A coating system customised for tailor-made silos: a new leap in quality for LAIFE page 22
Petrochemical corrosion and structural fire protection page 28
Revolutionizing tank coating: robotic solutions for surface preparation page 36
VERNICIATURE, PROTEZIONE DAL FUOCO E COIBENTAZIONE PER INDUSTRIA, ENERGIA, OFFSHORE ED INFRASTRUTTURE.
LAVORAZIONI IN SHOP E ON SITE.
Cuggiono Plant - Via Francesco Somma, 64, 20012 Cuggiono (MI) +39 02 97240792 - alexo@donelli.it
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MXP Plant - Via Quarto, 48, 21010 Ferno (VA) +39 0331 879174 - mxp@donelli.it
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Parlare di anima ci sembra profondamente coerente perché è appunto questo che troverete nelle nostre cinque sedi...
donelli.it
Raising the bar for protection:
Boosting wind and solar power
with corrosion prevention
A coating system customised for tailor-made silos: a new leap in quality for LAIFE
Petrochemical
Revolutionizing tank coating: robotic solutions for surface preparation
Significant performance improvements achieved in graphene enhanced water-based coatings
Advanced solutions for cathodic protection: when expertise makes the difference
Guaranteed corrosion protection for LPG tanks, with the right paint manufacturer
Corrosion
PFP
the
La XVI edizione delle Giornate Nazionali sulla Corrosione e Protezione si terrà ad Ancona nei giorni 25, 26 e 27 giugno 2025, presso la Facoltà di Ingegneria dell’Università Politecnica delle Marche.
Le Giornate rappresentano l’evento di riferimento a livello nazionale per la discussione e il confronto sulle questioni scientifiche, tecnologiche e produttive, nell’ambito della corrosione e protezione dei materiali. In particolare, il Convegno prevede la presentazione dei risultati raggiunti da vari gruppi di studio e da numerose aziende del settore.
Le sessioni tecniche saranno affiancate da uno spazio espositivo, un’ottima opportunità per tutte le aziende dei diversi settori rappresentati nel Convegno per far conoscere i propri prodotti ed innovazioni. Le proposte formulate per le aziende sono disponibili sulla pagina dedicata all’evento, sul sito www.aimnet.it
Organizzate da Media partners
I 1992 - Milano
II 1994 - Milano
III 1996 - Milano
IV 1999 - Genova
V 2002 - Bergamo
VI 2005 - Senigallia
VII 2007 - Messina
VIII 2009 - Udine
IX 2011 - Monte Porzio
X 2013 - Napoli
XI 2015 – Ferrara
XII 2017 – Milano
XIII 2019 - Palermo
XIV 2021 – Torino (online)
XV 2023 - Torino
Alessia Venturi
Editor-in-chief
Investing in the protection of steel structures today means safeguarding the future.
You will find this concept in one of the articles following my editorial in this April issue of Corrosion Protection, dedicated to the energy, petrochemical, and gas sectors. It is emblematic of the role that corrosion plays in the industrial world. It is also a statement that implicitly refers to sustainability, emission reduction, and reducing humanity’s footprint on the planet.
Extending the service life of steel structures through advanced and effective corrosion and fire protection technologies means investing in the long-term reduction of carbon emissions directly at source – a solution that is still overlooked, failing to realise that when corrosion is prevented or slowed down, steel structures do not need to be replaced. And this eliminates greenhouse gas emissions from the production of new steel.
As global steel demand grows constantly, especially in rapidly industrialising countries, corrosion and fire prevention and protection technologies are the secret to long-lasting structures and sustainable development. These safeguarding technologies’ sustainability and environmental impact can also be improved, provided that their environmental friendliness does not compromise their performance.
This issue of Corrosion Protection highlights some trends in R&D and marketing that are common to all major global players:
Focus on epoxy technologies that guarantee long-term durability
Management of the potential ban on PFAS
Compatibility between solvent-based and water-based systems to create hybrid coating solutions with an ultra-low VOC content.
Standardisation of formulations and creation of global product portfolios to ensure consistent quality results even on multi-region projects and easier implementation of technologies.
However, as with every issue, the observations I like to share with Corrosion Protection’s readers in these few lines are just a taste of the wealth of content they will find in the magazine. The one you are about to read is a particularly rich and interesting issue, with technical contributions from all corners of the world and featuring some prominent authors and opinion leaders who have chosen Corrosion Protection to disseminate their research, studies, and success stories.
Extending the service life of steel structures through advanced and effective corrosion and fire protection technologies means investing in the long-term reduction of carbon emissions directly at source – a solution that is still overlooked, failing to realise that when corrosion is prevented or slowed down, steel structures do not need to be replaced.
BASF and Sika have collaboratively developed Baxxodur® EC 151: a new amine building block for curing epoxy resins for flooring coatings tailored for applications in production plants, storage halls and parking decks. The new solution offers ultra-low volatile organic compound (VOC) emissions and optimised flow properties. Developed through a close collaboration between the two industry leaders, the product is engineered to deliver high-gloss, colour-stable and durable coatings that exceed modern environmental standards. With up to 90% less VOC emissions compared to conventional hardeners, Baxxodur EC 151 enables then paints and coatings manufacturers to create ultra-low VOC formulations.
“The development of Baxxodur EC 151 is further evidence of how we are supporting our customers in their green transformation. Working with Sika, we bring our extensive chemistry expertise to successfully implement new sustainable solutions through scalable and cost-efficient processes,” has stated Vasilios Galanos, the Senior Vice President for the Intermediates division of BASF in Europe. Designed with application efficiency in mind, it imparts low viscosity to epoxy resin flooring systems, ensuring excellent flow properties for a smooth and even spread. So, Baxxodur EC 151 minimises the need for additional thinner, reduces overall material usage and allows for greater incorporation of mineral fillers – factors that help lower production costs while supporting sustainable practices. Moreover, the rapid curing capability reduces downtime dramatically: coatings can be walked on shortly after application, even at ambient temperatures between 5 and 10 °C.
“Baxxodur EC 151 makes an important contribution to a resource-saving future in the construction industry. The close collaboration between Sika and BASF was crucial to the development of this innovative solution, which enables our customers to achieve their efficiency and sustainability goals even better,” has added Urs Burckhardt, the head of research at Sika.
www.basf.com
Elementis expands fire-retardant portfolio in China and APAC with sustainable CHARGUARD™ launch
Elementis has introduced its CHARGUARD™ fire-retardant synergist portfolio in China and the Asia-Pacific (APAC) region. This latest expansion includes CHARGUARD™ 1000, CHARGUARD™ 2000, and the newly developed CHARGUARD™ 2010, offering manufacturers a more sustainable solution for enhancing fire safety in plastics.
Manufactured using smectite-based organoclays, CHARGUARD™ products support environmental compliance while providing superior fire resistance. The portfolio’s latest addition, CHARGUARD™ 2010, is produced in China to cater specifically to regional market demands.
“With its unique lamellar structure, CHARGUARD™ promotes char formation, reduces smoke generation, and prevents dripping in thermoplastics—significantly boosting the efficiency of primary flame retardants. CHARGUARD™ 2010 empowers manufacturers in China to meet increasing safety and sustainability standards without compromising performance,” has stated Wendy Li, Elementis’ New Business Development Director.
The CHARGUARD™ range serves as a viable alternative to traditional fire-retardant synergists, such as antimony trioxide and PFAS-based products, aligning with growing regulatory restrictions and industry shifts toward non-halogenated solutions.
Product highlights:
CHARGUARD™ 2010 – Locally sourced for the China and APAC market, optimized for low-to-medium-polarity thermoplastics under 200 °C.
CHARGUARD™ 2000 – Designed for neutral-coloured plastics, offering high tensile strength and excellent melt-flow retention.
CHARGUARD™ 1000 – Ideal for consumer electronics and whiteware, with an ultra-fine hectorite-based composition for a bright white finish.
www.elementis.com
EnerMech has secured a five-year contract extension to provide North Oil Company (NOC) with leak testing and flange management services, building upon a strong relationship which stretches back to 2017.
The award, in the Al Shaheen Oil Field, Qatar, reinforces EnerMech’s in-depth expertise, strong relationship with NOC, proven track record of past performance and availability of resource within the country. Crucial to retaining the contract in a competitive tender was EnerMech’s intimate knowledge of NOC’s assets. The contract covers a range of services, including bolt tensioning and torquing, pipe freezing and training.
Qatar, and the wider Middle East, is an important growth region for EnerMech, with the company poised to take advantage of new markets with its innovation and technologies.
“By securing an extension to an already long-term project is testament to the commitment, hard work and professionalism of the Qatar team,” said Charles ‘Chuck’ Davison Jr., EnerMech
CEO. “I would like to commend Sean Lawless, Country Manager for Qatar for establishing EnerMech as a leading provider of leak testing and flange management services in the region, which puts us in a position to continue the evolution of EnerMech in the Gulf. We are proud to work with NOC and look forward to collaborating with our friends and colleagues to ensure the safe and smooth running of operations.”
“This arrangement is an important scope of work for EnerMech and highlights our expertise and depth of knowledge in the market. As 2025 progresses, we are eager to build on our strong footing in Qatar and continue to work with our clients to provide the best-inclass provisions,” concludes Dan Collins, Regional Director, AMEC. The Al Shaheen Oil Field is a production field off the north-east coast of Qatar in the Arabian Gulf, 80 kilometres north of the capital, Doha.
https://enermech.com
Fastener Fair Global 2025, which took place in Stuttgart (Germany) from 25 to 27 March, once again provided an impressive overview of the latest developments and trends in fastening technology.
With a steadily growing international presence, Fastener Fair Global was able to further underpin its importance as an established meeting place for industry players: this is where manufacturers of bolts and other fasteners, contract coaters and OEMs come together to discuss the latest developments and technologies. Once again this year, the trade fair attracted numerous trade visitors, who used the event primarily for an intensive professional exchange and for networking along the entire value chain. ‘We had intensive discussions with many customers and business partners about the economy, current innovations and the potential PFAS ban,’ says Christos Tselebidis, CEO Industrial Coatings Dörken. The discussions about the potential PFAS ban in particular took up a lot of space, as the handling of these substances in joining technology continues to be an important topic. As part of this, an event organised by the EIFI (European Industrial Fasteners Institute) took place on the first day of the trade fair, which dealt with the possible PFAS ban. The event was very well attended and demonstrated the industry’s great interest in current developments and the status quo. ‘With numerous experts and speakers from various areas of the industry, the event was a complete success,’
said Sabrina Hilbt, Strategic Sales Manager at Dörken Coatings, who was also a speaker at the event. ‘Special thanks to the EIFI for their excellent work in bringing together everyone involved in the value chain to discuss different perspectives and solutions.’
In line with current market developments, the core topic at the DÖRKEN booth was also ‘PFAS-free coating solutions’. The coating experts from Herdecke presented their new PFAS-free product range, which consists of basecoats and topcoats and has already been successfully tested in series production. These include DÖRKEN® SEAL 711 BLACK, DÖRKEN® SEAL 711 SILVER, DÖRKEN® BASE 120, DÖRKEN® BASE 105 and DÖRKEN® TOP 500 BLACK. The products show the well-known DÖRKEN quality, but are already PFAS-free, so that customers are already well prepared for the possible ban. DÖRKEN was also able to present results from series trials and projects generated with various PFASfree prototypes as well as initial specification entries with PFASfree systems.
‘For DÖRKEN, the Fastener Fair once again proved to be a complete success,’ Christos Tselebidis sums up: ’The excellently organised event offered us valuable discussions with existing and new partners.’
www.doerken.com
OMSG – Officine Meccaniche San Giorgio Spa has been specialising since 1961 in the design and manufacturing of shot blasting, shot-peening, and machine systems.
With a constant focus on product innovation, the company has recently launched its new wire mesh belt shot blasting machine, the CWB 1000 8T-15, specifically designed for the cast-iron foundry industry.
