2/2017 For Surface Protection

FOR

SURFACE PROTECTION CUSTOMER MAGAZINE BY FSP 2/2017

Fireproofing for biggest LNG container in Nordic Countries

➤ New technology enhances protection of railway bridge

➤ Growth in Poland

➤ High-quality ARC coating for harsh conditions

➤ Occupational safety at excellent level

contents

For Surface Protection is the stakeholder magazine of FSP Finnish Steel Painting Oy, published three times a year.

Content and visual design Viestintätoimisto VCA Oy Printing house Savion Kirjapaino Oy Cover photo Jouni Porsanger / Lapin Kansa Headquarters Kalliosolantie 3 FI-01740 Vantaa

www.fspcorp.com

FOR

SURFACE PROTECTION FSP Finnish Steel Painting Oy is one of the leading industrial surface treatment and value-added service providers in Northern Europe. Instead of the traditional surface treatment work, our future focus areas will be more on developing our production and services and offering new techniques and technology. As a result, our customers gain advantages such as improved competitiveness required in market leadership. We strictly adhere to quality, occupational safety, health and environmental (QHSE) requirements. FSP employs over 220 professionals in about 20 surface treatment facilities in Finland, Poland and Estonia, and has a turnover of around €23 million.

2

➤ FOR SURFACE PROTECTION

New technology enhances protection of railway bridge

4 Fireproofing for biggest LNG container in Nordic Countries

8

Growth in Poland

11 10 High-quality ARC coating for harsh conditions

12

editorial

New, innovative FSP Dear Customer, this year we have reformed our organisation and boosted our innovation activities. Our objective is to respond to the structural change in the industry by listening to our customers even more carefully than before.

Instead of the traditional surface treatment work, our future focus areas will be more on developing our production and services and offering new techniques and technology.

Our growth areas will in the future include powder coating, fireproofing, polyurea coating, insulation coating, special effect coating and thermal spraying, as well as other special coatings.

As a result, our customers get benefits such as improved competitiveness, shorter lead times and increased productivity. The innovations have also a positive influence on our personnel and the environment through sustainable development.

In the new FSP, the organisation is merged into one field which is then divided into two production sectors. Despite the changes, we will continue to do surface treatment on project sites and offer Engineering services with a specifically assembled organisation.

These pages offer a fresh insight into our innovations. On pages 4–6, we present the new technological solutions that we utilised in the surface treatment contract for the Lontilanjoki railway bridge. Pages 8–9 provide information on the fireproofing work that we completed for the largest liquefied natural gas container in the Nordic Countries.

Pages 10–11 include descriptions of the brand new type of production simulation we used during the ramp up process at our Polish factories. This helps us to guarantee not only top quality but the security of supply as well.

In the spring of 2017, we also opened a new surface treatment facility in Lappeenranta, where we have strong ARC coating experience in addition to the acid pickling and painting operations. Read more about the new plant on pages 12–13, where we also introduce our brand new pilot product, an innovative coating solution for thermal insulation.

We know our history since the establishment year of 1964, but we turn our eyes towards the future. We guarantee our customers the latest methods and technologies in the field of industrial surface treatment.

I welcome you all to meet us at the Subcontracting Fair in Tampere, Finland, at our department C 1019. You are also welcome to contact us for more information.

Pentti Virtanen CEO FSP Finnish Steel Painting Oy

Follow up on our company news on Facebook and Linkedin, as well.

Click the link on the fspcorp.com main page or directly on Facebook and Linkedin.

FOR SURFACE PROTECTION ➤

3

Photo

case

: K ai F ilppu la

4

➤ FOR SURFACE PROTECTION

New technologies bring improved protection for Lontilanjoki bridge New technological solutions have been utilised to protect the concrete and steel parts of the Lontilanjoki railway bridge in Akaa in Southern Finland. The innovative surface treatment job was completed in compliance with the strict quality, occupational safety, and environmental requirements.

