Deck piping on tankers, gas carriers and other vessels is exposed to demanding operating conditions. Saltwater, UV radiation, temperature cycles and mechanical movements gradually break down conventional insulation systems. As moisture enters the insul.ation, thermal performance decreases, heat loss rises and corrosion under the jacket begins to develop. This leads to higher fuel consumption, increasing maintenance requirements and a shorter service life for the entire piping system.
Retrofitting existing deck piping is therefore one of the most effective ways to restore performance and reduce operational costs. At LR Marine, we retrofit ageing systems using watertight, bonded LOGSTOR pre-insulated pipes designed specifically for long-term operation in the marine environment.
Most vessels with conventional insulation experience a loss of insulation capacity long before the carrier pipe itself is worn out. Even minor damage to the outer jacket allows moisture to enter, and once the insulation becomes wet, its thermal properties decline rapidly. The result is higher heat loss, unstable temperatures and increased fuel usage.
In many of the systems we inspect, the piping itself remains structurally sound; it is the insulation that has failed. Restoring the insulation with a fully bonded, watertight system is often all that is required to recover optimal performance.
Our retrofit approach is based on LOGSTOR pre-insulated pipes. These systems combine a steel carrier pipe with high-density polyurethane foam that is pressure-bonded to the pipe and protected by a fully sealed HDPE jacket. Because the insulation is bonded directly to the steel, water and vapour cannot penetrate the system. Even after decades at sea, the insulation maintains its performance and the carrier pipe remains protected from corrosion.
This watertight design ensures consistent thermal efficiency, reduces the need for maintenance and provides stable operating conditions for the
remaining lifetime of the vessel.
One of the strongest arguments for retrofit is the energy savings. When insulation has deteriorated, heat loss increases significantly, and the additional fuel required to maintain operating temperatures can become substantial. By replacing the insulation with a watertight system, heat loss is reduced immediately.
In several retrofit assessments performed by LR Marine, the investment was paid back in a matter of months. In one documented case, the complete retrofit of a deck piping system was paid back after 119 days of operation. Once the insulation is restored, the reduction in fuel consumption continues every day the vessel operates.
We prepare precise heat-loss calculations based on pipe diameter, length and medium temperature, giving operators a clear understanding of expected savings and payback time.
Retrofit work is typically carried out during dry dock, where efficient installation is essential. We deliver prefabricated pipe spools manufactured to match the vessel’s drawings and dimensions, reducing the amount of on-site work. Our installation concept, often referred to as “Sticks & Kits,” includes ready-to-install pipe sections together with all necessary joints and accessories.
Each field weld is insulated using our crosslinked heat-shrinkable joints, ensuring a complete watertight seal and uniform insulation quality throughout the system. This method provides a fast installation process and high installation reliability.
In cases where only parts of the insulation have been damaged, full replacement may not be necessary. Foam injection beneath a newly installed HDPE jacket allows us to restore insulation performance in localised areas without replacing the entire system.
LR Marine also performs insulation repairs on LNG, LEG and LPG cargo tanks. Cracks in polyurethane foam, delamination of insulation layers and damage to GRP or polyurea jackets can all be repaired on site. Depending on the operational and safety requirements, certain repairs can be carried out while the vessel remains in service.
Retrofit is not simply a repair of existing problems; it is a long-term upgrade that restores thermal performance, prevents corrosion and stabilises the operating conditions of the system. With a watertight insulation design, maintenance is minimal and the system remains reliable for decades.
For vessels experiencing increased heat loss, corrosion under insulation or rising fuel consumption, retrofit with a bonded pre-insulated pipe system remains one of the most cost-effective solutions available.
To evaluate the potential benefits for your vessel, we prepare detailed heat-loss calculations based on a few operational parameters. With this information, we can determine the expected reduction in heat loss and estimate how many operating hours are needed to pay for the retrofit.
For operators seeking a reliable and efficient upgrade to ageing piping systems, LR Marine provides proven retrofit solutions backed by decades of experience in marine insulation technology.