“This is the latest addition to the CWB series of automated and highly productive continuous shot blast machines with a metal wire mesh conveyor,” said Enzo Dell’Orto, OMSG’s CEO.
“It is already widely used for the treatment of aluminium die-castings and alloys in sectors such as automotive, food, furniture, lighting, telecommunications, electric tools, oxygen-flame cutting parts, etc.”.
The workpieces are placed on the wire mesh conveyor, which has high wear resistance, and are shot blasted both above and below in a single pass through the blast chamber. The speed of the metal wire mesh conveyor and the rotation of the blast wheels can be adjusted using an inverter. The number of blast wheels and the installed power may vary depending on the model.
OMSG produces several models, ranging from the smaller ones with a passage width of 500 mm, up to 1,500 mm of useful width. Loading and unloading of the workpieces can be done manually, or through automatic transport systems positioned before or after, or by robots, from the metal wire mesh conveyor.
CWB 1000 8T-15 features
The latest CWB 1000 8T-15 model is equipped with:
Usable width: 1000 mm
8 turbines of 15 kW each
Magnetic separator
Lower vibrating screen
By-pass for additional cleaning of the abrasive during downtime
Special filter for foundry application, FX model.
“Typically, this shot blasting machine is used in the die-casting aluminium industry (mainly automotive) and the laser-cut steel
plate sectors. For some types of simple-shaped parts, the CWB is the perfect machine: easy to use, highly productive, and very highperforming. This shot blasting machine is equipped with all the devices suitable for the foundry sector: vibrating screen, magnetic separator, by-pass for additional cleaning of the abrasive, and special filters,” concludes Dell’Orto.
Explore Evonik’s SPHERILEX® AC 45 and SPHERILEX® AC 45 HS – a significant advancement in anti-corrosion technology. Their innovative calcium silicate-based composition combined with their spherical morphology provides a compelling alternative to traditional pigments, offering enhanced performance, reduced environmental impact, and improved cost-effectiveness. Want to learn more?
Hempel has recently announced the launch of Hempafire Extreme 550, a new state-of-the-art epoxy passive-fire-protection (PFP) coating that provides up to four hours of fire protection, as well as exceptional durability and application efficiency. The new solution is fully compliant with global standards, including EN 13381, BS 476 and AS 4100.
Certified with Environmental Declaration Program, the Hempafire
Extreme 550 coating has been specifically formulated to contrast cellulosic fires, setting new benchmarks for fire safety in commercial and industrial projects. Moreover, the lower dry film thicknesses required to protect the steel reduces paint application by up to 40%, resulting in a faster and more cost-effective execution.
Hempafire Extreme 550 is then suitable for most steel sections and allows building designers to use lighter steel types, reducing overall weight and costs in steel structures. Providing an architectural-grade finish while meeting aesthetic and functional requirements, it is fully compatible with a wide range of topcoats, offering design flexibility for colour and gloss.
“The launch of Hempafire Extreme 550 represents a significant step forward in our mission to provide innovative and marketleading fire protection solutions. Its exceptional durability, loadings
efficiency and greater coverage to protect lighter steel buildings for longer make it a gamechanger for customers across industries. By addressing the needs of both specifiers and applicators, it ensures outstanding results at every stage of a project,” has stated Roger Soler, the product manager for Cellulosic PFP at Hempel A/S.
In addition, the new coating developed by Hempel is solvent-free and compatible with waterborne primers and topcoats, resulting in a fire protection and anticorrosive system with ultra-low volatile organic compounds, reducing CO2 emissions by up to 40% while enhancing safety and sustainability. As a matter of fact, since it is designed for toughness and resistance to mechanical damages and weather ageing, Hempafire Extreme 550 ensures long-term performance over twenty-five years – even in C5 environments according to ISO 12994 standards.
“With our latest innovation, we have combined the durability and mechanical strength of epoxy PFP technology with the paint efficiency and easiness-to-apply known from our previous Hempafire products. It underscores our commitment to enhancing both safety and productivity and reinforces our position as a leader in passive fire protection,” has concluded Soler.
www.hempel.com
Germany-based corrosion specialist Steelpaint is calling for urgent action to address the significant environmental impact of steel corrosion, warning that inadequate corrosion protection is contributing more to global CO2 emissions than the entire aviation industry. With the maritime industries consuming an estimated 100 million tonnes of steel annually, premature corrosion and subsequent steel renewal work is increasing carbon emissions dramatically, said Steelpaint’s Managing Director Klaus Müller.
“Addressing this issue through effective steel protection is an economical and environmental imperative. Every premature steel asset failure triggers a replacement cycle that indirectly undermines the industry’s decarbonization efforts.” Steel production remains one of the most carbon-intensive industrial processes. To produce a single 10m by 10m, 20mm thick steel
plate, for instance, emits about 3t of CO₂. Factor in transportation costs and the need for additional coatings, and the carbon footprint looms large.
“Without effective and reliable corrosion protection, early steel replacement initiates a cascade of carbon-intensive consequences – increased raw material extraction, higher energy consumption during manufacturing process, and transportation and installation – all of which contribute to a carbon footprint that extends far beyond the initial asset failure,” said Müller.
This is underscored by joint research study carried out by Curtin University and Ohio State University and published in 2022, which estimates that 25% of global steel production is lost to corrosion, with replacement and renewal accounting for 4 to 9% of total emissions globally.
Global demand for steel in 2024 was 1.8 billion tonnes and forecast
to grow by 2.9% by 2030. The shipbuilding industry alone consumes 32.2 million tonnes per year, of which China, South Korea, and Japan use 88.3%.
Dmitry Gromilin, Steelpaint’s Chief Technical Supervisor, said: “By extending the lifespan of steel structures with effective corrosion prevention technology we have the potential to reduce emissions further. But the link between steel protection and carbon emissions has so far been overlooked.”
Indeed, with mounting regulatory pressure and the shift toward decarbonisation, optimising the durability of steel structures does seem an important consideration if the industry is to meet the UN’s 17 Sustainability Goals.
“Coatings technology is so far advanced that, if properly maintained, maritime structures can last for decades, not only reducing the frequency and costs associated with steel replacement but also leading to a substantial decrease in greenhouse gas emissions. Global CO₂ emissions from steel
production could be reduced up to 1.6 gigatons annually,” said Gromilin.
The shipping industry remains one of the world’s largest emitters of CO₂, producing 858 million tonnes of carbon dioxide in 2022, surpassing the aviation sector. With IMO tightening emissions regulations, companies are under pressure to adopt low-carbon solutions that extend infrastructure life cycles while reducing environmental impact.
“The focus on corrosion protection is not just about extending material lifespan, it’s about reducing emissions at their source,” said Gromilin. “With our isocyanates-free, low VOC moisture-cure polyurethane Stelcatec coating we are enabling steel assets to remain in service longer, reducing the carbon emissions at source. Stelcatec is setting a new standard for steel preservation, ensuring a more sustainable future for the industry.”
www.steelpaint.de/en/
Sallaum Lines has taken a significant step towards optimizing hull performance and the environmental impact for its fleet with the investment in Jotun’s hull performance solution, HPS, including HullKeeper, for its 4 PCTC new buildings in Nanjing Jinling Shipyard. This investment demonstrates Sallaum Lines commitment to delivering value, embracing innovation, and setting new standards in clean shipping practices as they are renowned for. HPS, in combination with HullKeeper, integrates high performance antifouling coatings with expert technical support during newbuilding and performance analytics based on ISO 19030-2 and intelligent hull condition management programme through HullKeeper. HullKeeper leverages on a proprietary algorithm to evaluate fouling risk and recommends next course of action. Together, HPS and HullKeeper delivers a comprehensive dock-todock hull management solution and contributes to collaboration between all stakeholders to ensure the best possible outcome for Sallaum Lines new PCTC fleet.
“Jotun has been a long-time partner with Sallaum Lines and we have obtained excellent results with Jotun’s HPS in our in-service vessels and we like them to be part of our wavemakers”, said Puneet Arora, Head of Technical at Sallaum lines DMCC. Solutions like HPS and HullKeeper from Jotun will play a crucial role in advancing cleaner operations while ensuring cost efficiency
during fuel transition of the fleet, with the inevitable rise in cost of sustainable fuel choices.
“In near-term, optimizing hull performance will contribute positively towards regulatory requirements, such as IMO’s CII and potential carbon tax implications, as well as potential exposure to regional regulatory requirements like EU ETS and FuelEU in EU waters,” said Mohamed Ehab, Key Accounts Manager – Shipping, Jotun UAE Ltd.
In addition, the solution will support Sallaum Lines’ ambitious road map which lays out further plans, targeting a 40% reduction in CO2 emissions by 2030.
Sallaum Lines’ broader sustainability strategy as part of their programs ‘The Wavemakers Initiative’ reflects shared values between both parties as preserving fuels, cut carbon emissions and protect biodiversity contribute to operational excellence and supports a cleaner shipping industry. Sallaum Lines proactive approach to integrating yet another advanced solution with Jotun in its fleets ensures continued leadership in sustainable shipping practices and paves the way towards Sallaum Lines vision of fully optimized green fleets by 2026.
www.jotun.com and https://sallaumlines.com
Materials Performance (MP) magazine honoured Sherwin-Williams Protective & Marine with a 2025 MP Corrosion Innovation of the Year Award for its Heat-Flex® CUI-mitigation coatings during the 2025 Association for Materials Protection and Performance (AMPP) Annual Conference + Expo. Recognized by a panel of industry experts, the annual award spotlights cutting-edge technologies that significantly advance corrosion control and asset protection on a global scale.
MP chose 10 total winners from 60 submissions, a testament to Heat-Flex CUI-mitigation coatings – including flagship Heat-Flex® ACE (Advanced CUI Epoxy), an ultra-high-solids, solvent-free epoxy novolac with a broad dry film thickness range – which were singled out for their ability to slow or prevent damaging corrosion under insulation (CUI), extend service life and reduce operational downtime.
“CUI remains one of the most serious threats to productivity and safety in asset-intensive industries,” says Neil Wilds, Global Product Director of CUI and Testing, Sherwin-Williams Protective & Marine. “By delivering robust, long-term corrosion protection that lowers maintenance requirements, our Heat-Flex CUI-mitigation coatings help owners and operators save significant costs while enhancing reliability. We’re proud that Materials Performance has recognized the value and impact of these solutions”. The Heat-Flex CUI-mitigation portfolio also includes Heat-Flex® 750, a high-solids alkylated amide epoxy loaded with micaceous iron oxide for mechanical durability; Heat-Flex® 1200 Plus, engineered for harsh environments up to 1200°F (650°C); and Heat-Flex® 650, an epoxy phenolic designed for applications up to 401°F (205°C) with enhanced crack resistance and UV stability.
Sherwin-Williams accepted the MP Corrosion Innovation of the Year Award on Monday, April 7, at a special ceremony at the 2025 AMPP Annual Conference + Expo in Nashville, Tennessee. Immediately following, the Company helped kick off the Exhibit Hall Grand Opening with the ribbon cutting ceremony.
Sherwin-Williams maintained a prominent presence at the expo, hosting interactive demonstrations, sharing its latest product offerings and presenting technical sessions exploring solutions for critical corrosion challenges, including:
Exhibit Booth: The company showcased its next-generation Global Core Portfolio, featuring Zinc Clad® 2500, Macropoxy® 2600, Macropoxy® 4600 and Acrolon® 7700, all adhering to stringent global standards (see pages 68-69). Attendees could explore the future of energy coatings with Heat-Flex® Advanced Energy Barrier (AEB) and the award-winning Heat-Flex CUImitigation coatings. In addition, the company highlighted innovative infrastructure coatings such as Sher-Bar™ TEC and Sherplate™ 600.
for long-term anti-corrosion and waterproofing thermoplastic coatings
Industry Expert Presentations: Sherwin-Williams subject matter experts delivered several interesting presentations during the 3-day event (from April 7 to 9).
Department of Transportation Peer Forum Sponsorship (April 9): The Company is a breakfast sponsor and host for a Department of Transportation peer discussion.