The main contractor for the railway bridge is Finland’s leading infrastructure builder Kreate Oy. According to Kreate Site Manager Antti Kokkonen, co-operation has run smoothly with FSP, who is in charge of the surface treatment. Surface treatment work on the railway bridge was started in June, and despite the demanding working conditions, the project is progressing on schedule and the results have met the expectations. FSP was chosen for the job through a call for tenders.

“Price-quality ratio, strong expertise and previous good experiences flipped the scales for FSP,” Kokkonen describes the early stages of the project.

“We accepted the Lontilanjoki railway bridge

challenge with enthusiasm. FSP has a long and well-established history of bridge surface treatment, both in Finland and in the Nordic Countries,” says FSP Project Manager Pasi Kovalainen.

Covers to protect the environment The surface treatment project was initiated after Midsummer, when FSP started cleaning the badly rusted grids between the steel beams underneath the bridge by sand blasting. Before anything was done, scaffolding was set up around the railway bridge and covers put in place to protect the environment.

FOR SURFACE PROTECTION ➤

5

case

According to Kreate Site Manager Antti Kokkonen, the cornerstones of collaboration with FSP included environmental aspects, occupational safety, reliability of delivery, and quality. tos Pho

: Ka

i F il

ppu

la

“It was high time to do surface treatment on the bridge, as it has not been maintained since it was built in 1992. The steel structures of the bridge were in a horrible condition due to waterproofing damages,” explains Kokkonen.

During the project Kreate was in charge of the basic repairs done on the concrete parts and decks of the bridge, including the renewal of waterproofing. FSP was charged with the surface treatment of the steel beam structures beneath the bridge. The surface treatment work covered, among other things, repair work that included rounding the corners, washing, shot blasting and a triple-layer coating. The surface was finished with a beautiful bluish-grey paint.

Flexible operating methods

FSP was charged with the surface treatment of the steel beam structures beneath the bridge.

6

➤ FOR SURFACE PROTECTION

In this project, occupational safety was of vital importance, as the railway bridge was constantly used during the maintenance work. The bridge is located on the route of trains going to Turku and Helsinki, and as many as 150 trains cross the bridge each day. For this reason, each worker completed a railway safety training before the project was started. At most, there were 30 professionals working at the site.

In addition to environmental features and occupational safety, Kokkonen states that it was the security of delivery and quality of the work that formed the foundation for the co-operation.

“FSP has surface treated the steel structures in a reliable manner and therefore we have been able to complete the project on schedule. The work progressed smoothly, even despite the fact that we had to suddenly change the painting

system, which resulted in there being more surface treatment work than we had estimated,” explains Kokkonen.

The project was not slowed down even by the rainy July, as the railway bridge was covered with tarpaulins. Six blowers speeded up the drying.

Innovative execution Kokkonen underlines that the surface treatment project included also innovative execution methods. While treating concrete, FSP utilised e.g. impregnating agents and anti-graffiti agents which it has used in bridge surface treatment for a long time.

This approach was based on the fact that concrete is a porous material. For example, water is absorbed into concrete, which causes the surface of the concrete darken substantially. For this reason, the surface treatment work was complemented with impregnating agents that do not significantly change the colour of the concrete in comparison to a dry concrete surface.

The impregnating agents also prevent the water’s capillary transfer through the surface layer, and make the surface of the concrete water-repellent without forming a membrane on the surface.

The purpose of the anti-graffiti agents was to prevent the paints and markers used in doodling from absorbing deep into the concrete, thus limiting the need for cleaning to the surface of the concrete. As a result, the doodles are easily removed from the protective agent.

news

Porvoo’s strength lies in overall services This year, FSP’s Porvoo units have completed various overall service projects.

The ongoing year has been particularly busy at the Eerolanmäki and Nyby surface treatment facilities, as well as on site at our customer locations.

“We have taken on a lot of responsibility of different value-added services. In addition to traditional surface treatment, we have focused more on developing our overall services and offering new methods and technologies,” says Henri Kiminki, FSP Project Manager in Porvoo.

