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SURFACE PROTECTION CUSTOMER MAGAZINE BY FSP 1/2016

➤ New paint system for Valmet

Hiab skiploader production process optimized

➤ Luxury cruiser Silja Serenade surface treated ➤ Caverion’s gas pipe project went swimmingly

For Surface Protection is the stakeholder magazine of FSP Finnish Steel Painting Oy

Hiab skiploader production process optimized

contents

Content and visual design Viestintätoimisto VCA Oy

Cover photo Antti Verkasalo / VCA Oy Headquarters Kalliosolantie 3 FI-01740 Vantaa Tel. +358 9 278 6270

Caverion’s gas pipe project went swimmingly

4 © Merja Ojala

Printing house Savion Kirjapaino Oy

www.fspcorp.com

Founded in 1964, FSP Finnish Steel Painting Oy is one of the leading surface treatment providers in Northern Europe. It offers surface treatment services for machinery, equipment, ships, bridges, storage tanks, steel structures and off-shore equipment on a turnkey principle. The company follows strict quality, environmental, occupational safety and health standards. In 2015, FSP's turnover was about Meur 23. FSP employs over 200 surface treatment specialists in 30 painting shops in Finland, Sweden, Norway, Estonia and Poland.

Luxury cruiser Silja Serenade surface treated

Researching pretreatment and acid dipping

8 © Pekka Leino

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10 © TVO

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editorial

Steps in a new direction DEAR PARTNER, THIS YEAR WE HAVE TAKEN SIGNIFICANT STEPS TOWARDS A NEW DIRECTION. HERE, I WILL HIGHLIGHT THREE OF THOSE STEPS. Firstly, our modern surface treatment facility in Northern Poland is now operational. Now FSP has two surface treatment facilities in Poland, in the city of Stargard Szczeciński, one of which is located in the Cargotec factory facilities and the other in the facilities of a factory built by Hydroline. We are happy to see that volumes are increasing. In addition, the production facilities enable us to provide other customers within the area with surface treatment services, as well. Secondly, this year we have renewed our business structure in Finland and in the international market. The objective of the new organisation is to achieve the strategic goals, develop new operating methods and services, and to ensure the adequacy of sales and marketing resources. The main goal is to answer the current market situation at a global scale. Thirdly, there are strong indications that the investments have started to have effect. This is seen in, among others, the manufacturing industry and project operations. Consequently, the investments have also boosted the surface treatment services. On these pages, we present our latest company news and case stories. Pages 4–7 present our partnership with Cargotec. FSP developed surface treatment processes at the Cargotec production facility to meet the needs of the new skiploader as extensively and cost-efficiently as possible. We are constantly developing new surface treatment methods through collaboration. Pages 12–13 show how FSP is involved in two extensive surface treatment testing projects focused on passivation, acid dipping and pretreatment methods. The goal is to receive reliable, common research data, but also to compliment FSP's range of services. Now we are well-prepared and ready to take first steps in the new direction. See our For Surface Protection magazine, in which we present our industrial surface treatment expertise in offshore business, surface treatment facilities, Engineering specialist services and project operations. Our goal is to be a local partner in the international market areas. Contact us and we are happy to tell you more. Best Regards,

Pentti Virtanen CEO FSP Finnish Steel Painting Oy

Follow up on our company news on Facebook, as well. Click the link on the fspcorp.com main page or directly on Facebook.

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case

New-generation skipload optimised production pro

Juha Mäkelä (left), Jari Vehmas, Seppo Tuomaala, Simo Sorjonen and Tom Eriksson were involved in the development project aimed at creating an optimised production process for the skiploader.