Equity in Math Education Research Grants (EMERG) Scholarship Support: As part of its commitment to supporting the future workforce, Sherwin-Williams sponsors scholarships through AMPP’s EMERG program, with awards presented at the EMERGing Leaders Bash on April 8.
“In addition to demonstrating our advanced CUI solutions, this year’s AMPP Annual Conference + Expo was the perfect venue to highlight our Global Core portfolio,” said Grady. “By standardizing formulations worldwide, we help specifiers and asset owners achieve consistent results – no matter where a project is located.”
https://industrial.sherwin-williams.com/emeai/gb/en/ protective-marine.html
Temperature resistance from -40°C to +100°C approx depending on the powder grade and application
Resistance to extreme weathering, UV and salt spray protection
Immediate use of coated items
Easy to repair
IBIX coatings meet the highest standards, offering cost-effective solutions to extend the lifespan of steel structures, pipelines, and machiner y
Specif ic powder grades for Oil & Gas coating for 3LPE / 3LPP coating systems
Edited by Säkaphen (Gladbeck,
Germany) &
CP Phenolics (Moordrecht,
Netherlands)
A leading supplier of sprinkler pipes from the Netherlands chose to turn to leading applicator CP Phenolics for the corrosion protection of its critical fire sprinkler system’s pipeline. In turn, CP Phenolics relied on the expertise of Säkaphen, a leading manufacturer and applicator of special coatings and linings, to develop a new paint product, MIC-Shield, ideal for safeguarding sprinkler pipes and other cooling pipelines susceptible to Microbiologically Influenced Corrosion (MIC).
In every building, whether residential, commercial, or industrial, fire prevention is paramount for protecting lives and assets. Fire sprinkler systems are among the most widespread and effective water-based fire suppression solutions in buildings today.
According to the Fire Protection Association (FPA), “Over the past 130 years, they have had a better than 99% success rate in controlling fires around the world. The installation of fire sprinklers will virtually eliminate all deaths from fire, reduce injuries by at least 80%, reduce property damage by 90% and substantially reduce damage to the environment from fire.”1
Fire sprinkler systems generally consist of pipes connecting fire equipment and conveying water, gas, or other media. They are typically made in carbon or galvanised steel and coated red to distinguish them from different pipes. Of course, there is another crucial reason to paint these pipelines: protecting them against corrosion caused by the fluids they contain, also considering that these flow in the pipes at all times so that the sprinkler system can be immediately activated in case of fire.
1 https://www.thefpa.co.uk/advice-and-guidance/advice-and-guidance-articles/how-do-firesprinklers-work-
Firefighting pipes and MIC
Indeed, protecting internal pipe surfaces from corrosion is crucial for ensuring longevity and efficiency. In particular, sprinkler pipes must be safeguarded against Microbiologically Influenced Corrosion (MIC), an aggressive, accelerated type of electrochemical corrosion process due to the growth of microorganisms, e.g. bacteria and fungi, which form deposits on the internal surfaces of tubes and cause pitting and pinhole leaks. That can lead to permanent damage from leaks emptying the system to corrosion particles clogging the nozzles, making the firefighting system ineffective, with potentially lethal consequences. It also means frequent maintenance operations must be performed, thus raising the system’s operating costs and causing long downtimes.
This was also the problem a leading supplier of sprinkler pipes from the Netherlands wanted to tackle when it decided to rely on the expertise of CP Phenolics (Moordrecht, Netherlands), a market leader in the application of heat-cured phenolic coatings. The task at hand entailed the replacement of the fire sprinkler system serving a railway tunnel with new piping.
The key requirement imposed by the manufacturer on CP Phenolics, of course, was the high-quality protection of the tubes’ inner surfaces against MIC, especially considering the critical intended environment.
CP Phenolics used
Säkaphen’s Si 57 E coating, an epoxyphenolic lining product with excellent chemical and temperature resistance, as the base to blend a new, modified version specifically designed to provide enhanced protection under demanding conditions where microbial activity accelerates corrosion: MIC-Shield.
That is where CP Phenolics’ MIC-Shield coating came into play. As a special baked phenolic-based lining developed to provide exceptional internal protection for sprinkler pipes and other cooling pipelines susceptible to MIC, it was the perfect choice for this project. With over a decade of successful field applications, MICShield has been rigorously tested against multiple variations of MIC, and it provides a long-lasting solution, ensuring structural integrity and reducing maintenance costs over time. Its service life expectancy is 30 years, and the application warranty offered by the company is 15 years. As with the other heat-cured coatings applied by CP Phenolics, it also has exceptionally high chemical resistance and is not susceptible to extreme temperature fluctuations
because the coating layers are crosslinked on a molecular level.
To develop this lining solution for the project, CP Phenolics relied on the expertise of Säkaphen (Gladbeck, Germany), a company with 70 years of experience in corrosion protection products and processes. Its solutions for the pipeline sector include a wide range of heat-cured phenolic and epoxy-phenolic coatings, cold-cured epoxies, and Novolac vinyl ester and epoxy vinyl ester products. In particular, its Si 57 E is an epoxyphenolic lining product with excellent chemical and temperature resistance. CP Phenolics used this coating from Säkaphen as the basis to blend a new, modified version specifically engineered to withstand MIC, offering enhanced protection under demanding conditions where microbial activity accelerates corrosion: MIC-Shield. Beyond the railway industry, of course, it has many other fields of application. Indeed, many critical structures feature firefighting lines that call for excellent MIC protection. A typical example is that of big storage tanks for flammable liquids.
At its workshop, CP Phenolics used its proprietary tube lining machine to treat the railway tunnel’s firefighting pipes. This system can apply a 360° spray pattern inside long, straight or slightly bent pipelines, ensuring uniform coverage and optimal protection. The process entailed the application of multiple layers of MIC-Shield lining, each followed by an intermediate baking operation and, subsequently, a final one. On the other hand, the tubes’ outer surfaces were treated with a powder coating product.
The customer was very pleased with the results achieved, ensuring the protection of this critical pipeline infrastructure, system reliability, efficiency, and long-term cost savings. That is perfectly in line with what both CP Phenolics and Säkaphen stand for: investing in corrosion protection today means safeguarding the future. ‹
Edited by Cortec ® Advertising Agency
IF A WIND OR SOLAR INSTALLATION DOESN’T LAST AS LONG AS ITS EXPECTED 20-30 YEAR SERVICE LIFE, IS IT REALLY A SUSTAINABLE USE OF RESOURCES? WITH CORROSION AS A KEY ENEMY OF WIND AND SOLAR LONGEVITY, CORTEC® REMINDS MANUFACTURERS AND INVESTORS NOT ONLY OF THE IMPORTANCE OF PROPER MATERIALS SELECTION DURING THE DESIGN PHASE, BUT ALSO OF THE BENEFITS OF A FEW SIMPLE CORROSION PREVENTATIVE STEPS DURING SHIPPING AND MAINTENANCE.
One of the first corrosion prevention tasks is to get solar panels and wind turbines to the jobsite in like-new condition. This can be challenging when fluctuating temperatures, humidity, and even salt spray heighten the risk of corrosion during the journey. The right protective packaging can eliminate this problem.
When packaging photovoltaic equipment, manufacturers should think of protecting ESD (electrostatic discharge) sensitive components such as bypass diodes, as well as the metal supports, frames, wires, and electrical contacts that could be subject to corrosion. EcoSonic® VpCI®-125 HP Permanent ESD Films and Bags take care of both concerns. Vapour phase Corrosion Inhibitors in the film inhibit corrosion on a variety of ferrous and non-ferrous alloys, including galvanized steel, aluminium, and brass; while permanent static-dissipative properties help reduce or eliminate static buildup in the package.
In the case of wind turbine components, size, rather than ESD protection, is one of the big issues. Large wind turbine shafts, rings, and hubs often receive the brunt of attack from harsh weather because they may be transported on open truck beds or stored onsite for several years until installation is completed. Fortunately, VpCI®-126 HP UV Shrink Film and MilCorr® VpCI® Shrink Film are two anticorrosion films designed to hold up well in outdoor conditions and available in sizes large enough to shrink wrap giant components. If needed, additional protection can be added, such as VpCI®-368 D removable coating for more vulnerable surfaces and/or Desicorr®
VpCI® Pouches for additional corrosion protection plus desiccant action within equipment and packaging voids.
Once solar panels and wind turbines are put into service, the job of corrosion protection is not over. Solar panels and wind turbines are inherently equipped with wires and electrical contact points that merge inside control boxes potentially subject to the ingress of oxygen, humidity, and chlorides. Placing a small self-stick device such as the VpCI®-105 or VpCI®-111 Emitter inside is an easy and effective way to guard against corrosion surprises that would require early repair or replacement of any exposed electrical contact points
within the panel. Similar to VpCI® films, these devices release corrosion inhibiting vapours that diffuse throughout the space and adsorb on metal surfaces (ferrous and non-ferrous) to which they are attracted. It is much easier to replace these once every two years as part of routine maintenance rather than risk the potential of corroded metal contacts that could interrupt operations and require more extensive repair.
In some cases, extra coatings may be desirable on various structural components.
For instance, wind turbine base bolts are especially prone to corrosion and
ONCE SOLAR PANELS AND WIND TURBINES ARE PUT INTO SERVICE, THE JOB OF CORROSION PROTECTION IS NOT OVER. SOLAR PANELS AND WIND TURBINES ARE INHERENTLY EQUIPPED WITH WIRES AND ELECTRICAL CONTACT POINTS THAT MERGE INSIDE CONTROL BOXES POTENTIALLY SUBJECT TO THE INGRESS OF OXYGEN, HUMIDITY, AND CHLORIDES.
are good candidates for VpCI®-368. Although classified as a removable coating, VpCI®-368 offers such heavy duty corrosion protection that it is often used in offshore platform layups. If (unlike normal) solar panel frames and supports are made of carbon steel rather than corrosion resistant aluminium or galvanized steel, an extra protective coating such as EcoShield® VpCI®-386 or a primer/topcoat combo such as VpCI®-396 and VpCI®-384 is definitely in order to reduce solar structural corrosion. In some extreme conditions, owners may even find supplementary coatings warranted for an additional layer of protection on aluminium or galvanized steel in the severest environments. In these cases, a wash primer such as VpCI®-373 should be used before top-coating for better adhesion.
While the suggestions above do not cover all possible corrosion concerns for wind and solar energy, they are good places to start for basic corrosion prevention. Protecting solar and wind components during transit is critical to getting off to a good start, while protecting control panels and vulnerable structural components as part of routine maintenance can promote desired longevity by reducing corrosion at some of the easiest points to address. Contact Cortec® to learn more about protecting solar and wind components during shipping and maintenance to maximize the sustainability of renewable energy. ‹
Consulting for the professional and productive world.
Germedia addresses both the professional and productive sectors. Thanks to its cross-disciplinary expertise, it collaborates not only with professionals such as architects, engineers, and law firms, but also with builders, paint manufacturers, and craftsmen.
Gabriele Lazzari, ipcm®
LAIFE is characterised by high quality and, optionally, customised finishes. These are applied with a coating system that Savim custom-designed in collaboration with CM Automazione, which developed the overhead conveyor. In line with the company’s focus, in which each product results from a combination of careful design, technical expertise, and attention to detail, this new coating line increases manufacturing flexibility and product quality.
In the last few years, sheet metal processing has undergone a profound evolution both in Italy and abroad, driven by increasingly complex needs in terms of technical performance, safety, quality, and sustainability. From handling, air and water treatment, and energy applications, there is a growing demand for tailored solutions that guarantee high durability.
It is not just functional expectations regarding high-performance materials, precision welding, and ease of maintenance that are changing; the corrosion protection also plays a strategic role today, especially in contexts where plants are installed in aggressive environments. The uniformity and quality of their coated surfaces are thus becoming distinctive elements, often requested in combination with customised colours or finishes. To meet these challenges, manufacturing companies invest in increasingly cutting-edge painting systems that guarantee consistent quality, operational efficiency, and environmental sustainability. Advanced coating technologies, therefore, take on a central role, contributing to the protection and durability but also to the visual identity of structures.