“We are able to offer, for example, small-scale steel structure reparations and welding, as well as fireproof coating. We do surface treatment work even on large structures, either in our facility, at the customer’s facilities or on site at the project location. We are flexible and offer everything from pipeline coatings to special effect coatings,” Kiminki sums up.

“The overall service concept has received a positive response from our partners. We have signed new multi-annual agreements for surface treatment with Borealis and Neste,” Kiminki continues.

This year, FSP has completed e.g. several surface treatment projects for containers and pipelines as well as maintenance paintings.

In addition, FSP has carried out maintenance painting at the KPP power plant co-owned by Neste, Borealis and Veolia, which is currently

”This year, FSP has completed e.g. several surface treatment projects for containers and pipelines as well as maintenance paintings.”

reaching its rooftop height. The key element has been short lead-time, which has been developed further.

“Neste is a demanding client in a good way, as they make us continuously develop our occupational and environmental safety.”

FSP has also carried out pipeline coating projects and maintenance painting during the major shutdown at the chemical company Borealis. Workers were then able to reach process locations that are inaccessible during a normal visit. The contract included e.g. surface treatment work on a 43-metre long factory hall column.

A slightly more special project comprising the surface treatment of a sea buoy was commissioned by the Finnish Transport Agency. The target was a buoy steering traffic outside Harmaja, and more precisely its underwater steel structure, which must resist the corrosion caused by sea water. In such cases, the surface treatment work must meet extraordinarily high expectations, as a sea buoy needs to endure the stress caused by the harsh operating environment.

“We have also performed surface treatment on lighting columns in the Kalasatama art district, and continued the park bench project commissioned by Stara, where the legs of park benches are given a surface coating to make them look like birch trees.”

“We offer our services flexibly for the entire Helsinki-Uusimaa Region, as well.”

FOR SURFACE PROTECTION ➤

7

case

Fireproof coating for largest LNG container in Nordic Countries The Nordic Countries' largest liquefied natural gas container has been erected this year in Röyttä, Tornio, located on the shore of Bothnian Bay in Northern Finland. The diameter is approximately 43 metres and height 50 metres. FSP performed fireproofing on the tank top process module installed on top of the container.

According to Esa Räihä, Project Manager for Caverion Industria Oy, FSP was a natural choice as the partner, as Caverion and FSP have previously worked in close co-operation.

“We chose FSP to carry out the fireproofing project because FSP is a reliable partner and the industrial leader in Finland,” Räihä sums up and continues that the two partners collaborate closely also in the Arctic 6 sales organisation.

The main contractor for the liquefied natural gas container was Wärtsilä, who had then selected Caverion Industria to build and assemble the steel structures and pipe system for the container. The estimated costs for the massive contract were approximately 100 million euros.

The main user of the natural gas will be Outokumpu’s Tornio steel mill, but the terminal will be open for the industrial operators, mines and other gas users in the area as well.

“Fireproofing was carried out in accordance with the fire load instructions issued by the Finnish Safety and Chemicals Agency, Tukes. The basic principle was that the steel structures must

8

➤ FOR SURFACE PROTECTION

have adequate load bearing capacity in case of fire,” explains Räihä.

Multi-phase task The project was started in the fall of 2016 at FSP’s surface treatment plant in Raahe, where the steel structures got a fireproof coating. Next, Caverion assembled the structures into a module in Rahja, and they were transported by sea on a barge to Tornio.

Possible damages caused during transport were repaired with touch-up paintings on site in Röyttä, Tornio, once the module had been lifted on top of the round container, 50 metres above the ground.

The volume of the entire gas container is approximately 50,000 cubic metres. When gas is transported to Röyttä in Tornio, it is stored, and can then be vaporised back into natural gas. The terminal also has two natural gas refuelling stations for tank truck deliveries.