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©: Antti Verkasalo

der gets ocess Hiab, part of the Cargotec group, introduced the new generation Multilift Future skiploader to the market in 2015. In connection with the launch, FSP developed surface treatment processes at the Raisio production facility to meet the needs of the new machine as extensively and cost-efficiently as possible.

ari Vehmas, Production and Logistics Manager of Cargotec's Multilift production facility in Raisio, has been satisfied with the co-operation with FSP in the production of the Multilift Futura skiploader. This was a significant launch, in which Hiab renewed a previously manufactured machine to a whole new level. "The new solution has over a hundred smart innovations that will lift the machine's efficiency, safety and flexibility to a whole new level," Vehmas explains. The new features include, among others, the

re-designed, light and durable EvoLight steel structure, which makes it possible to move loads even 300–500 kilograms heavier than before. The innovative SwanNeck solution extends the reach of the skiploader without disturbing the stability of load handling. The system is developed especially for challenging environments, such as narrow streets, and it makes it possible to handle bigger loads and improve fuel efficiency. The demanding environment has set high quality requirements for the surface treatment process, as well.

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©: Cargotec

case

Multilift Futura • New-generation skiploader. • Includes over a hundred new innovations. • Enables handling of bigger loads and improves fuel efficiency. • Raises efficiency, safety and flexibility to a new level. • Re-designed, light and durable EvoLight steel structure. • Extends the reach of a skiploader without disturbing the stability of load handling. • Suitable for challenging environments.

Cargotec Oyj • Leading provider of cargo and load handling solutions. • Business areas MacGregor, Kalmar and Hiab are known for leading solutions in the field of cargo and load handling. • Operation in more than one hundred countries. • Turnover EUR 3.4 billion (2014). • Employs approximately 11,000 people.

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FSP involved already during development stage FSP was closely involved with the Hiab Multilift already during the development stage at the Raisio production facility. "The objective of the project was an optimised production process, in which the skiploader proceeds from manufacturing to the surface treatment phase in a cost-efficient manner and according to the queue-controlled production schedule," describes Vehmas. To start the development project, the partners first went through the designs and discussed how surface treatment would be intertwined with the assembly line. From Cargotec, the development project was attended by, among others, Tom Eriksson and Juha Mäkelä from the Production Development Unit, and Mechanic Seppo Tuomaala. From FSP, the project was participated in by Head of Unit Marko Heininen and Foreman Simo Sorjonen from the Raisio facility. According to Vehmas, the development collaboration ran smoothly, as FSP has already

been working closely with the Hiab Multilift in the Raisio facilities. FSP's surface treatment operations have been tightly integrated in the Hiab Multilift assembly line in Raisio. FSP is in charge of the surface treatment of demountables at the Raisio factory. The welded and machined structures are transported on a line through shot blasting and anti-corrosive coating directly to the assembly line. "As a result of the development work, customised transport carts and hangers were developed specifically for the new skiploader. The role of the carts is to take the machine parts from the surface treatment process to the assembly line unharmed,” Eriksson explains. Hangers are needed when the machine parts are hung on the line where they get surface treatment, stage by stage. Ovens in the surface treatment process shorten the drying time of epoxy and polyurethane based coatings, and reduce lead times.

The skiploader parts get a durable surface treatment at the Raisio production facility.

Good communication Vehmas appreciates three characteristics in FSP’s operation. As one key feature he points out good communication, in which partners can openly ask each other for development ideas regarding future projects in a "how about this -style". The second significant characteristic results from a controlled supply chain, accurate daily steering, and short lead times. An optimised production process time has been set for the skiploader, and it is approximately 2–3 days. "Skiploader parts are delivered to the assembly line for each machine at the exact right time. For this reason, surface treatment must be carried out in the supply chain quickly and as planned. We are aware of the progress of the line system with the accuracy of one hour," Vehmas explains and continues that exact delivery times have been set for finished products. The functionality and lead time of surface treatment are monitored in daily meetings, in which the production progress of each day is discussed in detail. Careful controlling of surface treatment decreases also the need for repair painting. Hundreds of demountables are produced at Hiab's Raisio facility each month.

Mechanic Seppo Tuomaala from Hiab, a part of the Cargotec concern, assembling a skiploader.