One company that has always paid particular attention to the finishing of its products is LAIFE SpA (Poppi, Arezzo, Italy), which offers a wide selection of painting cycles and supports its customers both in the design and in the development of coating cycles tailored to the mechanical and aesthetic needs of each product. After working with Savim Europe Srl (Arbizzano, Verona, Italy) to install a manual coating line in 2013, LAIFE chose to rely on this plant engineering company again to develop a second line equipped with a power & free overhead conveyor from CM Automazione Srl (Giussano, Monza e Brianza, Italy) to make its painting operations more flexible, thus increasing productivity without sacrificing coating quality nor giving up the possibility of quickly applying multiple different colours.
Two examples of the storage solutions entirely manufactured and coated by LAIFE.
Born from the mind, hands and heart of founding partner Luca Chiarini, LAIFE immediately established itself in the storage market as a reference on the national territory. Founded in 1971, it still wears the fundamental principles that President Chiarini has always transmitted by example. Strengthened by what has been learned over the years, LAIFE works with passion and determination every day, taking on challenges both in terms of new products and new solutions to offer. Constantly evolving in investment in new machinery and technologies, as well as in the continuous training of the staff. Ready to take on new projects every day and curious to learn information.
“Our core values – integrity, expertise, dialogue, and endless passion – have made us a dynamic and high-quality metalworking company in terms of both products and services. Customer assistance during the system development and after-sales phases is our real added value beyond our machined steel,” states Alessia Chiarini, CEO of LAIFE and the founder’s daughter. “We like to think of ourselves as a bespoke metal workshop that creates products meeting each customer’s needs.”
Although Italian customers account for 90% of LAIFE’s annual turnover, most of its products are ultimately installed abroad, in extreme conditions and with very diverse but equally demanding
intended uses. That is why this company offers highly versatile solutions that ensure high quality, attention to detail, and certified documentation, putting itself at the complete service of its customers through a highly flexible production process that includes multiple phases. LAIFE produces each required system based on the customer’s order, but if necessary, it can also carry out a preliminary study of technical specifications, estimates, regulation analyses, structural calculations, and product modelling activities to design a tailor-made solution suited to every need, thanks also to its expert team.
“We can support our customers throughout the implementation phase from construction choices to layout design, also providing the required documentation in compliance with national and international regulations and current laws,” adds Chiarini. “Once a system has been designed, we receive the raw sheet metal from selected Italian suppliers and carry out the necessary machining operations, including oxycutting, bending, and drilling, with both our automated CNC centres. These are followed by submerged arc or pulsed welding operations done by three robots.”
After machining, the structures are taken to the coating department to apply finishes that meet corrosion resistance requirements up to class CX. The paint layer is key to protecting their surfaces. “Our customers are highly demanding and experienced, requiring approved and certified coating systems. Some send us their specifications with all the technical characteristics to be met, whereas others prefer to rely on us to identify the finish that best suits their needs. In the latter case, we investigate the characteristics of the structure’s intended environment and use, and we collaborate with our coating suppliers, which include international companies such as Jotun, Carboline, and International, to select the most suited paints for the specific performance requirements. We also pinpoint the most efficient application process,” explains Chiarini.
LAIFE’s corporate evolution has always been characterised by investments geared towards improving production processes and achieving new
quality standards, as demonstrated by the EN 1090-EXC3 certification, the CE certification for the structures and the FROSIO certification obtained by the CEO for coating. For the finishing phase, LAIFE uses a bench system installed by Savim in 2013, treating workpieces with maximum dimensions of 30 metres in length and 6 metres in width. In 2024, this was integrated with a second manual coating system from Savim, to further increase production flexibility.
The coating cycle performed by LAIFE starts with a pre-treatment phase in an automatic shot blasting machine provided by Turbotecnica (Legnano, Milan, Italy) or in a manual booth for parts with a section of over 3.5 m. Then, depending on their size and shape, the workpieces are either sent to the bench coating system or loaded by the operators onto the CM Automazione power & free overhead conveyor to be taken to the new plant. The line for larger parts, installed in 2013, is equipped with Wagner OptiMixer airless pumps, tanks that automatically mix the components externally before feeding the guns, and burners that feed a ceiling of pipes that introduce hot air into the environment, so as to guarantee suitable climatic conditions in terms of temperature and humidity every day of the year.
LAIFE chose to rely on Savim to develop a second line equipped with a power & free overhead conveyor from CM Automazione to make its painting operations more flexible.
The CM Automazione power & free overhead conveyor transporting workpieces of different sizes and geometries.
On the other hand, the new line has been developed to easily manage smaller workpieces. The Power&Free overhead conveyor by CM Automazione, which includes eleven load racks with a maximum capacity of 1,000 kg each, allows for the easy management of the components, while the loading/ unloading station is equipped with a descender, ensuring safe and ergonomic operations. The painting cycle is then optimised according to the number of coats to be applied.
“The new Savim line consists of a manual liquid coating booth with a Wagner Intellimix Touch unit for paint mixing and dosing directly in the spray gun, a flash-off tunnel, and a drying oven, giving us the flexibility we need to quickly meet the performance and aesthetic requirements of our customers,” says Chiarini.
LAIFE has obtained multiple certifications (e.g. ISO 9001, ISO 3834-2, and EN 1090 EXC3) thanks to its rigorous control and testing procedures. Its traceability system allows it to constantly monitor the flow of materials and information. Using dedicated management software and a barcode reading system, all the raw materials procured are checked as soon as they enter the factory,
and all subsequent processing stages and the operators carrying them out are recorded up to the end product.
This way, the company can access detailed information about the materials used for each item, even years later.
In addition, all welded joints are examined before the structures can be put on the market or undergo further processing. LAIFE’s staff is qualified according to European and American standards for performing surface and volumetric tests using ultrasound.
“We pay the utmost attention to the surface treatment of our products. Before coating them, we systematically check the absence of contaminants and the achievement of an optimal profile for paint adhesion (in any case, never lower than SA 2.5) through shot blasting. Environmental conditions inside our coating department are also monitored constantly,” continues Chiarini.
“After coating, our in-house laboratory subjects the products to a series of specific tests, including thickness and gloss measurements, adhesion tests, and Holiday tests.”
All pressure tanks are hydrostatically tested to ensure maximum safety, even under the most demanding operating conditions. The company can also carry out other types of tests, such as magnetic or radiographic checks, in collaboration with certified partners.
Finally, it subjects its structures to scrupulous electrical tests in order to always provide the safest products possible.
“The painting process in recent years has taken on a fundamental role in the creation of carpentry. The customer is increasingly expert on the topics such as environmental sustainability and tanks installations and increasingly sensitive to the definition of durability. Furthermore, the storage of wastewater necessarily requires us to possess a deep knowledge not only of products for the exterior, but also of actual liners for the immersed parts”, underlines Chiarini.
For this reason, LAIFE’s latest plant engineering-related investment meant a leap forward in terms of finishing quality and further improved flexibility and competitiveness. The new manual coating system supplied by Savim Europe has been designed to adapt dynamically to production volumes and the numerous variables related to products customisation, thanks to a modular structure also including two storage buffers, one upstream of the booth and the other upstream of the oven, which allow for smooth
and optimised management of production flows.
However, LAIFE’s collaboration with Savim was not limited to the system’s supply but also proved strategic regarding staff training. During the start-up phase, the company’s operators were supported by specialised technicians to ensure correct cycle management and full compliance with the expected application parameters, with a view to continuously improving quality performance.
“Savim is one of our long-standing partners, and we trusted it without thinking twice because we know its team is highly professional. For example, to meet our request to increase the plant’s flexibility, it suggested we include a CM Automazione conveyor. In addition, its technicians will soon return to our headquarters to conduct a one-day training dedicated to our new operators. This is a successful collaboration that has lasted for over ten years,” Chiarini concludes with satisfaction. ‹
The new manual painting system supplied by Savim Europe has been designed to adapt dynamically to production volumes of LAIFE and the numerous variables related to products customisation.
by Nick Karakasch
Total Corrosion Consultants – Victoria, Australia
nkarakasch@gmail.com
When determining the most effective protection for structural members, evaluating engineers discover that there are numerous methods available for selection.
In the early years, concrete was the only material available that was suitable; consequentially, it achieved recognition as a proven material. With improved knowledge and technology, specialised materials were developed, and it became obvious that there was a large discrepancy in performance between traditional concrete and these new materials.
The primary role of fire protection is to safeguard human life and to delay the temperature rise of structural elements to minimise the consequences of fire and prevent escalation.
Steel members are often highly stressed to meet structural requirements while minimising the weight of steel. However, the strength of this material starts to decrease significantly when exposed to temperatures above 550 °C, resulting in possible deflection and collapse (Figure 1). Petrochemical fires can reach temperatures of 1,200 °C within 3 to 5 minutes.
Where process vessels are exposed, the temperature rise is somewhat slower due to the internal liquid acting as a heat
1 - Carbon steel rapidly loses strength and will deflect or collapse when temperatures increase above 550 °C. Petrochemical fire conditions can reach 1,200 °C within 3 to 5 minutes.
sink, but there are limitations, as well as a much higher risk of a catastrophic BLEVE (Boiling Liquid Expanding Vapour Explosionsee YouTube).
Fire performance is considered in terms of three main elements:
1) Thermal: relates to the properties of the fire protection material.
2) Mechanical: the relationship between steel temperature and load-bearing capacity.
3) Stickability: the ability of the fire protection material to remain in place throughout the fire period.
Major load-bearing members must be protected to maintain stability until appropriate fire control measures can be taken. The length of time during which a steel structure is required to maintain stability will depend on local circumstances, such as the types of plant, protection system, and available firefighting services. Passive fire protection is one of the most effective and economical means of providing reliable fire defence. The key factors to maintain stability include:
the type of fireproofing material and its applied thickness
the area to mass ratio or the heated perimeter to crosssectional area (Hp/A) ratio of the structural member
the applied load
the intensity of the heat input from the fire
the installed systems’ ability to remain in place during a fire episode. Failure to provide an exterior weather sealer will promote corrosion beneath the fireproofing compound, ultimately weakening the structure and reducing its load-bearing capacity and resistance to fire.
The systems in question are conventional concrete and lightweight cementitious materials. During the early 1960s, proprietary fireproofing products were introduced which showed numerous advantages over traditional concrete. Evaluation of the available data at the time concluded that conventional systems were based on commercial and domestic fire principles, as described in standards such as ASTM E-119, AS 1530 Part 4, BS 476, ISO 834, and DIN 4102.
However, ASTM E-119 was first published in the early 1900s, based on a standard time-temperature curve established from burnout tests in structures incorporating organic materials with potential heat values equivalent to those of wood and paper. This fire type is known as “cellulosic” (Figure 2). While conventional concrete was and is still being used, it has been recognised that ASTM E-119 and its subsequent equivalents did not adequately represent the fire conditions experienced in oil and chemical facilities.
New tests were developed in 1983 by the USA UL Laboratories (UL 1709 rapid rise hydrocarbon test), along with a new hydrocarbon fire curve by Mobil Oil. Although these tests were not national standards at the time, they were accepted as industry standards for hydrocarbon fire conditions.
Testing has now developed to the point where national standards are applicable and recognised, e.g. British Standard BS 476 Part 20:1987, Appendix D. Lightweight cement-based materials were the first compounds to be given full certification for hydrocarbon conditions by the UK Government (Loss Prevention Council) based on this new National Standard. Experience has shown that conventional concrete has failed and has been replaced at one time or another with specifically formulated fireproofing compounds. Lightweight cementitious materials have proven to be very effective, particularly as they can be applied off-site with minimal touch-up after erection and at lower costs.
For example, using concrete entails as follows:
The cost ratio of concrete encasement is approx. 60/100, in favour of lightweight cementitious materials.