The primering and fireproofing provided the structures also with adequate protection against

rion : C ave Pho to

corrosion. At the end of the project, FSP submitted documentation on the performed fireproofing procedures.

The tank top module under treatment was lifted onto a round container, 50 metres above-ground.

Surface treatment on a tank top module The tank top module, which was the target of the surface treatment project, contains process pipe systems that transport liquefied natural gas chilled to -162 degrees Celsius. By converting gaseous natural gas into liquefied form, the volume can be reduced into approximately one sixth, which makes transporting the gas by LNG vessels and storing it much easier and more cost-effective.

There are grand expectations for natural gas in the future. It is going to be utilised in marine traffic as well as in large-scale industries. Natural gas can be used to replace liquid gas in industrial processes and fuel oil in heat generation, and it is also used as fuel in land and maritime transport.

Terminal commissioned in early 2018 The first gas vessel is scheduled to arrive at the Tornio terminal in November 2017, and the actual delivery to the owner of the terminal will take place in early 2018. The terminal is owned by Manga LNG Oy, whose customer base includes Outokumpu Oyj, SSAB, Skangas Oy and EPV Energy Ltd. The LNG terminal in Tornio provides the North with a new, clean energy option, which promotes the protection of the unique natural landscape.

During the last few years, FSP has carried out fireproofing at several locations, including e.g. the process pipeline systems at the Neste oil refinery and data centres built in Finland. In Sweden, FSP has performed fireproofing work at e.g. Volvo Penta’s facility in Gothenburg. In addition to fireproofing, FSP has also performed traditional anti-corrosive coatings at the locations.

FOR SURFACE PROTECTION ➤

9

case

Pho to : Danie l S tok ow ie c

Growth from Poland Poland offers promising prospects for the future, and we expect FSP to almost triple its business in Poland in 2018. These are the thoughts of FSP Business Director Jarno Huttunen.

10

➤ FOR SURFACE PROTECTION

The growth is originated at the two FSP surface treatment facilities in the West Pomerian Special Economic Zone industrial park in Stargard Szczeciński, Northern Poland. One of these is located in the Kalmar factory, where FSP is in charge of coating and finishing the straddle carriers and reachstackers assembled at the factory.

The other FSP surface treatment plant is located in the Hydroline Oy hydraulic cylinder plant opened in the fall of 2016, where FSP is operating the surface treatment lines. In addition to the hydraulic cylinders of Hydroline, FSP has its own line system where it performs surface treatment on the products of Cargotec and other customers.

According to Jarno Huttunen, the volumes of the Polish plants are clearly on the rise. The growing volumes will also increase the number of personnel to 40 by the end of this year. Surface treatment work is carried out in three shifts, if necessary.

drive from Stargard Szczeciński to the German border in half an hour and to Berlin in two. The entire Europe is near.

Lately, the metal manufacturing industry has seen a shift from Asia back to Europe. Countries such as Poland, Hungary and Romania are now logistically convenient. Shipping from Asia to Europe takes 6–8 weeks, whereas transport

Marcin Belgrowa works as Production Manager at FSP’s Poland facility, in which straddle carriers and reachstackers are surface treated and finished.

Innovative co-operation “FSP’s Hydroline surface treatment plant will be fully commissioned for production after product auditing, that is by the end of this year. The plant is well-equipped for a growth spurt, thanks to its two wet coating lines and one powder coating line system.”

“FSP and Hydroline have a long history of innovative co-operation, as well as a common customer base in Finland. This facilitated the commencement of co-operation also in Poland.”

“FSP will also start performing surface treatment at Cargotec facilities on new product groups, which will further increase the volumes.

The annual unit volumes will increase up to thousands.”

In Huttunen’s view, one of Poland’s most important advantages is geography. One can

”FSP and Hydroline have a long history of innovative co-operation, as well as a common customer base in Finland. This helped in launching the collaboration in Poland, as well. ”

times within Europe are merely days or hours.

