From Precision Survey to Global Delivery
100% workshop-prefabricated — no on-site hot work required
Our Services
From new-spool prefabrication to emergency repair, from refurbishment to global delivery — we solve every seawater-piping problem you face.
- Prefabricated from Automet® digital-twin models, with allowances reserved for gaskets and coating — dimensional deviation controlled to near-zero.
- Carbon-steel, stainless and alloy spools to DIN and JIS marine standards (elbows, tees, reducers, basket strainers and other shaped fittings).
- Every piece ships after PE lining, external coating and hydrostatic testing, with classification-society inspection certificates included.
- Newbuild and FSRU seawater-cooling, ballast and scrubber system pipework.
- BWTS and EGCS retrofit pipework where on-site hot work is restricted.
- Projects where the owner wants to avoid on-site welding, coating and NDT.
100% first-time fiton installation — no on-site rework, with installation man-hours cut by 60%+
China-factory pricing, delivered worldwide — without the local-yard premium
No on-site hot work at any stage, and no dependence on drydock scheduling.
- Once the old pipe is removed: sandblast to bare metal → internal rotary PE lining (2–10 mm) → external recoating → flange repair → pressure test.
- On completion you get a full 5-year drydock-to-drydock warranty and a design service life of over 15 years. We handle batch refurbishment (tens to hundreds of spools) — the larger the batch, the lower the unit cost.
- Batch processing (tens to hundreds of spools) brings unit cost down further with volume.
- Seawater lines with lining loss, rubber-lining delamination or external corrosion, where the parent steel wall thickness still meets spec.
- Owners tightening drydock budgets, compressing dock time, and cutting carbon by reusing the existing pipe and reducing steel waste.
Main-material cost runs at roughly50%-60%of new-pipe cost (down to ~40% on large batches)
Turnaround compressed from 2–3 weeks to 3–5 days, cutting vessel off-hire losses substantially
Over a 10-year life cycle, total spend versus full replacement is reduced by50% or more.
- Suits the full DN50–DN1600 range (straight pipe, elbows, tees, reducers, strainers).
- Thickness adjustable 2–10 mm — 10–100× a conventional coating — with strong impact resistance.
- HDPE or LDPE modified compounds available, resisting seawater, acid and alkali, with lining water absorption below 0.01%.
- Existing carbon-steel lines or tanks needing internal corrosion protection, or a cost-controlled alternative to stainless steel.
- Shipyards and design institutes specifying a “carbon steel + PE lining” package, outsourcing the lining work.
- Re-lining of old pipe and contract PE lining of newbuild spools.
Service life is3-5× that of rubber lining, eliminating water-absorption and delamination failures
At DN250 and above, cost is 13–20% below GRE/GRP, with no ageing or embrittlement risk.
The whole process holdsABS-PDAproduct certification, compliant with international classification-society rules.
- Outputs isometric drawings with fabrication tolerances, reserving flange gaps, gasket and coating allowances.
- The data drives workshop prefabrication and builds a digital archive of ageing pipework, so the model can be reused for spares and repairs.
- Ageing vessels with no original drawings and no dimensional basis for pipe renewal.
- Complex, irregular pipe runs where manual measurement is error-prone.
- Cross-border projects where customs rules prevent shipping the old pipe back — production runs remotely from the digital model.
Avoids the distortion errors of copying an old pipe — first-time installation acceptance of prefabricated spools reaches100%
Reduces on-site tack-weld rework and saves2~5days of drydock time.
- We dispatch certified surveyors aboard to capture the digital twin (covering the US, UK, Philippines, Türkiye and more).
- Our Shenzhen factory builds precisely to the digital model, 100% prefabricated, with English-language certificates.
- Shipped by sea or air to the destination port, with an installation team available or coordination with the local yard.
- Vessels operating where no class-approved PE-lining facility exists locally, and owners are concerned about remote after-sales cover.