Possible construction delays.
Concrete starts to spall, crack, and explode at temperatures above 380 °C1.
Loss of 50% structural strength after fire: replacement can be difficult and costly.
Fire performance is influenced by the amount of concrete cover over the reinforcing steel, which limits structural design capabilities due to weight.
Concrete density averages 2,200 kg/m³ compared to lightweight cementitious mixes at 800 kg/m³.
It requires considerable construction foundations with heavier steel members.
On the other hand, lightweight cementitious materials ensure benefits including:
Design flexibility.
Improved fire rating.
1 Hydrocarbon fire temperatures average 1,200 °C. Steel starts to lose structural strength and deflect with possible collapse at temperatures beyond 550 °C.
Does not spall or explode at hydrocarbon fire temperatures (i.e. 1,200-1,600 °C).
No need for replacement after fire, in some cases.
No formwork required and, therefore, no waiting time for curing purposes.
May be applied to a lesser thickness for the same fire rating.
Economical and practical when installed into existing facilities or where access is restricted.
Easy to maintain if accidentally damaged, does not require the use of specialised personnel or equipment.
The design philosophy of these products is based on limiting heat absorption and maintaining temperatures within defined limits, allowing for specific emergency measures to be implemented.
The basic aim is to protect human life and minimise damage to facilities.
Protective systems need to conform to the following parameters:
Limit the temperature of a structure below the maximum permitted value over a specified period in fire conditions.
Not fail suddenly at the end of this specified period but continue to offer a predictable measure of protection beyond this point.
Ensure system integrity (stickability, integrity, and insulation) so that protection remains in place during a fire and be able to
withstand both thermal shock and water impingement from fire hoses or monitors.
Be non-corrosive to the substrate and not be affected by environmental conditions.
Not become a hazard, e.g. by spatting, spreading flames, or producing toxic fumes.
Be easy to apply in various environmental conditions.
Be durable and easily repaired.
Be cost-effective for the risk involved.
Be compatible with a wide range of existing paint systems (including lead-based materials) where removal may not be applicable due to environmental or safety considerations when upgrading existing concrete structures.
Fire protection is usually provided to combat the heat input from one of the following three fire types:
a flammable liquid pool fire, which typically has a heat flux of approximately i20 kW/m² – i50k W/m² with flame temperatures of 1,000 °C – 1,200 °C.
an intensive, torching type of impinging flames, such as may occur from a high-pressure gas or vapour leak with turbulent premixing with air from a leaking flange. This could produce a heat flux of up to 300 kW/m² with flame temperatures up to 1,600 °C.
radiant heat from an adjacent fire.
Torching fires are smaller than pool fires, but they are more intense
Materials are required to undergo testing by an independent authority to simulate, as closely as possible, the conditions of fire exposure in order to meet the fire endurance rating needed.
and can cause rapid failure where they impinge directly onto a steel structure. It is important to identify in advance the points where this may occur and fire-protect those areas as a priority. Significant radiant and convective heat will also be generated from a torching flame.
Since, in practice, all three conditions can occur, heat flux is difficult to measure accurately. Various fire resistance tests have been developed for classification into two basic categories: “cellulosic” and “hydrocarbon”. Both are based on a temperaturetime curve (Figure 2) and do not account for heat flux. By their very nature, fire tests are designed to act as a benchmark to determine in a consistent manner the performance of structural elements exposed to a standard fire type for a pre-determined period. Fire resistance tests provide a reproducible method for evaluating the performance of fire-protected structures. Failure temperatures vary slightly among countries (i.e. USA: 590 °C, UK: 550 °C, Australia: 540 °C); lower temperatures entail an extra conservative built-in safety factor. The name “cellulosic” is applied to the type of temperature-time fire curve obtained when cellulosic materials or solid organic fuels such as paper or wood burn. The name “hydrocarbon” is applied to the high-rise temperature-time curve for fires where petrochemical products, oils, and natural gas products are ignited.
Materials are required to undergo testing by an independent
authority to simulate, as closely as possible, the conditions of fire exposure in order to meet the fire endurance rating needed. Manufacturers’ in-house fire tests are not permitted or acceptable unless witnessed and acknowledged by a recognised national independent testing authority.
Standard fire tests are designed to act as a benchmark for determining the performance of products under specific fire conditions. What these tests cannot do is to determine the performance of:
wind turbulence
thermal shock caused by water from fire hoses and/or sprinkler systems
jet flame impingement.
Insulation thickness values are based on either the Hp/A factor (heated perimeter/cross-sectional area) or the area/mass ratio of steel. Material suppliers are required to conduct a series of independent tests (minimum 9 to 12) so that charts or graphs can be drawn up for a whole range of steel sections. Tests related to load-bearing members are conducted for 1, 2, and 4 hours. Heat uptake is slower as thickness increases, so thinner insulation is required; conversely, with lighter sections, thicker insulation is needed.
Bracing components receive a nominal Hp/A factor for basic cover and protection. What these tests provide is a regression formula (window) for varying steel sections, which defines interpolation limits for calculating the required insulation thickness. Strict
limits are applied to the use of the regression formula: no material thicknesses are acceptable if they fall out outside the test window. Where no regression formula is available, a single prototype test must be conducted for the steel member involved. Thickness can only be derived through interpolation (mathematics, transitive verb: to estimate the value of a mathematical function that lies between known values, often by means of a graph) and not extrapolation (transitive verb: to estimate a value that falls outside a range of known values). Materials should never be offered or accepted via extrapolation without the minimum test requirements.
Evidence has shown that many fires last considerably longer than the designed protection period. This unpredictability has been brought into focus in many parts of the world, where fires have continued for some considerable time, well over the anticipated protection period. Some materials, particularly lightweight cementitious products, have been exposed to real fires where their performance exceeded the design parameters (e.g. a 1.5-hour rating extending to over 5 hours of protection).
Fireproof material systems should meet the following minimum test parameters:
Standard fire test for stickability, insulation, and integrity
Flame impingement test where appropriate
Thermal shock test (from fire hoses/sprinkler systems). When concrete comes up for consideration, its use should be discouraged: it has never been tested for hydrocarbon or even
All high-rise buildings require protection for all structural elements, including columns, beams, trusses, and the underside of all concrete floor slabs throughout the building. The systems employed are mostly spray-applied, lightweight materials incorporating vermiculite in either concrete or gypsum plaster.
cellulosic fire resistance. The reason it would not pass is that its temperature resistance is only 350 – 380 °C. Concrete exposed to higher temperatures results in spoiling, severe cracking, and major dislodgement, and it has been known to lose 50% residual strength when exposed to temperatures above 350 °C. Existing concrete structures can be upgraded where necessary in numerous ways – the most practical and least expensive method being the use of lightweight cementitious materials. It is worth mentioning that the fire protection of concrete in the commercial building industry is mandatory throughout Australia and the industrialised world. All high-rise buildings require protection for all structural elements, including columns, beams, trusses, and the underside of all concrete floor slabs throughout the building. The systems employed are mostly spray-applied, lightweight materials incorporating vermiculite in either concrete or gypsum plaster. When fire-tested, however, reinforcing steel must not exceed 250 °C, a much lower failure criterion than for steel members. Fire conditions under these circumstances are normally considered cellulosic.
A rare exception was the Twin Tower buildings on 9/11, where the condition encountered was initially hydrocarbon (1,200 °C) due to aviation fuel, which in turn ignited a cellulosic fire in the interior building components. The sheer weight of the concrete floors and the inward deflection of steel were sufficient for the buildings to collapse in a concertina manner.
Another classic example of concrete failure was the Channel Tunnel fire. Originally, a cementitious material was proposed to protect the concrete, but this was rejected at the time of design. The fire that evolved graphically demonstrated the extent of the damage that can occur. The estimated cost at the time was in excess of $ 100 M, with 6 months for restoration and a revenue loss of $ 2 M per day. Ironically, the repair material used was the lightweight cementitious product originally recommended. The choice of aggregate in all concrete mixtures is another important factor. River pebbles should never be used as they contain water and, when heat-stressed, explode.
Fireproofing products were not designed for anti-corrosive purposes. The industry test standard to determine any corrosion properties for fire-resistant materials sprayed on steel is ASTM E93 7-83, Standard test method for corrosion of steel by sprayed fire resistive materials applied to structural members. Where corrosion protection is necessary, the use of well-designed anti-corrosion coating systems is required, all of which should be based on steel protection standards. The addition of fireproofing cement materials provides a further envelope covering the steel surface, creating an extra
barrier against corrosion. Cement products with a strong alkaline value of pH 11 or higher inhibit the corrosion of steel, whether it is completely bare or coated, as long as the cement remains alkaline. To emphasise this point, storage vessels containing strong alkaline solutions require no anti-corrosion treatment whatsoever. If lightweight cement materials are used without any exterior waterproofing coating systems, steel corrosion is likely to commence where airborne chloride contaminants are present and able to penetrate the material through to the steel surface, lowering the pH factor back to neutral or the acidic side of the scale – a process known as carbonisation of the cement component.
To ensure this situation is addressed where corrosion prevention is necessary, the following systems are recommended:
Anti-corrosive coating system
Selection is made appropriately for each project, considering the projected service life and the environmental conditions of exposure. Systems should be selected from the AS/NZS 2312 Guide to the Protection of Iron and Steel against External Atmospheric Corrosion or similar international standards.
- Hot dip galvanising (HDG)
- Zinc-rich primer/ epoxy sealer to a minimum dry film thickness of 275 microns.
Of the two systems, HDG has been shown to be the most competitive, with a case history spanning over 50 years. In the past, there has been some reluctance to the use of lightweight cementitious materials. This was largely due to cases where some products had caused severe corrosion to the
underlying steel. Indeed, some early formulations were based on cement, fibreglass fibre, magnesium oxychloride, and in some cases asbestos. The use of fibre and, in particular, fibreglass contributes to the causes of corrosion through the phenomenon known as “wicking”, whereby water, together with chlorides, is transported through the material to the metal surface through capillary action.
While magnesium oxychloride provides extra hardness, it is renowned for its propensity to produce a hydrochloric acid solution, which causes corrosion in steel. Fibre is the vehicle for transporting the acid solution to the steel surface. Fortunately, these products are now obsolete and are no longer available.
Fireproofing specifications (lightweight cementitious material)
The required thickness (20-50 mm) includes galvanised mesh reinforcement, joint sealing, and water shedding where the appropriate thickness is dependent on the mass of steel involved, and it is followed by a waterproofing top coat to protect the Portland cement component from water ingress and carbonation. The coatings used for this purpose are either flexible chlorinated rubber or acrylic-based products applied to a thickness of 250300 microns. These coatings are relatively inexpensive and require some maintenance every 12-15 years.
Current lightweight cementitious products are inert materials, completely free of fibre materials, non-toxic, and non-flammable during application or under fire conditions. Their neutrality makes
Economies of scale in any evaluation exercise would indicate that considerable savings can be achieved by using lightweight cementitious mixers without compromising fire protection principles.
them environmentally friendly and non-injurious to operational personnel.
Current estimates show that lightweight systems are quicker and easier to install, with considerable savings. The cost examples shown (in Australian currency) are related to the following parameters – although I would expect similar principles would apply to other international jurisdictions:
two-hour hydrocarbon fire rating
no allowance for scaffolding
no waterproofing or mastic sealant for conventional concrete.
There are also hidden savings when compared to conventional concrete; steel is always on the critical path of construction.
Construction delays have a direct bearing on plant commissioning and possible revenue losses in production.
Considering the industry, there is no doubt one construction delay could have a large impact on daily production values.
Requires smaller steel sections
Requires smaller construction foundations
Fewer construction delays
Faster installation.
Economies of scale in any evaluation exercise would indicate that considerable savings can be achieved by using lightweight cementitious mixers without compromising fire protection principles.