According to Vehmas, the third key characteristic is expertise, which ensures the quality of products and security of supply. Constant quality development FSP's Raisio facility has introduced the 5S concept which is aimed e.g. at boosting work efficiency and is a part of the so-called Lean management ideology.

FSP Foreman Simo Sorjonen states that the goal is to further improve quality, lower the operational costs and shorten the surface treatment lead times. Hiab's load handling solutions are used in various sectors of the transport field, including construction, forestry, recycling, distribution and the defence sector. ■

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©: Merja Ojala

case

Gas pipes of Naistenlahti got durable coating Gasum introduced a new natural gas transmission pipeline in Tampere between Santalahti and Naistenlahti in the fall of 2015. The massive project set high quality requirements for surface treatment, as the pipeline structures were placed at the bottom of the Näsijärvi lake at the depth of about 30 metres. In addition to the quality of surface treatment, the key features in the project were flexibility and reliability.

n the view of Pekka Myllymäki, Purchasing Manager of Caverion Industria Oy, top-quality surface treatment protects pipes from constant moisture stress, prolongs their lifespan and increases the maintenance interval. The mechanical installation contractor for the natural gas pipeline construction project was Caverion Industria, who chose FSP

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Finnish Steel Painting Oy as its surface treatment partner for the project. FSP has been in charge of the surface treatment of pipe elbows and T-pieces. According to Myllymäki, the project placed strict requirements with regard to quality, documentation, occupational safety and environmental concerns. "Strict standard requirements were set for

The especially large pipe elbows got a top-quality surface coating at FSP's surface treatment facilities in Tampere and Porvoo.

From FSP surface treatment facilities, the pipe bends were transferred to Tampere to the Santalahti prefabrication area, where they were welded, concreted, floated by water to Naistenlahti and then sunk to the bottom of Lake Näsijärvi.

Caverion Oyj • Designs, builds, operates and maintains technical solutions for properties and industries. • Services are used in offices, business facilities, apartments, public buildings, infrastructure and industrial facilities. • Turnover of EUR 2.4 billion (2014).

the surface treatment of the steel structures of the pipes. The pipes were coated with a sturdy 1,500-micrometre layer of epoxy coating," explains Myllymäki. Quality, flexibility and reliability Myllymäki sees three key characteristics in FSP's operation that ensure top-quality surface treatment results. The first is, of course, expertise, which is evidenced by FSP's strong references from previous decades. "FSP has long been a good partner, with whom we have carried out demanding and large-scale surface treatment projects. FSP's surface treatment facility in Porvoo had experience of Gasum's requirements," explains Myllymäki. The second key feature, in Myllymäki's view, is flexibility, which becomes ever more important as the work load increases. It is essential to keep up with the delivery schedules due to the hectic atmosphere at the worksite. The worksite requires all

contractors to understand the nature of project deliveries. "Co-operation has been smooth during the project. Flexibility has been there, even in urgent cases," says Myllymäki. The third key characteristic is reliability, because the surface treatment work is carried out according to strict standard requirements. "FSP has experience of producing surface treatment solutions for demanding conditions. We also have faith in them on a personal level. FSP delivers as promised," Myllymäki says. Myllymäki appreciates FSP's vast size as the surface treatment partner, as the company can be entrusted with demanding coating work along with the related inspections and reporting. The near-by location of FSP's surface treatment facilities played also a part in the accomplishment of a good end result. ■

• 17,000 employees in 12 countries in Northern, Central and Eastern Europe. • Head office in Helsinki.

The project group • City of Tampere as the final customer. • Gasum Oy as the developer and Maanrakennusliike E.M. Pekkinen Oy as the main constructor. • Caverion Industria Oy project services as the mechanical installation contractor and Finnsukellus Oy as the water system contractor. • Dekra Industrial Oy as the structure inspector. • Gasum Tekniikka Oy as the performer of cathodic protection work. • FSP Finnish Steel Painting Oy as the surface treatment contractor.

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case

Karri Lempinen acted as the FSP Supervisor in the demanding surface treatment contract for Silja.