- Cross-border projects constrained by import/export rules, where the old pipe cannot be sampled across borders — production runs remotely from the digital twin.
We deliver China-factory pricing worldwide
Removes old-pipe customs clearance and sea-freight loss risk.
5-year global warranty — after-sales support available wherever the vessel calls.
- On-site ultrasonic wall-thickness testing plus borescope inspection define the damaged section.
- The faulty section is cut out and replaced with a bolted, flanged prefabricated PE-lined spool — entirely weld-free.
- Hydrostatic test on completion, with a formal repair report issued.
- Sudden perforation, flange leakage or wall cracking that cannot wait for a planned drydock.
- Vessels waiting to load or facing tight dock berths, where demurrage costs are high.
24h emergency line— most faults resolved the same day
Repair cost is under50%
On completion you receive a5-year warrantywarranty (same standard as pipe refurbishment).
Manufacturing Process
Our process covers the full pipe life cycle across 9 precise steps, grouped into three stages: on-site digital survey, precision workshop prefabrication and lining, and finished-product inspection with global delivery.
Global Survey
Automet® digital-twin technology measures pipework precisely in service — no need to copy the old pipe.
Precision Fabrication & Lining
CNC cutting + rotary weldingPE rotomoulded lining, for complex fittings above DN50
Quality Control & Delivery
End-to-end quality inspectionGlobal logistics — ready to install on arrival
Stage 1 — Precision Survey & Data Capture
Traditional pipe renewal means removing the old pipe and copying it in the workshop — slow and prone to error. Our digital-twin approach changes that.
Step 1
Survey / mapping (Automet® 3D digital measurement)
Using a Leica total station with the Automet® system, we capture a high-precision 3D scan with the pipe still in service and bolted in place, generating an accurate digital-twin model without removing the old pipe.
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Each spool takes only 2–3 minutes to survey.
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Simultaneous 3D check of squareness, alignment and dimensions.
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Instant 3D digital deviation report.
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Reverse-engineered drawings for older vessels with no plans.
Representative project: survey in Brazil → fabrication in China → installation in Türkiye | Zhoushan DN800 project — digital survey straight to prefabrication
Stage 2 — Precision Fabrication & Corrosion-Protection Core
From steel to corrosion-protected pipe, every step is engineered for the harsh marine environment.
Step 2
Cutting / material intake
Material requirements are calculated precisely from the digital-twin data. Raw material is rigorously verified before stock-in to ensure quality at source.
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Full material certificates for carbon steel, stainless and alloy.
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Spectrometer material re-verification.
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CNC cutting ensures pipe-end accuracy.
Step 3
Fabrication / welding
CNC cutting plus precision welding by certified welders in an enclosed workshop, with welds compliant to ABS / DNV / BV classification-society procedures.
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CNC cutting eliminates manual bevel defects.
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Rotary-axis welding improves consistency.
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TIG root pass + FCAW fill and cap.
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Workshop prefabrication replaces on-site hot work — safer.
Step 4
Sandblasting
Blast-cleaned to Sa 2.5 with a controlled roughness profile to ensure PE lining and external coating adhesion.
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Surface cleanliness: Sa 2.5 (ISO 8501-1).
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Roughness: Rz 50–75 μm.
Step 5
PE lining / rotomoulding (core process)
Usingrotary liningtechnology, evenly applying high-performance polyethylene powder to the pipe's inner wall, fused at high temperature into a dense, seamless corrosion barrier — like giving the steel pipe a permanent inner skin.
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LDPE / HDPE / Super Seal LDPE options.
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Uniform coating thickness, tolerance < 0.5 mm.
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Seamless, with no weak points.
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Suits complex geometries above DN50.
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Passes 1,000-hour salt-spray testing.
Service life: PE-lined seawater pipe over 15 years, with a 5-year warranty
Stage 3 — Quality Control & Global Delivery
Before it ships, we are more demanding than the customer — every pipe must pass final inspection.