There are legal implications attached to fire protection, particularly where materials do not comply with hydrocarbon fire resistance or OH&S regulations, should any person be injured or killed. Those persons involved in the supply chain, i.e. specifier, construction manager, material supplier, or installer, have a shared responsibility for the protection system’s performance or usefulness in the event of an untoward fire. Where deficient installation has been found, the supplier and construction managers can no longer claim the responsibility was not theirs because they had no control over the installation. The concept of a voluntary duty of care is no longer enough; in most industrial countries, it is now a legal obligation. The use of non-compliant installation or approved materials would allow insurers the opportunity to deny liability. For individuals or corporations to ignore these issues would demonstrate a lack of responsibility. Proven performance, backed by independent test data, is the only safe and secure basis for selection. ‹
Nick Karakasch is the retired principal of Total Corrosion Consultants Australia. Nick’s experience spans 50 years, specialising in services for the protective coating, corrosion, and fire protection industries with a focus on galvanising, inorganic and organic zinc coatings, and structural fire protection. He spent many years in a management and technical capacity with the Dimet Coating organisation, the company that invented inorganic zinc silicate coatings through its founding director, Victor Nightingall, which are now used in over 70 countries. He has also been the principal consultant to the Galvanizers Association of Australia. While living in South Africa in the mid-1970s, he was employed as a Contracts Manager for R.J. Southey Pty Ltd., Africa’s largest protective coating contractor.
References:
- UL 1709 (Rapid Rise Hydrocarbon Test)
- ASTME 119
- ASTME 937-83
- AS 1530 Part 4
- BS 476 Part 20 – App. D
- AS/NZS 2312
- Corrosion under fireproofing compounds, N. Karakasch
- LPG vessel protection, N. Karakasch
- Ref. to BLEVE can be found on YouTube
- DGL Contractors Pty/Ltd (re: cost estimates)
by
Meshari Al-Otaibi,
Mana Al-Mansour, Khaled Abusalem, Abdulla Al-Issa, and Abdulsalam Al-Turki
Saudi Aramco, Dhahran - Saudi Arabia
Robotic tank blasting technology has advanced significantly, enhancing precision and automation in surface preparation for oil and gas tanks. Saudi Aramco has utilised a robotic blasting technology that offers significant advantages, including reduced labour, time, and material wear, while improving operator safety and the quality of blasted structures.
Tank surface preparation is a technique used to clean, prepare, or modify the surface of various materials. It’s crucial processes in the oil and gas industries which involves propelling abrasive materials, such as garnet, grit, or steel shot, at high speeds onto the surface to remove rust, paint, or scale from metal surfaces, preparing surfaces for painting or coating that allows for better adhesion of coatings. Proper surface preparation is essential to ensure the integrity of tanks and protect them from the corrosive environment they operate in.
A brief description for the main components of abrasive blasting set-up, illustrated in Figure 1, is listed as follows:
Air compressor: provides the necessary pressure to propel the abrasive particles and provides breathing air for the blaster.
Abrasive: removes surface contaminants. Common abrasives include steel grit and garnet.
Blast machine/pot: holds the abrasive material.
Air filters: ensures clean air is delivered to the blasting pot as well as to the blaster.
Air respirator: protects the blaster from harmful particles and provides breathing air.
Nozzle: directs the abrasive stream onto the surface to be treated.
Blasting hose and hose safety couplings: deliver abrasive material securely.
This approach is time-consuming, labour-intensive, and poses significant safety risks to worker (Brown, 2018).
Components of conventional abrasive blasting equipment (source: “Sandblasting machinery: types, applications and benefits”).
The use of robots in industrial settings has been steadily increasing across various sectors. In 1985, the automotive industry embraced painting robots to achieve dramatic improvements in productivity and quality. Manual car painting, which previously took months, was reduced to a matter of hours with the introduction of robots. The oil and gas industry embraced robots for internal pipe coating 25 years ago. The development of pipeline robots has undergone several stages of improvement due to the complexities of field applications. The development and adoption of robots specifically for tank surface preparation began only 15 years ago (Nguyen, 2021). In 2014, Saudi Aramco successfully deployed the first surface preparation robots in RT Refinery, with subsequent use in several other facilities. However, the lack of a dedicated coating application robot at that time limited the overall demand for surface preparation robots. Developing efficient coating application robots involves addressing several factors, including atmospheric temperature, wind speed, humidity, flow rate, pump pressure, tank surface conditions, safety and environmental considerations. These complexities delayed the production of a viable coating robot until 2021.
The integration of surface preparation and coating application robots represents a significant leap forward in tank coating technology. This new approach holds the potential to transform the industry by eliminating the need for scaffolding, blasters, coaters, abrasives, and associated materials and services (Patel & Cheng, 2020).
The main objective of the pilot field trial conducted by Saudi Aramco was to assess the performance of robotic tank blasting in terms of blasting rate and abrasive material rate of consumption, and to assess the blasting quality, including surface profile and chloride content.
Robotic tank blasting technology is a specialized cutting-edge technology that can perform abrasive blasting tasks with precision and consistency. This technology is operated with a closed abrasive circuit that propels steel abrasives at high velocity to the mouth and impact with the substrate. The bouncing impact of metallic abrasive onto the surface to be treated thoroughly removes surface contaminants, (epoxy) coats on different types of surfaces (Connor, 2023). This blaster is also a dust free when connected with a dust collector, thus creating a safe working environment (Roberts, 2019). There are two main types of robotic tank blasting technology, vertical robotic tank blasting and the horizontal robotic tank blasting.
The vertical robotic tank blasting is run with a closed abrasive circuit, as shown in Figure 2, utilized for surface preparation of vertical flat surface like storage tank shell. It can be used through navigating toward elevated surfaces, which are challenging for humans to reach.
The blaster is attached securely to the metallic surface of the equipment to be blasted using a magnetic mouth seal. Bounced abrasives are caught by the mouth seal and passes to a filter to remove dust, then reintroduced into the storage hopper, giving a continuous cycle of production and ensuring circularity of abrasives (Harper, 2021). All dust, coatings, rust removed from auto blasting during the operation are drawn out to vacuum dust collector. Dust collector uses hoses connected to the blasting unit to collect the foreign particles (dust, rust and paints).
Robotic tank blasting, shown in Figure 3, is a horizontal blasting machine equipped with a closed abrasive circuit, similar to the vertical robotic tank blasting. This machine is mainly used for the blasting activity during the surface preparation process of large diameter tanks’ bottom plates, and other large-scale horizontal surfaces. This technology represents a significant advancement in labour safety, as it enables a dust-free environment, as shown in Figure 4, where the bounced abrasives together with the associated dust and contaminants from the blasting activity are immediately captured to be filtered and circulated (Williams & Turner, 2022). The machine is connected to a duct that sends the collected dust and contaminants to the dust collector outside the tank. This solution also reduces labour intensity as it is equipped with an intuitive control system that simplifies its operation and manoeuvrability for the operator. The machine is easily moved and repositioned by the operator over large-scale horizontal surfaces as its wheels are driven by an electric motor.
Saudi Aramco successfully piloted and evaluated the robotic tank blasting. The main objective of these field trials was to assess the performance of robotic tank blasting in terms of blasting rate and abrasive material rate of consumption, and to assess the blasting quality, including surface profile and chloride content. In addition, noise and air pollution were assessed during the pilot tests. The field demonstration to conduct a pilot on the shell plates for a water formation storage tank with a 32 m diameter and an 8.9 m height using the vertical robotic tank blasting at one of company capital projects. Abrasive used for blasting was also steel shots and grit (80% shot and 20% grit). A pilot test was also conducted on the bottom plates of a utility water storage tank at one of company capital projects. A summary of the pilot test results for both shell and bottom plates is illustrated in Tables 1 and 2.
Table 1 - Results of the vertical blasting robot.
Table 2: Results of the horizontal blasting robot.
Abrasive
m2 per day
kg per m2
Surface profile readings {51, 55, 57, 60} µm
mg per m2
Air
As shown in Table 3 below, the manpower saving for both technologies vertical and horizontal is estimated to be 50%. Automation of the robotic blasting also plays a crucial role in reducing the time required for surface preparation and increasing productivity. Based on the blasting rate, this technology is capable of completely blasting the 67% faster than conventional method for shell plates while 50% faster for bottom plates. In addition, the closed abrasive circuit which ensures continuous cycle of filtering and circularity of abrasives, reduce the material consumption significantly. Circularity performance indicates the saved consumption of abrasives will be 93.3% for shell plates while 95% for bottom plates.
Table 3: Manpower, time and abrasive savings for robotic blasting method for shell and bottom plates compared to the conventional method.
This cutting-edge technology promotes for a significant cost-effectiveness, accelerates project deliverables, improves quality assurance and sustain safe and friendly environment. The implementation of robotic blasting machine is streamlined with Saudi Aramco strategic objectives toward Automation & Robotics, Environmental Sustainability and Circular Economy.
Recommendation and conclusion
The robotic tank blasting is a fascinating area that has seen significant advancements in technology, automation, and the realm of Industry 4.0. When it comes to technology advancements, robotic systems have become more sophisticated and precise. The ultimate advantage will be related to accelerating project deliverables, improving quality assurance and sustaining a safe and friendly environment for storage tanks in the oil and gas plants.
The use of robots will eliminate scaffolding, significantly reduce manpower, time and materials. As a result, this cutting-edge technology promotes for a significant cost-effectiveness, accelerates project deliverables, improves quality assurance and sustain safe and friendly environment. The implementation of robotic blasting machine is streamlined with Saudi Aramco strategic objectives toward Automation & Robotics, Environmental Sustainability and Circular Economy. ‹
References
- “Sandblasting Machinery: Types, Applications and Benefits.” Iqsdirectory, Editorial by Industry Quick Search, 2025, www.iqsdirectory. com/articles/sandblasting/sandblasting-machinery.html. Accessed 12 Feb. 2025.
- Brown, J., 2018. Safety and Health Risks in Industrial Processes. Oxford University Press.
- Nguyen, L., 2021. Robotics in Surface Preparation and Cleaning. Robotics Review, 28(1), pp. 58-65.
- Williams, J. & Turner, S., 2022. Enhancing Safety and Efficiency in Blasting Operations. Safety & Efficiency Journal, 27(3), pp. 75-82.
- Connor, T., 2023. Technological Innovations in Blasting Equipment. Tech Innovations Press.
- Patel, R. & Cheng, H., 2020. Precision and Efficiency in Abrasive Blasting with Robotics. Journal of Robotics, 35(3), pp. 140-148.
- Harper, D., 2021. Sustainable Practices in Modern Manufacturing. GreenTech Publishing.
- Roberts, C., 2019. The Environmental Benefits of Abrasive Blasting Recycling Systems. Environmental Innovations, 12(5), pp. 89-95.
Edited by Sparc Technologies Kent Town, South Australia info@sparctechnologies.com.au
The tests conducted by the Australian company Sparc Technologies Limited have demonstrated a significant improvement in the corrosion performance of graphene-enhanced water-based acrylic epoxy coatings.
Sparc Technologies Limited announced the results of initial test work in water-based acrylic epoxy coatings. The testing has demonstrated significant corrosion performance improvements through the incorporation of low dosages of carefully selected grades of graphene compared to an unmodified control. Testing has been performed using two industry-recognised electrochemical measurement techniques. Water-based coatings are gaining prominence due to better environmental credentials compared to more widely used solventbased coatings which contain fossil fuel derived organic solvents. These results are the first evidence that Sparc has seen whereby graphene significantly improves the corrosion performance of water-based coatings. This extends Sparc’s reach into a new and
rapidly growing area of the coatings market where there are clear performance challenges to address. It also complements Sparc’s flagship ecosparc® product range.
Nick O’Loughlin, Sparc Managing Director, commented: “There is an increasing push from the coatings industry towards more environmentally friendly water-based products, however their performance has not been adequate for wide scale industry adoption in corrosive applications. Our results clearly demonstrate a significant performance improvement with graphene which has the potential to unlock significant growth in this developing area of the coatings market. Pleasingly, these results have been achieved by leveraging Sparc’s proprietary knowledge and expertise working with graphene-based additives in the significantly larger solvent-based anticorrosion market and allows us to broaden our customer engagement.”
