Pipeline Cover Protection Solutions

Concrete Pipeline Protection

Use HYDROTEX fabric forms to cast a concrete pipeline protection system and save millions in labor and installation costs.

Get a project estimate today:

Concrete Pipeline Protection

Use HYDROTEX fabric forms to cast a concrete pipeline protection system and save millions in labor and installation costs.

Get a project estimate today:

HYDROTEX fabric-formed concrete mattresses are one of the best pipeline protection methods in the industry.

Permanent and custom-made, a HYDROTEX pipeline cover is the most effective countermeasure against corrosion for pipelines underwater and above ground.

Used in conjunction with cathodic protection, HYDROTEX can be installed over, under, and around a pipeline to provide superior erosion protection and prevent soil movement under the pipeline.

How is HYDROTEX used for pipeline protection?

The Problem

Like bridges and piers, pipelines are subject to scour and erosion, which can significantly reduce the longevity of the structure. Such damage can lead to catastrophic failure, costing millions in repair costs.

The Solution: HYDROTEX Fabric Forms for the In-Situ Casting of Concrete

Use HYDROTEX fabric formworks to cast a permanent concrete mattress that will protect the pipeline bed from erosion. With HYDROTEX, you can also cast a permanent concrete structure that will support freespan pipelines, preventing critical failure.

Best HYDROTEX Fabric Forms for Protecting Pipelines

Articulating Block Concrete Mat on Slope

HYDROTEX® Articulating Block

SUBSEA Formworks

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HYDROTEX: The Best Oil Pipeline Protection Product

Oil and gas pipelines must be protected from corrosion and damage with a proper armoring system, ensuring the longevity of the pipe. HYDROTEX fabric-formed concrete is a cost-effective way to cover pipelines, fortifying them and ensuring the ground around them experiences minimal erosion during their lifetime.

Pipeline protection is typically needed for:

Industrial plant
Ship at port

Offshore Pipeline Cover Protection

Don’t leave an underwater pipeline to the mercy of the ocean’s elements.

The metal is subject to scour and corrosion, which could lead to a failure of the pipeline system. HYDROTEX fabric-formed concrete mattresses can be installed over and around the pipeline to provide much needed protection against scour.

Related Solutions

Subsea Formworks – Mattresses, Supports, Covers, Sleeves, and Shells

Subsea Formworks – Mattresses, Supports, Covers, Sleeves, and Shells

Synthetex installs fabric formed concrete supports, mattresses, covers, sleeves and shells to prevent pipeline damage and scour, and support pipeline freespans.  Jack-up supports can be used to raise a pipeline or structure.  The flexible, high-strength synthetic woven fabric bags are cost effective to make and are easy to deploy by an ROV or diver.

Portland cement fine aggregate grout is mixed on deck, then pumped through a deepwater grout pipe that has been pre-connected to the formwork and lowered to the seabed on a sled.  The formwork is positioned by an ROV or diver and checked for orientation and position and monitored to assure even filling.  Many formworks can be filled in one stage. Due to their size and volume others may require multiple compartments and filling stages.

Freespan Rectification

In order to determine the design and path of underwater pipelines and cables, surveys of seabed topography and investigations of local currents enable engineers to evaluate the potential occurrence of scour and the need for freespan measures.

Eliminating unacceptable freespans, resulting from undulating sea floors, will require pipeline supports that meet the regulatory requirements, following design codes such as DNV-RP-F105 for freespans.  Seabed scour around pipelines and structures will occur as a result of increased velocities caused by localized currents.  Fabric formed concrete mattresses can be designed and installed to protect both new and existing pipelines from the loss of supportive sediment.

Engineers used computer modeling software to identify tens of potential freespans that would need addressing along a recently completed project, in the Bay of Bengal, that required formwork supports for a new 32 in export pipeline and a 14 in intra-field pipeline.

Custom subsea grout bags were designed and manufactured to suit the terrain and height of the freespans.  The large-base grout bags had anti-scour protection skirt sleeves built into them, which slows down the local current and causes suspended particulate matter to settle.  Over time, the skirts become engorged with sediment, reinstating the seabed.

The grout bags required filling in two or more stages due to their volume.  This was achieved by injecting grout into the lower section of the bag and allowing it to cure to provide a stable support for the grout injected in the upper sections.  The formworks were installed in water depths up to 186 m across a 90-day campaign.

Deepwater Pipeline Separation

There are other subsea applications for fabric formworks, such as jacking or separating crossing pipelines.  Jack-up supports protect the lower pipeline.  An ROV will remove the formwork from the deployment sled and maneuver it into position.  With the pre-connected grout pump already attached, fine aggregate supports are filled with fine aggregate concrete.

Ordinary Portland cement (OPC) grout is mixed on deck, then pumped to the grout bag via a deepwater grout umbilical, connected to the formwork deployment sled.  After sufficient grout has entered the formwork to stabilize the bag, checks are made to ensure that the bag orientation and position is still correct and that it is filling evenly.

The crossover grout bag is designed to be filled in three stages due to its size and volume.  The lower compartment is filled and allowed to cure sufficiently to support additional grout in the upper compartments.

HYDROTEX® Articulating Block

Articulating Block (AB) Concrete Linings

Articulating Block (AB) Concrete Linings

Articulating Block Mats form cable-reinforced concrete block mattresses that resist erosive forces. They are often constructed where a revetment is exposed to frontal attack by wave action.

AB Mats are typically used to protect coastlines, canals, rivers, lakes, reservoirs, underwater pipelines, bridge piers, and other marine structures from propeller wash, ship wakes, wind waves, currents, and high velocity flows. They are also used in environmental construction for landfill caps, down chutes, and collector channels.

The AB fabric form consists of a series of compartments linked by an interwoven perimeter. Grout ducts interconnect the compartments, and high-strength revetment cables are installed between and through the compartments and grout ducts.

Once filled, the AB Mats become a mattress of pillow-shaped, rectangular concrete blocks. The interwoven perimeters between the blocks serve as hinges to permit articulation. The cables remain embedded in the concrete blocks to link the blocks together and facilitate articulation.


Submit a Request for an Articulating Block Specification

We’ll get back to you within 1-2 business days. All specifications are available in both nylon and polyester configurations.

Submit a request for a technical specification

We’ll get back to you within 1-2 business days. All specifications are available in both nylon and polyester configurations.

HYDROTEX® Filter Point

HYDROTEX Articulating Block

HYDROTEX Uniform Section

HYDROTEX Filter Band

HYDROTEX Enviromat