Step 6
Painting / surface finishing
After PE lining, the pipe exterior is coated. We offer a range of anti-corrosion coating systems to suit the customer — protected inside and out.
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Epoxy zinc-rich primer + polyurethane topcoat (standard marine spec).
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Customisable to the customer's specified coating system.
Step 7
Pipe inspection / final QC
Every pipe must pass a full inspection routine:
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Automet® second scan to verify dimensional tolerances.
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PE peel-strength test and borescope inspection.
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Hydrostatic / pneumatic pressure testing.
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Coating-thickness and visual inspection.
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Stamped with a traceable “inspection passed” mark
Step 8
Finished spool
Every pipe that passes all checks carries a unique traceability code, linking the full record from raw material to dispatch.
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100% dimensional fit — no on-site modification.
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Dual protection: internal PE lining + external coating.
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Complete quality file included: material certificates, welding records, inspection reports.
Step 9
Handling / shipping & loading
Finished spools are professionally packed and braced, shipped to any port worldwide, with full logistics tracking to ensure zero transit damage.
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Standard urgent orders: 6–8 day fast delivery.
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Global delivery network across Asia, Europe, the Middle East and South America.
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Timber-cradle bracing + moisture wrap + lifting-point marking.
Global delivery example: survey in Brazil → fabrication in China → installation in Türkiye | international delivery of the Sweden pipe project
Warranty Policy
5-year drydock-to-drydock warranty
Every PE-lined new or refurbished pipe shipped by Irwin carries a 5-year warranty from the date installation is completed.
| Item | Details | Covered |
|---|---|---|
| PE lining | Peeling, delamination, blistering and excessive wear not caused by external force | ✅ Covered |
| Flange sealing face | Unevenness or leakage caused by lining or manufacturing defects | ✅ Covered |
| External coating (standard epoxy) | Peeling or blistering not caused by external force or chemical attack (per ISO) | ✅ Covered |
| Welded joints | Weld-quality defects confirmed by NDT (cracks, lack of fusion, etc.) | ✅ Covered |
| Third-party or external-force damage | Damage after installation from impact, cutting, over-temperature operation, etc. | ❌ Not covered |
| Over-temperature / chemical attack | Sustained conveying above PE's temperature limit (>80°C) or organic solvents | ❌ Not covered |
Start:Calculated from the date the pipe is installed on site and passes its pressure test.
Term:5 years (covering the full drydock cycle).
Refurbished pipe:Identical to new pipe — the same 5-year drydock-to-drydock warranty.
Design life:Beyond the 5-year warranty the PE lining keeps performing, with an expected life over 15 years (case-supported, not an additional guarantee).
Report the issue
For a pipe leak, lining issue or similar, call our 24h line +852 5128 3422 or email warranty@irlservice.com.
Fast response
Acknowledged within 2 hours, with a technician arranged for video or on-site inspection within 24 hours.
Liability assessment
In warranty → free repair / replacement; out of warranty → a paid repair proposal.
Carry out repair
Prefabricated PE spools and flange replacement, typically completed in 3–5 days.
Sign-off
The customer signs off; Irwin retains the repair record so later service is traceable.
- The customer must retain the original purchase contract or order number.
- The pipe must be used per Irwin's operating guidance (no over-temperature, no organic solvents, etc.).
- No welding, cutting or modification of the pipe without Irwin's authorisation.
- Normal wear and flow reduction from marine growth are not covered.
- Damage from accident, fire or improper operation is excluded.
Ready to upgrade your seawater-piping solution?
Book a consultation
Book a 15-minute Teams call with David Schaus to discuss your project.
Download resources
Get“Marine Seawater Pipe: Refurbish vs Replace — Life-Cycle Cost Comparison”, with the full comparison data
Free Assessment
No removing old pipe, no shipping scrap steel — tell us your pipe's condition and we'll assess and quote, free of charge.