Initial testing was conducted with internally formulated waterbased 2-pack acrylic epoxies with dry film thicknesses of approximately 75 microns applied to garnet blasted cold rolled steel. Formulations incorporating several grades of graphene at low dosage rates and an unmodified control without graphene were produced for the testing. Coated panels were tested via two electrochemical impedance spectroscopy (EIS) techniques within Sparc’s laboratory:
Rapid Electrochemical Assessment of Paint (REAP): short term electrochemical testing to estimate the long-term corrosion resistance of coated metals. The testing measures a water uptake value and disbondment rate to determine a time to failure (TTF) in number of hours. The method was developed by and all calculation factors are based on the experiment results of Kendig, 19961
Accelerated Cyclic Electrochemical Technique (ACET): application of cycles of EIS measurements, cathodic polarizations and potential relaxation. Degradation of the coating system is accelerated by cathodic polarization; EIS and potential relaxation monitor changes in the coating system. Testing was conducted according to the ISO 17463 (2022) standard. The graphene enhanced coatings demonstrated a significant improvement in corrosion protection across both testing methods:
REAP: graphene enhanced coatings showed slower ingress of water through the paint film to the steel substrate significantly reducing the disbondment rate and improving the TTF of the coatings by 5.5x to 11.6x (Figure 1) compared to the unmodified coating.
ACET: graphene enhanced coatings showed improved coating resilience with significantly less blistering and no corrosion after six cycles of cathodic polarization (AC/DC/AC) as evidenced by visual inspection.
Results with internally formulated coatings were subsequently validated by the testing of a commercially available waterbased coating which showed similar levels of performance improvement through the incorporation of graphene. In addition to electrochemical testing Sparc has successfully incorporated relevant graphene grades into additives suitable for use in waterbased epoxy coatings which have shown good initial stabilities. This demonstrates the potential for Sparc to develop an additive product for this area of the coatings market.
Water-based epoxy coatings use water as a carrier instead of fossil fuel derived organic solvents. The key benefits of water-based epoxy coatings include non-toxicity, low odour and low VOCs (volatile organic compounds) and ease of application and clean up. Despite these advantages, the durability, performance and cost of water-based epoxy coatings is generally worse than equivalent solvent-based products which has limited market adoption. With tightening regulations on VOC content and both industry and individual consumers seeking more environmentally friendly alternatives, there is an increasing push to develop higher performing water-based products. The global waterbased epoxy market was valued at US$1.6 billion in 2022 and is projected to reach US$2.9 billion by 2029, at a CAGR of 8.9% during the forecast period2. In comparison, the global market for anticorrosion coatings is estimated at US$43 billion by 20293 ‹
2 Sourced from 24ChemicalResearch, https://www.24chemicalresearch.com/reports/202538/ global-waterborne-epoxy-coating-market-2023-2029-411
3 https://exactitudeconsultancy.com/reports/3960/anti-corrosion-coatings-market/
Cathodic protection technology is widely used to protect underground or submerged metal structures and concrete reinforcing bars against corrosion. The first experiments in this field date back to the first half of the 19th century when the first discoveries (and a famous fiasco) by Sir Humphry Davy definitively gave way to the replacement of the copper-coated wooden hulls of warships with more resistant and safer metal ones, which could finally be protected from the aggression of the highly saline marine environment through the first cathodic protection systems. Based on the recent discoveries of the Italians Luigi Galvani and Alessandro Volta, on 22 January 1824, Davy reported to the British Royal Society that when the electrical state of a metallic material becomes more negative, it is possible to eliminate the forces generated and thus prevent the onset of corrosion. Therefore, he had the idea of using iron, tin, and zinc anodes to make copper more negative, eliminating the problem of corrosion. These results laid the foundations for cathodic protection technology and made it possible to use metal materials in maritime structures in total safety. Since then, this technology – still widely studied in university research programmes and many other fields – has developed to become a standard method for corrosion protection, applied in various industries from the maritime sector to bridges and infrastructures, from public and private buildings to underground and submerged
In
the niche sector of cathodic protection, some SMEs offer innovative solutions to
optimise this well-established process through
their
in-depth know-how. With over 25 years of experience in this industry, SAIT has recently launched a new product, the IRON PROBE® highconductivity potential probe, which improves and simplifies corrosion monitoring operations.
pipelines, up to everyday objects such as kettles and water heaters.
Marco Facciadio, the founder and CEO of SAIT Srl (Umbertide, Perugia, Italy), a company specialising in the protection and maintenance of metal infrastructures with a special focus on corrosion prevention through advanced cathodic protection techniques, studied at Politecnico di Milano. “The cathodic protection process has been well established for a long time; the systems and materials are the same for all companies in the sector. Theoretical knowledge is essential for a thorough understanding of the electrochemical process behind the reaction generating it, but what really makes the difference is hands-on experience. That is why SAIT stands out internationally for the degree of innovation and quality of its solutions. And recently, thanks to the many years of experience we have gained and our in-depth specialisation in this corrosion protection technology, we have been able to develop and patent the IRON PROBE® potential probe, a cutting-edge tool designed to monitor the effectiveness of cathodic protection in a precise and reliable way.”
SAIT was founded in 1981 and began offering excavation work to install pipelines and cathodic protection services. In 1990, it expanded its portfolio, specialising in other services linked to this
technology, with systems designed to prevent corrosion on steel metal structures such as underground pipes and other assets at risk, e.g. aqueducts and tanks. “Over the years,” says Facciadio, “we have aimed to specialise our staff as much as possible through courses to obtain 3rd-level certifications under the ISO 15257:2017 standard; in 2001, we also obtained ISO 9001/2000 certification. In 2015, SAIT added CANUSA-CPS products for coating steel pipes to its range dedicated to the anti-corrosion sector while also providing technical support in the selection of the most suitable solutions. The following year, we integrated our offer with a corrosion control service for district heating pipes, through which we install and maintain ad hoc control units. “Finally, in 2022, we filed a patent for the new IRON PROBE® potential probe we developed in-house, which marks a significant step forward in the field of cathodic potential measurement. Thanks to its unique design and patented technology with an integrated single or double coupon to measure the Eoff potential, this probe can operate in extreme environmental conditions while offering accurate and consistent measurements, which is crucial for maintaining the long-term integrity of structures.”
IRON PROBE® is a specific type of potential probe measuring the Eoff potential of metal structures such as pipelines, tanks, and underground steel infrastructure. “Unlike traditional potential probes,” explains Facciadio, “its high conductivity allows installing it even in particularly resistive soils, obtaining Eon potential measurements that are very similar to the true Eoff potential.”
One of the main characteristics of IRON PROBE® is precisely its ability to provide very precise measurements of the Eon potential, which differs by only 20-30 mV from the true Eoff potential, even in high-impedance soils. It also eliminates interference from disturbance currents that cannot be eliminated with reference electrodes. “Therefore, from an operational point of view, it has two unquestionable benefits: no more doubts – because the use of a probe that simulates the true potential reduces measurement uncertainty and improves the reliability of the collected data –and a better correlation with metal – because, as mentioned, its readings are more closely related to the actual Eoff potential, making the measurement technique simpler and eliminating measurements done with the ON-OFF method.”
The patented porous septum is made of a low-resistance, highconductivity material suitable for any type of soil. “That means it can also be installed far from the structure to be measured with considerable savings in terms of excavation and restoration while still ensuring a very accurate and precise measurement of the potential.” The mixture of copper sulphate, also patented, prevents leakage by capillarity.
“The effectiveness and precision of IRON PROBE® are guaranteed by compliance with the strictest technical regulations in the industry, in accordance with international standards. This commitment to excellence ensures that each device not only meets but even exceeds the expectations of the most demanding customers.”
This innovative probe can be used to monitor localised corrosion. “Indeed, it can identify specific points along a pipe or structure where the potential indicates a risk of corrosion. It is also useful in electrically complex environments, where stationary and nonstationary interference can affect the results, as IRON PROBE® offers a more representative measurement of the potential, largely eliminating non-real interference.”
“Ever since its launch on the national and international markets, IRON PROBE® has undergone continuous improvements and
IRON PROBE® is a specific type of potential probe used in the context of cathodic protection, especially to measure the Eoff potential of metal structures such as pipelines, tanks, and underground steel infrastructure.
received positive feedback. We have managed to make ourselves known worldwide, even in industries that are difficult for a small company to penetrate, such as the oil & gas sector, where cathodic protection has been standardised for some time now. At the same time, there are sectors where this is not yet the case, such as the water industry, and we are pressing for it to be made mandatory. The control and maintenance of water networks, currently considered a secondary asset, are traditionally entrusted to their managers. But at a time like this, when this resource is increasingly scarce and our society is becoming more aware of the need to find ways of limiting its loss, SAIT is at the forefront of the fight against wastage. According to ISTAT data1, the water lost in public supply networks in Italy alone in 2022 would have met the water needs of 43.4 million people for a whole year. As a service company able to offer effective solutions against such losses, we propose making cathodic protection mandatory also for steel water pipes.”
1 https://www.istat.it/en/press-release/istat-water-statistics-years-2020-2023/
Drawing on its extensive know-how, SAIT can offer solutions to the most complex corrosion issues. “Our expertise is what makes the difference. Cathodic protection systems are affected by many variables, including resistivity, acidity, soil conductivity, pipeline conditions, the type of coating already applied, and temperatures. Analysing and/or predicting all these variables is impossible,” concludes Facciadio. “That is why I would like to emphasise that in this sector, experience and professionalism are the key factors at the basis of every service we offer – from design and installation to maintenance and monitoring of cathodic protection systems, from technical consultancy for corrosion risk analysis and for the selection of the best infrastructure protection solutions to training and technical support for companies that need to improve their cathodic protection and corrosion managementrelated skills.” ‹
Ilaria Paolomelo, ipcm®
On the national and international stage, CPS is a benchmark for quality, innovation, and reliability in the production of LPG tanks. Each product results from a process planned down to the smallest detail – including the coating phase, which is key to ensuring high resistance, performance, and protection against corrosion. To meet these standards, this Italian company has relied on paint manufacturer Mirodur for over a decade, which, over time, has developed customised formulations for the different types of underground and aboveground tanks manufactured by CPS.
In the last few years, the Italian market for LPG tanks has grown significantly, driven by the increased adoption of this energy source in both the residential and automotive sectors. LPG is widely used for heating homes and cooking food, as well as in numerous industrial applications. It is a fundamental choice for many households and businesses, especially in areas not reached by the natural gas network, also known as non-methane areas. Recently, the sector has seen a significant technological evolution with the introduction of increasingly safe and efficient storage and distribution systems that optimise supply management and reduce waste.
From top, clockwise:
After machining, the raw tank is transferred to the main factory for surface treatment and accessory assembly.
The pre-treatment and coating process varies depending on whether the tank is intended for underground or aboveground use.
A specialised operator inside a tank.
In this context of rapid growth and transformation, CPS Srl, a leading company in the production of underground and aboveground LPG tanks based in Montalto Uffugo (Cosenza, Italy), has established itself as a key player in this industry, responding to new market demands with innovative solutions and constantly striving to develop new products. Thanks to its close collaboration with paint manufacturer Mirodur (Aprilia, Latina, Rome), the company has also developed ad hoc coating solutions designed to guarantee the highest quality and durability of its tanks. In fact, this partnership has allowed CPS to become one of the leading players in the sector, distinguishing itself for its products’ reliability and high performance.
A young and dynamic company operating in one of Italy’s long-standing markets
CPS was founded in 2010 by Pietro Carbone, the current CEO, as the result of his entrepreneurial experience in the plant engineering, air conditioning, and heating sector. Already at
the helm of Carbone Climatizzazione Srl, active since 1981, Carbone wanted to expand his vision with a company capable of responding to the challenges of modern industry with innovative and high-performance solutions. “From the beginning, CPS’ goal has been to offer high-quality LPG tanks and impeccable service to meet the specific needs of every customer,” explains Andrea Rotondaro, the company’s technical director. “It is not just about supplying a product but also building relationships based on trust and long-term collaboration. We strongly believe in the value of human relations, which are a key factor in our success – not only with customers but also with our partners and suppliers, such as Mirodur.”
