The splash zone has long been one of the most demanding environments in offshore operations. Constant exposure to wave loading, corrosion, and structural movement puts sustained pressure on Caissons and Conductors , often leading to wear, reduced performance, and ongoing maintenance challenges.
Traditional solutions such as mechanical shims and centralisers have struggled to consistently perform under these conditions, particularly on ageing assets. AquaShim was developed to change that. Over the past decade, it has evolved from an engineering concept into a proven offshore solution shaped by rigorous design, testing, and real-world application.
Meeting the needs of a changing industry
As offshore infrastructure continues to age, operators are placing greater emphasis on solutions that reduce intervention, minimise risk, and extend asset life. Today’s stabilisation systems need to deliver long-term reliability with minimal maintenance. That’s where AquaShim stands apart. With ten years of development and deployment behind it, AquaShim has built a track record that gives operators confidence, not just in theory, but in practice.
From concept to offshore reality
Development of AquaShim began in 2017, with a clear objective: to rethink how conductor stabilisation is achieved in the splash zone. Rather than relying on rigid interfaces, AquaShim was designed to accommodate movement and reduce wear, addressing the root causes of failure seen in traditional systems. Backed by detailed design modelling, FEA analysis, and material testing and supported by funding from the Oil and Gas Technology Centre in 2018, the concept quickly moved towards offshore application.
The first installation in 2019 marked a key milestone, transitioning AquaShim from development into live operational use.
As AquaTerra’s Technical Manager, Kevin Nelson, explains:
“It is easy to underestimate the time required to develop a product from concept through to offshore application. AquaShim has evolved through continuous design work and practical experience over several years.”
Proven performance in the field
Since its first deployment, AquaShim has been installed across 78 systems on a wide range of offshore assets. Each installation has contributed to ongoing refinement, ensuring the solution continues to evolve based on real-world performance. By distributing load and accommodating movement within the splash zone, AquaShim reduces wear between components and supports long-term structural stability. Importantly, it also avoids the limitations of rigid or bonded systems, offering advantages during operation and also also when it comes to future decommissioning.
Delivering results offshore
AquaShim has been successfully deployed across a variety of offshore environments, with each installation tailored to specific asset requirements. On the Piper Bravo platform, AquaTerra was tasked with resolving failures in steel centralisers that had caused significant wear to both the guide and caisson. Installation was further complicated by existing welded steel bands. Through onshore trials and close client collaboration, an offset liner solution was developed. Using prefabricated urethane spacers and a full 360-degree urethane pour, AquaShim delivered effective centralisation and eliminated further wear.
The project, which included removal of existing centralisers, lift planning, and installation of four bespoke systems, was completed successfully and in line with the agreed plan. On the Claymore platform, AquaShim was deployed following repeated failures of previous mechanical and smart shim systems, which had resulted in ongoing conductor damage.
In 2021, two AquaShim systems were installed by a four-person team over seven days. The fully managed scope , from design through to installation, delivered a long-term stabilisation solution with no ongoing maintenance requirements.
A decade of progress, and counting
From its early development in 2017 to 78 successful installations, AquaShim has been shaped by continuous innovation and proven performance in the field. Today, it stands as a reliable, field-tested solution for splash zone stabilisation ,helping operators protect critical infrastructure, reduce maintenance demands, and extend asset life.
And as offshore challenges continue to evolve, AquaShim continues to evolve with them.