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©: Pekka Leino

Silja Serenade received surface treatment in Rauma The maritime company Rauma Marine Constructions Oy carried out modernisation work on the shipping company Silja Line's m/s Silja Serenade at the Rauma shipyard in late 2015. FSP was in charge of the surface treatment work on the passenger ferry's interior areas, such as tanks.

rto Vainiola, Project Manager for Rauma Marine Constructions Oy which was the company in charge of the vessel's technical docking, is satisfied with the partnership with FSP. "We already have a long history of co-operation with FSP at the Rauma shipyard. For this reason, FSP was the natural choice as our surface treatment partner," Vainiola explains. "Surface treatment plays an important role in this kind of modernization project. In addition, the amount of work increased slightly during the contract," continues Vainiola. This technical docking was part of Silja Serenade's maintenance program, and in connection to the docking, the vessel operating between Helsinki and Stockholm went through many modifications and lots of technical work, the results of which are visible to passengers. For the contract period, the vessel was moved to the Rauma shipyard's dry dock with closed gates. Surface treatment on tanks and deck To entertain child passengers, Silja Land was built on the ship. The room surface of the play and activity area is approximately 300 square metres. The vessel's café and restaurant areas and meeting facilities were also improved and renewed. All of the vessel's 60 delux cabins were completely refurbished from top to bottom. The modernization contract was carried out on a tight schedule, during a period of approximately two weeks. Silja Serenade, known for its Promenade

deck stretching almost the entire length of the ship, returned to operation after the modernisation work on 23 November 2015. The previous time Silja Serenade went through significant modifications was in early 2014. During the surface treatment contract, FSP was in charge of the sand blasting and coating work on e.g. three drinking water tanks, a biowaste tank, two ballast tanks, and two cofferdams serving as auxiliary void spaces. The contract also covered cleaning and coating work on the car deck. The scale of the contract is evidenced by the fact that FSP had at most as many as 25 surface treatment workers on the vessel. The people responsible for the project were Supervisor Karri Lempinen, Site Engineer Mikko Ala-Kauppila and Project Engineer Janne Heimonen. Flexibility is essential "During the project, flexibility emerged as the key feature, because we carried out all the surface treatment work during 13 days. We did surface treatment work in three shifts, also during the weekends. We practically worked day and night," says Lempinen. "The work progressed in accordance with the exact order and schedule we had agreed upon. Thanks to the top-quality surface treatment, the tanks and the car deck got a durable coating which will protect the surfaces against corrosion in the damp conditions of the Baltic Sea," says FSP Project Leader Juha Granholm.

During 2015, FSP has completed other surface treatment contracts at the Rauma shipyard, as well. For example, FSP has been in charge of surface treating the front, deck structures and interior areas, such as tanks, of the icebreaker Otso and oil recovery vessel Louhi. ■ Rauma Marine Constructions Oy • Established in 2014 to continue the shipbuilding tradition in Rauma. • Finnish-owned maritime industry company. • Operational model emphasises strategic partnerships. • Focus on building off-shore structures, passenger ferries and special-purpose vessels such as icebreakers and Navy vessels.

Silja Serenade • Operates the route between Helsinki– Mariehamn–Stockholm under the Silja Line brand. • Completed in 1990. • Length 203 and width 31,5 metres. • Passenger capacity of 2,852. • Vehicle capacity of 95 passenger cars and 60 trucks. • Number of decks 13. • Sister vessel M/S Silja Symphony. • Owner AS Tallink Grupp.

