these options are finally exhausted, recycling is possible through both closed loop and open loop processes, informs EuCIA.

The material – Glass Fibre Reinforced Polymer (GRP)

Glass Fibre Reinforced Polymer (GRP), also known as fiberglass, is a composite material made from a polymer matrix that is reinforced with fine glass fibers. This non-metallic combination results in a material that has exceptional strength-to-weight ratios, high durability, and excellent resistance to corrosion and environmental damage, making it ideal for various industries.

Composition and Manufacturing

GRP is typically composed of glass fibers embedded in a thermoset resin, such as polyester, epoxy, or vinyl ester. The glass fibers provide mechanical strength, while the resin acts as a binder, giving the composite its shape and helping to distribute the stress across the fibers.

CSUB has factories in Eydehavn in Norway and in Lithuania. We are world-leading providers of subsea composite solutions, and our employees are the foremost experts on building large composite structures.

The fabrication of our products combines advanced technology with expertise and dedication to quality. By using CAD technology, we can make precise models and molds of the subsea systems. Later, dry reinforcement materials, such as fiberglass or carbon fiber, are laid out in this mold. The mold is then sealed with a vacuum bagging film.

– A vacuum is applied to the mold, removing air and gases from the space between the reinforcement and the mold. This creates a pressure differential that allows resin to be drawn into the mold, saturating the reinforcement. Our vacuum infusion technology creates a proportion of reinforcement close to 70%, which is the success factor in making strong, lightweight composite solutions, informs factory manager, Frode Langnes.

Once the mold is fully infused with resin, it is cured using heat or chemical catalysts. This solidifies the resin, bonding the reinforcement materials together and forming the final composite part. The vacuum infusion process ensures uniform resin distribution throughout the part, minimizing voids and inconsistencies. This leads to parts with consistent mechanical properties and improved performance.

Properties and advantages

• Lightweight and strong: GRP offers high tensile strength while being much lighter than traditional materials like steel or concrete. This strength-to-weight ratio makes it ideal for use in areas where reducing weight is crucial.
• Corrosion resistance: One of GRP’s biggest advantages is its resistance to corrosion. Unlike metals, GRP does not rust or degrade when exposed to water, chemicals, or salt, making it a popular choice for subsea applications, such as in offshore wind farms, oil and gas, and subsea infrastructure.
• Durability and low maintenance: Due to its inert nature, GRP can last for decades without significant wear and tear, reducing the need for regular maintenance. This longevity is especially useful in challenging environments like the ocean or harsh chemical facilities.
• Design flexibility: GRP is highly adaptable and can be molded into complex shapes, allowing for greater flexibility in design and construction.

Applications

GRP is used across various industries, including:

• Construction: GRP is used for structural components, cladding, and reinforcement in buildings and bridges.
• Marine and offshore: Its corrosion-resistant properties make it ideal for boat hulls, subsea production systems, subsea protection systems, and offshore platforms.
• Transportation: In automotive parts, aerospace components, and rail systems to reduce weight and improve fuel efficiency.
• Energy: GRP is increasingly being used in renewable energy projects, including wind turbines, where it forms strong, lightweight blades and structural supports.

In summary, GRP’s versatility, strength, and resistance to environmental factors make it a superior choice for a wide range of applications, especially in sectors where traditional materials may fail or require constant maintenance​.

Reduced costs and emissions regarding shipping

Due to the material being up to 50-70% lighter than steel and concrete, CSUBs subsea support structures, and protection systems has a lower shipping cost than other solutions.

Our modules are designed to be stackable, which allows for better space utilization on cargo ships. Resulting in the use of smaller vessels and cranes, and fewer trips to get the products on site. By reducing the number of campaigns, you save fuel, time and money.  Which benefits both you as a customer, and the environment.

Norways largest engineering department

To ensure the highest of quality and customizability when it comes to our products, CSUB has Norway’s largest engineering department dedicated to Glass Fibre Reinforced Polyester (GRP) structures.

The department is located in Arendal on the Norwegian south coast. This is where all main management functions, the global engineering, and project execution capabilities, are located, and it lies in close vicinity to one of our factories located at Eydehavn.

– Our unrivaled expertise is the driving force behind our cutting-edge subsea protection systems and subsea support structures, ensuring unmatched quality and durability, says Design Lead, Christian Brattekås.

Composite is an incredible malleable material, and its characteristics makes the manufacturing process time efficient – but very skill-intensive. Our engineering departments cutting-edge expertise, combined with our highly skilled factory workers, enables us to have an extremely efficient lead time.

– We build complex shapes in one piece, which reduces the number of parts, simplifies the assembly, and gives us the ability to collaborate and optimize the design. Our engineers always design according to the specifications and needs of our clients, Brattekås continues.

Leading provider worldwide

CSUBs adventurous journey started in the Northern Sea with a delivery all the way back in 1992. Our first delivery of subsea structures made with GRP was a success. Since then, we have had countless deliveries to projects in the North Sea. In 2003 we became known as CSUB. Around the year of 2005 we broadened our horizon, releasing the potential of our non-metallic subsea solutions to other parts of the world. 