Poland leads the way for quality and documentation Huttunen claims that the FSP surface treatment plants in Poland represent in many respects the top of the field.

“The level of documentation and quality control in Poland is higher than in Finland. The Polish surface treatment plants lead the way for the other FSP facilities with their good practices.

We have thus been able to harmonise the right and best practices.”

“For instance, FSP performed a production simulation with specific software during a ramp up process at the Polish factories. The objective was to find out in detail which product groups could be included in serial production and surface treatment, and with what kind of timetable and resources. This way we can guarantee our customers the best quality and security of supply, and keep our promises of agreed schedules.”

FOR SURFACE PROTECTION ➤

11

news case

High-quality ARC coating for demanding conditions FSP’s Lappeenranta surface treatment plant in Finland possesses decades’ worth of strong ARC coating expertise.

The innovative ARC coating is particularly aimed for products which must endure high temperatures and mechanical and chemical stress in demanding conditions.

“ARC coating offers protection that is substantially superior in comparison to traditional coatings. ARC coatings provide excellent protection against erosion, corrosion, abrasion, and chemical corrosion,” says Jyrki Inkiläinen from FSP’s surface treatment plant in Lappeenranta.

“ARC coating is also a safe and environmentally friendly solution. Majority of the coatings are completely solvent-free, so they do not cause any harmful VOC emissions,” Inkiläinen continues.

ARC coating targets in Lappeenranta have included e.g. large filters, machines and other steel structures facing major wear and tear in demanding mining conditions.

A more protective surface According to Inkiläinen, the industrial sector deals constantly with harmful environmental conditions that corrode structures. Consequently, the reliability and safety of production machinery usually decrease, and production volumes are reduced.

A typical, good example of a suitable ARC coating target is a sulphuric acid container. The

12

➤ FOR SURFACE PROTECTION

advantages of ARC coating include improved corrosion resistance, longer service intervals, reduced maintenance costs and shorter downtime periods.

Tuuri for Supervisor at Lappeenranta Tommi Tuuri has been appointed as the new Supervisor of FSP’s Lappeenranta surface treatment facility starting from June 2017. In addition to surface treatment, Tuuri has extensive experience from the industrial service sector. Manager Jarkko Peltonen, who successfully supervised the startup phase, has relocated to Pori to act as the head of FSP’s Sampo-Rosenlew unit.

The Lappeenranta unit is currently handling various products related to mining and processing industries. The customer base includes e.g. several significant companies in the workshop and energy industries.

In addition to the acid pickling shop operating within the Outotec facility, the plant includes a separate paint shop and a shot blasting chamber, where the region’s metal industry enterprises can get their products of various sizes and materials a top-quality coating.

New coating for thermal insulation In the summer of 2017, FSP completed an innovative project in which the company piloted a brand new kind of coating solution for thermal insulation.

Ph

oto

:A

ntt iV erk

as

alo

The product is particularly well-suited for the surface treatment of hot process pipe systems and container structures. The insulation coating was utilised in a project where the roof of a customer’s oil container was insulated with the new coating instead of the traditional insulation.

“The coating is suitable for hot conditions and it saves energy, cools down the treated surface, and makes the surface safer and easier to handle. The product cools down a surface with a temperature as high as 190 degrees Celsius,” explains FSP Project Manager Pasi Kovalainen.

Surface treatment of the pilot target went smoothly. The new product offers excellent insulating and anti-corrosive features, and it is cost-effective, easy to implement, versatile and safe. It is well-suited for high temperatures, non-flammable, and easier to maintain than the traditional solutions.

FOR SURFACE PROTECTION ➤

13

news

Occupational safety at excellent level FSP’s Finnish units in Ikola and Kangasniemi were awarded in the national “Haastamme” challenge organised by the Technology Industries of Finland. The “Haastamme” competition is aimed at raising the productivity, safety and comfort of companies to a top level with the help of outside evaluations, and to improve the public image of occupational safety work in the field.