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research & development

New surface treatment features through co-operation FSP is involved in two extensive surface treatment testing projects focused on passivation, acid dipping and pretreatment methods. The goal is to receive reliable, common research data, but also to discover new features to compliment FSP's range of services.

uring spring 2016, the focus is on studying acid dipping and passivation methods of stainless steel. Parties involved are FSP’s customer Outotec, Savonia University of Applied Sciences, and the commissioner of the analyses, Somotec. During the project, tasks are distributed so that Outotec supplies the welded steel material to FSP, who then performs surface treatment on the pieces and delivers them to Savonia for analyses. Along with the project, a diploma work in machine and production engineering will be completed. Acid dipping and passivation are carried

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out at FSP's production facility in Outokumpu, and pretreatment testing is done in Kuopio and Jyväskylä. "Outotec has provided us with steel pieces of different sizes welded together, which we will subject to the following treatments: cleaning the welding seams by brushing, washing the pieces, acid dipping and passivation. There are at least two cleansing phases. The surface of the piece is evaluated between the different treatments by a visual inspection, but Savonia will then perform the actual analyses," says COO Jarno Huttunen.

Producing quality faster and with respect to the environment Acid dipping is a familiar treatment method for FSP. It was used to e.g. ensure the corrosion resistance of fuel storages at Olkiluoto 3 nuclear power plant. "Passivation is more of a new procedure for us, and one we can offer our customers in a more extensive manner in the future. Passivation protects and strengthens the surface layer of steel." The other testing project was started in late 2015. The project is carried out in collaboration with the industrial gear unit manufacturer Santasalo Gears Oy and the

Acid treatment can be done for instance by dipping or spraying. FSP has performed succesful acid treatment at the international Olkiluoto nuclear plant project.

chemical supplier Candor, and the focus is on studying the use of zirconium-based products in pretreatment. "The primary question is how the traditional iron phosphating method could be replaced with a nanoceramic i.e. zirconium coating. The benefits of zirconium treatment include excellent anti-corrosive properties, better paint adhesion and environmental sustainability. The treatment is carried out in room temperature, which reduces heating costs and water consumption. In addition, less sludge is produced, which reduces the maintenance costs," lists Huttunen. Zirconium has traditionally been used in e.g. dental medicine, but it is not a completely new product in the surface treatment industry, either. FSP has used zirconi-

um-based coatings in, for example, the surface treatment of cylinders. "The tests performed so far have shown that zirconium has good tensile strength properties and it improves the quality of the paint work. It also provides better corrosion protection. A more extensive industrial launch of this substance is merely a matter of time. Authority approvals and inspections take their time; it is not a question of price or processing problems," Huttunen clarifies. ■

Acid dipping and passivation • Acid dipping, or chemical pre treatment, removes a thin oxide layer from the surface of stainless steel. This ensures that the metal endures the welding stage, during which it is heated strongly. Untreated welding seams are particularly vulnerable to corrosion, which makes acid dipping an essential work stage. It also removes any surface impurities. • Steel is a passive material by nature: the alloy elements on its surface form a transparent surface, which is renewed by the effect of oxygen in air or in water. In other words, in this situation passivity means selfrepairing. If, for some reason, steel loses some of its corrosion resistance, then it is a case of activation. Passivity can be improved with the help of an oxidising acid – for example nitric or citric acid.

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Dubai's lighting poles get special coating

©: Tehomet

news

FSP is in charge of the special effect coating work on the steel parts of lighting poles for the Dubai zoo, and the work is carried out at Tehomet's modern production facility in Kangasniemi.

architecturally impressive look. The first stage of the ongoing project will be completed in late 2016, when the Dubai Zoo is to be opened," says General Manager of Tehomet Group, Jarkko Kettunen. The surface treatment work is carried out at the Kangasniemi production facility. The benefits of powder coating include short production lead times, environmental friendliness and anti-corrosive properties. "The powder coating line gives us versatile capacities to offer top-quality surface treatment on a tight schedule. A product that has been powder coated in the morning is ready to be packed and delivered by noon, due to the short drying time of the paint," explains Lauri Leppänen, Supervisor at FSP Finnish Steel Painting Oy. ■

