Flexilon Systems for Subsea Infrastructure

01 — Application

On-Pipe Applications

Liquid-applied polyurethane systems for casting directly onto pipe — for field joint coatings and full line pipe insulation. Compatible with J-Lay, S-Lay, and Reeling deployment methods. Our Flexilon chemistry delivers superior hydrolysis resistance in hot-wet conditions where conventional polyurethane fails.

• Service temperatures from −40°C to +140°C (hot-wet rated)
• Fast-cure options for project-critical vessel schedules
• Superior bond strength to parent coating
• Low-pressure application using standard dispensing equipment
• Processing temperatures below 100°C

02 — Application

Moulded Applications

Pre-formed polyurethane components manufactured to precise tolerances for rapid offshore installation. Moulded thermal insulation covers and cable protection — factory-produced and ready for deployment.

• Factory-moulded to project-specific dimensions
• Moulded thermal insulation covers
• Cable protection in 85 Shore A polyurethane (Flexilon 3215)
• Castings up to 300mm thickness
• Minimal exotherm (~120°C) during production

03 — Application

Custom Coatings

Bespoke coatings for complex subsea geometries that cannot be addressed with standard on-pipe or moulded solutions. Manifolds, Christmas trees, wellheads, and other structures — each with a tailored formulation and application method.

• Tailored formulations for unique operating conditions
• Complex geometry coating for manifolds and structures
• Subsea equipment encapsulation
• On-site and factory application capability
• Full technical support from formulation to deployment

The Science

Why Flexilon Chemistry?

Polyurethane is widely used in subsea energy, offering ease of processing, compatibility with RIM technology, and efficient installation through lower processing temperatures and fast cycle times.

However, conventional polyurethane systems, particularly under prolonged exposure to high-temperature, hot-wet subsea environments, can be susceptible to hydrolytic degradation. At elevated temperatures above ~80°C, water ingress can lead to progressive breakdown of the polymer structure, reducing long-term mechanical performance.

As subsea developments move into deeper, hotter environments, this becomes a critical design limitation.

Rosehill’s Flexilon systems, built on Networked Epoxy Modified Olefin chemistry, are engineered to overcome this challenge. The hydrophobic, crosslinked epoxy-modified olefin network significantly reduces water uptake and maintains structural integrity under sustained hot-wet conditions.

The result is a material system capable of delivering reliable long-term performance at service temperatures up to 140°C, where conventional polyurethane systems may struggle.