–  We are world leading with our experience and size. Coming from the Norwegian oil, gas, and subsea industry, and the strict requirements that follows regarding health, safety and environment (HSE) and documentation, we have established a good reputation for ourselves, says CEO, Anders Holm.

Today we have a significant market share. Delivering products to Africa, Brazil, the Middle East and to southeast Asia, to name a few.

– In the North Sea we have delivered a great amount of subsea protection systems created and tested to withstand huge load cases. We have further developed this knowledge and created new solutions that are applicable in the Middle East and in other parts of the world, the CEO continues.

New venture in the Middle East

As a result of CSUBs investment in the market globally, we opened a new venture in Qatar summer of 2024. Mathias Berg, former VP of Market and Technology, is today General Manager for this division.  

– It’s incredible to be a part of this new era. The Middle East is a market we have followed for a long time. It started with our first delivery to the North Field Production Sustainability project in 2022 and we are now increasing our focus and resources to gain a dominant market position for subsea GRP structures in the region. I look very much forward to leading this initiative and establish GRP as the preferred material for subsea structures in the region, he says about the venture.

The establishment of production in Qatar is a partnership agreement between CSUB and Qatar Shipyard Technology Solutions. It marks a significant milestone for CSUB, being the first agreement for production of GRP in the Middle East for the company.

– Together we can make GRP the go-to material for subsea structures in the Middle East region. These non-metallic solutions include subsea bridges, crossings, sleepers, foundations, and adjustable pipeline free span correction, among others.

High demand for non-metallic subsea solutions

In line with the increasing focus on the environment and green solutions we are experiencing a growing demand for alternatives to steel and concrete. Of which non-metallic solutions in GRP is sailing up to become a favorite.  

– The demand is increasing. With the growing focus on sustainability and the future, you will fall behind if you don’t start to choose more eco-friendly solutions. We at CSUB already have a great alternative for the industry but are constantly evolving to give our customers the best solutions, says Holm.

EuCIA highlights following points as a some of the environmental benefits of using composite:

• Lower energy consumption and lower greenhouse gas emissions
• Longer component life even in the absence of maintenance
• Improved performance and greater safety

Subsea sleepers and buckling initiators

CSUB’s Sleepers are robust structures specifically designed to support and stabilize subsea pipelines. They play a crucial role in controlling lateral buckling caused by thermal expansion and contraction and are vital for maintaining the integrity of pipelines over their operational lifespan. 

CSUB’s buckling initiators are engineered to ensure that subsea pipelines buckle in controlled, predetermined locations or patterns, significantly reducing the risk of unexpected or harmful buckling. While sharing key quality features with CSUB’s sleepers, these buckling initiators are specifically tailored and ballasted for controlled buckling, meeting the precise requirements of subsea pipeline specifications. The product is available in various configurations to accommodate different pipe specifications, metocean data, soil conditions, and other project-specific needs.

Subsea crossings and bridges

CSUB’s crossing structures are engineered to facilitate seamless and safe crossings for subsea pipelines and umbilicals. Designed to ensure minimal environmental impact and straightforward installation, these structures are essential for maintaining the integrity and efficiency of subsea infrastructures.

Pipeline freespan correction

CSUB offers specialized support structures designed to stabilize pipelines and spools experiencing challenges with free span control. Our solutions are engineered to be deployed post-installation, providing effective responses to issues such as seabed scouring. 

Foundations

CSUB’s GRP Support Structures are engineered to provide support for pipelines, subsea structures, and equipment across challenging marine environments. These structures are pivotal in diverse applications such as buckling mitigation for pipelines and providing firm landing areas for flexible risers.

Subsea protection covers

CSUB Protection Covers are used to protect subsea pipelines, equipment and structures from external impact from dropped objects, trawl and anchor loads 

The combination of strength and flexibility of the GRP material used in the Subsea Protection Covers provide unique properties to absorb energy from dropped object/trawls. Testing has been performed up to more than 300 kJ, and based on this result we can simulate and analyze any impact. High impact covers with approx. 500 kJ has been delivered and CSUB has designed covers with impact requirement up to 800 kJ.

Subsea production systems

CSUB specializes in GRP protection systems for subsea production/processing equipment, due to their high strength, excellent surface finish, superior chemical resistance, and robust temperature properties. Our composite solutions significantly enhance the performance and durability of subsea structures.

Subsea cable protection

At CSUB, we offer lightweight, stackable, and durable Cable Protection Solutions, developed from over 20 years of subsea engineering experience. All our products are made from robust, non-metallic composites, ensuring superior resistance to harsh ocean conditions. Our systems are customizable to meet your specific needs, designed for easy installation, efficient handling, and long-lasting performance. These solutions help extend cable life and ensure reliable operations across various applications, including offshore wind farms, oil and gas, and telecommunications.

Subsea hatches

CSUB offers innovative subsea hatches designed for integration into subsea structures, XTs, manifolds, templates, and ITS systems. Our hatches leverage Glass Reinforced Plastic (GRP) technology to provide lightweight yet robust solutions that enhance operational efficiency and safety.