FSP gives VR Group more visibility IN DECEMBER 2015, THE NATIONAL RAILWAY COMPANY (VR) AND FINNISH STEEL PAINTING OY, LAUNCHED A COLLABORATION PROJECT. In the next three years, FSP will provide a specialised surface treatment service, in which the safety handles in VR’s freight train fleet will be equipped with a bright yellow coating. The role of the coating is not only to protect the stainless steel handles but to give them increased visibility. The project comprises 15 000 handles that come in 20 different shapes and sizes. The coating used is a specialised Plascoat product, which offers an anti-bacterial, anti-corrosive and colour-tenable end result and is also environmentally friendly. The powder paint does not have any organic volatile compounds and moreover, it dries very quickly. The VR project is carried out at FSP’s Kangasniemi facility, which specialises in powder coating solutions. ■

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nvironmentally friendly powder coating is utilised as the surface treatment method, and it gives the poles' pipe bases and upper joints a bronze special effect finish. Tehocoat powder coating makes the surface of the poles visually impressive, durable and elastic. This surface treatment project is part of the largest single wooden pole order in Tehomet Group's history, under which Tehomet will deliver 788 ornate wooden columns equipped with solar panels, as well as steel light fitting arms, to the Dubai Zoo in the United Arab Emirates. "Orders for effect surfaces and special coating are increasing constantly, both in the domestic and the international market. Effect coating gives a pole's surface an

VALMET COMMISSIONED A NEW STANDARD PAINT SYSTEM IN ITS FACILITIES AT THE BEGINNING OF 2016. Sami Pappinen, surface treatment expert in the Paper business line, believes that the new standard paint system will reduce production lead times with as much as 25 percent when compared to the previous system. In the definition phase of the new paint system, Pappinen acquired professional services from FSP. "During the project, we were in positive and flexible collaboration with various FSP surface treatment experts," describes Pappinen. The new standard paint system was preceded by an extensive testing phase, when the products of different paint factories were tested in laboratory conditions. In collaboration with the paint suppliers, Valmet studied e.g. how well the paints were suitable for the paint system and how they met the standard requirements. In addition to quality, the requirements included painter-friendliness, ease of use and availability. Pappinen sees two benefits in the modification project. Firstly, the new paint system utilises to a larger degree the environmentally friendly epoxy and polyurethane paints, which have a high content of dry solids. Secondly, the number of paint layers is reduced due to the modification, which again speeds up the process, boosts productivity and cuts total costs. In Pappinen's view, top-quality surface treatment plays an important role with regard to the end product. The product must have chemical durability and anti-corrosive properties in different temperatures. ■

Stena Oil gets Humidor treatment THE SWEDISH OIL TRANSPORT AND STORAGE COMPANY STENA OIL HAS ORDERED AN OIL TANK SURFACE TREATMENT PROJECT FROM FSP. The work consists of cleaning and surface treating the inside of the oil tank, which is located off the Gothenburg port area. The project is carried out by FSP's Swedish branch office FSP For Surface Protection. Project Manager Ismo Rönkkö says that the one month has been allocated for the work and it will employ four surface treatment specialists and a supervisor. The project was started at the end of March. The oil tank, constructed about 100 years ago, is rivet-jointed and ten metres high. Its diameter is 28 metres. The coating system used is Humidor, a liquid epoxy compound that has been designed for the extremely demanding maritime conditions. The product is also used in the protection of industrial waste water tanks, so its anti-corrosion properties are very high. Another benefit is that as a solvent-free liquid, it dries very quickly. When dry the product remains elastic. The required coating thickness is achieved by just one treatment. ■

New standard paint system for Valmet

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FSP Finnish Steel Painting Oy Kalliosolantie 3 FI-01740 Vantaa Tel. +358 9 278 6270 www.fspcorp.com

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A longer life span

Our industrial surface treatment, engineering and added-value services are well-acknowledged both in Finland and internationally. We offer surface treatment services for machines, equipment, ships, bridges, storage tanks, steel structures, oil and gas drilling rigs on a turnkey basis. We help you save time and focus on your own core competence and its development.

We use non-polluting working methods, we recycle and we practise safe storage techniques. We follow quality, environmental, industrial safety and health standards ISO 9001, ISO 14001 and OHSAS 18001.

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