In the service and maintenance industry’s category, Ikola took the first prize and Kangasniemi was third. The panel of judges evaluated the safety culture in the companies and the quality and timeliness of their risk assessment operations. In addition, the jury examined the companies’ absence and occupational accident percentages.

“Our working environment is clean and well organised, and co-operation is smooth with Tehomet which is operating in the same facilities. All these features have a positive impact on occupational safety and welfare,” says Lauri Leppänen, Head of Unit at Kangasniemi.

“We are constantly striving for a smoother production flow. Early this year, our unit awarded a development suggestion, which resulted in the creation of a new type of painting stand which allows for even shorter lead-times than before.”

possible deviations are analysed and solved immediately once they are discovered,” says Ikola’s Head of Unit Sami Tarvainen.

The prizes for the "Haastamme" competition winners were awarded at the seminar of Technology Industries’ Work Cycle Carries project. The Work Cycle Carries is a joint national project of the employers’ and employees’ organisations in the field, and its purpose is to increase welfare at work and extend working careers.

The expert advisor for evaluations was Heikki Laitinen, Doctor of Technology and the Senior Adviser at the occupational safety expertise and programming enterprise 3T Results Ltd. “The “Haastamme” contest is a uniquely fruitful safety program in all of Europe. Accident risks at the participating companies have been reduced to one fourth from the initial situation at the beginning of the 21st century. Finland has presumably the safest technology industry in the world,” says Laitinen.

Ikola has the best work environment

Photo: Shutterstock

As for Ikola, the unit was rated as the best work environment for the fourth time.

“We have a highly motivated staff, a strong preventive maintenance system, and a well-functioning 5S system to maintain occupational safety. We carry out regular risk assessments, and all

14

➤ FOR SURFACE PROTECTION

FROSIO inspection at Trogir Shipyard in Croatia

Photos: Shutterstock

fspcorp.com

Photo: Harri Joensuu

During the spring and summer of 2017, FSP carried out IMO-regulated FROSIO certification inspections at the Croatian Trogir Brodogdadiliste shipyard to control the quality of steelwork and anti-corrosive coatings.

The target of the inspection was a part delivery for the hull of an Arctic tanker ordered by Arctech Helsinki Shipyard.

The NB 515 tanker is built partially in Finland and in Croatia. The vessel’s fore, consisting of various sectors and measuring 167 metres, is manufactured in Croatia. FSP’s FROSIO inspector controlled the quality of the steelwork and anti-corrosive coating work on site as the work was finished.

“With the inspector travelling to the location, we were able to avoid having to acquire IMO certification for the anti-corrosive coatings at the Arctech shipyard in Finland.

FSP offers FROSIO inspections around the world according to our customers’ needs. Our experts have done inspections for example in Denmark, China, Uruguay and Norway,” says FSP Area Manager Jukka Lähde.

Surface treatment is of crucial importance, as the tanker is exposed to both corrosive sea water and the demanding ice conditions of the Northern Sea Route. The tanker is capable of breaking through almost two metres of ice. The vessel utilises the Finnish innovation of a double-acting vessel concept, where the ship is optimised to run ahead in open water and proceed astern in heavy ice conditions.

FSP worked on site for four months, during which the surface treatment work performed on the vessel was submitted to both visual inspections and technical measurements. The objective was to audit the level of quality in the subcontractors’ processes, to observe quality monitoring, and to point out potential problems if necessary.

Particular attention was paid to e.g. the level of steelwork quality, the roughness of a pretreated surface, the dust concentration, the paint coat film thickness, the conditions, and the general outlook of the paint work.

FSP Finnish Steel Painting Oy Kalliosolantie 3 01740 Vantaa www.fspcorp.com

FOR SURFACE PROTECTION ➤

15

Š VASTAVALO.FI

A longer life span Welcome Alihankinta 2017

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.

FSP FINNISH STEEL PAINTING OY | KALLIOSOLANTIE 3 | 01740 VANTAA | WWW.FSPCORP.COM