Thanks to a team of highly qualified professionals, CPS has quickly gained the trust of important national and international companies, of which it is now a qualified and verified supplier. Its constant commitment to the search for efficiency and quality led it to inaugurate a new production line for pressure vessels in 2015. The implementation of automatic and numerically controlled
machines for processing large and thick metal sheets was then a turning point that further raised the company’s production and quality standards. “Technological innovation has been one of our priorities from the start,” continues Rotondaro. In particular, “automating the handling, sandblasting, and coating line, which is now entirely remote-controlled, has enabled us to optimise production management while improving safety and quality.” Today, CPS is present in the Middle East, North Africa, and Eastern and Northern Europe. In Italy, a widespread network of agents and warehouses guarantees prompt and flexible service. “Being close to our customers means not only having efficient logistics but also offering tailor-made solutions capable of responding to the different needs of the market,” states Rotondaro. “‘Our philosophy is clear: combining innovation and reliability to build the future together with our partners.”
CPS specialises in constructing and regenerating LPG tanks with capacities ranging from 300 to 50,000 litres, focusing on underground and aboveground fixed cylindrical tanks for residential and industrial applications and for use in service stations. “Our production process follows a well-defined flow from raw material procurement to coating, assembly, and final testing. At its headquarters in Montalto Uffugo, CPS has three factory halls devoted to these different phases,” illustrates Rotondaro. The first of these is dedicated to the design and production of new tanks. Here, sheet metal is subjected to precision machining with robots, including calendering and welding. After this stage, the raw tank is transferred to the main hall for surface treatment and accessory assembly. “Within this second factory, CPS has invested heavily in automation to achieve an efficient and highly standardised production process. Thanks to our IT team and its advanced management solutions, we have developed an application and a portal for real-time monitoring of production, product availability,
and our warehouses throughout the country,” explains Andrea Rotondaro.
The pre-treatment and coating cycle varies depending on whether the tanks are intended for underground or aboveground use.
“To guarantee maximum corrosion protection and efficiency of our products, it is essential to select specific surface treatments and appropriate paint products according to their intended environment.” In both cases, the tanks are loaded and taken along the coating line’s stations by a power & free conveyor. They start by entering one of the two automatic shot blasting machines and then, when necessary, the manual one reaching the SA 2. 5 degree, ensuring perfect surface cleanliness and optimal paint adhesion. After pre-treatment, the tanks are transferred to the manual coating booth with a vertical suction system. A tablet at its entrance scans the QR code associated with each product, thus automatically identifying the type of paint to be applied.
THANKS
WITH PAINT
ITS
MIRODUR, CPS HAS ALSO DEVELOPED AD HOC COATING SOLUTIONS DESIGNED TO GUARANTEE THE HIGHEST QUALITY AND DURABILITY OF ITS TANKS.
For the coating of underground LPG tanks, CPS uses a highperformance two-component epoxy paint applied with a minimum thickness of 500 microns. Its dielectric properties protect the tank from galvanic currents present in the ground. “This high-solid epoxy-based product is certified to withstand galvanic currents up to 10,000 amperes. It is a highly technical product with a very short pot life, so mixing it directly in the spray gun is essential to optimise the coating process. That allows complying with the hardening times necessary to sustain the production rhythms of CPS, which manufactures between 12,000 and 15,000 tanks a year, or about 40-50 a day,” explains Riccardo Vitelli, the sales manager of Mirodur.
In addition to the passive protection provided by the coating, CPS integrates a cathodic protection system with sacrificial anodes, which offers active protection and ensures high resistance to corrosion, thus further extending the service life of the underground tanks.
On the other hand, for tanks intended for aboveground installation, a polyurethane primer is applied after shot blasting, followed by a wet-on-wet RAL 9010 (pure white) top coat. The total thickness of the resulting coating is around 120 microns. “For this type of tank, we have developed a paint designed specifically for CPS. Unlike traditional products, this can be applied in very thick layers and even in a single coat if necessary.”
A tank coating phase.
The demand for increasingly safe and efficient storage and distribution systems that optimise supply management and reduce waste has increased in recent years.
Aboveground tanks are built in compliance with the PED 2014/68/EU directive and are CE marked.
“For underground tanks, the paints are applied through a highpressure airless system, with pumps featuring pressing plates to directly mix the products inside the spray gun. For aboveground tanks, on the other hand, the line uses electronic pumps connected to the base coat and top coat tanks (with a capacity of 1,000 kg each) and the catalyst one (with a capacity of 200 kg),” notes Vitelli. The base coat and the top coat are formulated to use the same catalyst and catalysis ratio, thus optimising material management and production efficiency. Specifically, an operator first applies a base coat layer with a precise catalysis ratio to guarantee optimal surface protection, then changes the spray gun and applies the top coat with a wet-on-wet operation using the same catalyst, which gives the tank final protection.
Once the coating phase is complete, the tanks are transferred to the drying oven, where they dwell for a varying time according to the type of paint used. After drying, they are taken to the accessory assembly and final check phases. Finally, through a conveyor belt, they are stored in the warehouse, ready for shipping. “The entire coating cycle is managed by a PLC system that allows remote and real-time monitoring of all process stages,” says Rotondaro.
“The collaboration between CPS and Mirodur is a perfect example of strategic synergy where the development of coating solutions goes hand in hand with the evolution of production needs,” says Riccardo Vitelli. “The products formulated by our R&D department are the result of a shared journey stemming from CPS’ desire to guarantee the highest quality and durability for its tanks. A concrete example of this collaboration was the adoption of an acrylic base coat, a winning solution that allowed CPS to achieve the required thicknesses without increasing the amount of paint applied, thus avoiding additional product-related costs. The choice of a base coat with the same chemical characteristics as the top coat also proved strategic, as the possibility to use the same hardener optimised production times and guaranteed high productivity without interruptions.”
“Mirodur is a point of reference in our sector, and choosing them as a partner came naturally,” says Rotondaro. “Working with a supplier with in-depth knowledge of the market has allowed us to develop high-performance solutions right from the start. Today, we are expanding our range with paints in different colours for tanks
containing technical and fire extinguishing gases, which require specific protective treatments that differ from our standard cycle. In collaboration with Mirodur, we are developing a new polyester paint designed to meet these needs.”
The relationship between CPS and Mirodur is based on a continuous exchange of skills and knowledge: CPS’ technical department gathers information on customer needs, analyses it, and develops an optimal production strategy, liaising with Mirodur to define the most effective coating solution. “This approach allows us to offer a highly specialised and tailor-made service,” concludes the technical director of CPS. “Mirodur is not just a supplier but an actual partner that guarantees flexibility and constant support, essential for facing the challenges of a constantly evolving industry.” ‹
THE BASE COAT AND THE TOP COAT ARE FORMULATED TO USE THE SAME CATALYST AND CATALYSIS RATIO, THUS OPTIMISING MATERIAL MANAGEMENT AND PRODUCTION EFFICIENCY.
by Nick Karakasch
It is not uncommon for facility owners to get into a quandary when trying to determine the least expensive way to protect a structure for a given period. Corrosion prevention methods are assessed in terms of the cost required for implementation and maintenance over the protection period. In the first instance, the expected performance and cost of annual expenditure need to be determined. Assuming the projected service life of an initial coating system can be achieved, other factors, such as paint material, application and installation costs, future maintenance, replacement costs, inflation, and cash flow, also need to be considered.
The corrosion engineer or the evaluating authority, when faced with a decision between alternate methods, comes to realise that it is the time component for a given period that tends to complicate the issue. The longer the required period, the more uncertain the decision. For example, should an inexpensive coating system be used, maintained and replaced as required, or is it better to allocate more money initially to minimise maintenance expenditure in future years?
Corrosion protection, like other facets of a business, is a matter of economics. This aspect can be analysed by considering the initial cost, upkeep over a projected period, payback period, time to recoup expenditure, and annual rate of return on investment. These are some of the factors used to determine the most appropriate method of protection. One factor often overlooked is the timing of cash flow requirements.
Money invested today will earn interest at a given rate and will increase by the amount of interest added; this concept allows for comparisons between alternate systems through techniques such as present value analysis and discounted cash flow. These are based on a simple method of convention. If present-day costs for corrosion protection are known, and we assume they will remain the same, e.g. for 10 years, how much money would have to be put into a bank investment initially so that in 10 years, the original investment plus interest equalled the money required for protection? The answer depends on the rate at which the interest is earned over that period. Table 1 shows several examples of the same initial investment over a 10-year period with varying interest rates.
In the last row, $ 10,000.00 invested at 10% will earn $ 17,070.00 in interest, and the sum in the bank will be $ 27,070.00, more than enough to compensate for the original paint job and even to pocket the original $ 10,000.00 invested. The $ 27,070.00 sum is termed the ‘future value’, whereas the $ 10,000.00 sum is called ‘present value’. This simple convention enables the analysis of complex investment decisions, such as determining the least expensive way of protecting a structure for a set period. The future estimated costs of painting operations are converted to presentday values, providing a comparison between alternative systems based on their respective present-day values. Present value is the sum that must be invested at a specific interest rate to ensure that there is enough money in the bank at a future date to carry out the painting job. The alternative with the lowest present value is the most economical proposal over the considered period. Table 2 illustrates a simple example where deferred payment plan expenditure is shown as negative, i.e. money flowing out.
Alternative 2 is the least expensive; the factor to convert its present-day value was based on an earning rate of 10% compound interest over 3 years.
Where the deferred payment option is equalised, say over 5 years, as illustrated in Table 3, the savings are considerably larger and would, for example, include further savings in terms of investment allowances (if applicable), tax benefits, depreciation, and cash flow predictability.
Less payments on years 1-5, totalling $ 7,200,100 expensed each year as maintenance against general revenue (if applicable).
One alternative method for assessing capital investment associated with corrosion protection is to consider a maintenance program, which may include a low-cost coating system or a deferred top coat application, where payments are spread equally over a contracted period. Maintenance to a large degree will be necessary at some point; therefore, using low-cost materials or deferring a top coat application becomes a matter of choice. The conventional arrangement for painting is to pay a lump sum on completion for a one-off paint job and then repeat the exercise when deterioration has occurred to an unacceptable level. In addition to the initial work, it is often necessary to pay periodically for minor repairs. On the other hand, with a planned maintenance program, the client can have all the comprehensive work done, enjoy regular maintenance throughout the contract period, and spread the known costs over numerous years. This type of arrangement allows the facility owner to budget more effectively as they do not have to pay large initial lump sums and know their yearly expenditure in advance, with only minor adjustments in accordance with increases in the costs of labour and materials. Accordingly, accounting is greatly simplified because the client receives only one invoice per year. Another benefit for the client is that this avoids the payment of large lump sums, which in turn reduces the capital outlay and allows money to be used for other
One alternative method for assessing capital investment associated with corrosion protection is to consider a maintenance program, which may include a low-cost coating system or a deferred top coat application, where payments are spread equally
.
purposes within the business or for further expansion. A deferred payment plan is a significant departure from the conventional ad hoc approach to maintenance painting. It ensures that the facility will be kept in sound condition and not left to deteriorate to an unsatisfactory level where extensive reinstatement becomes necessary. Because the coating system is maintained on an annual basis, any minor breakdown can be rectified by sectional repair at the next annual service. Regular maintenance thus ensures that the coating system serves its function in providing a good appearance and structural stability over the projected period. In this way, the true life expectancy of the coating system is therefore achieved.
This type of approach relieves the client of the time, cost, and risk burdens associated with in-house major construction and maintenance requirements. The traditional method has been for organisations to employ their own personnel or independent consultants to carry out a status report for determining the condition of a facility and formulating a scope of work. Then, they must evaluate various recommendations to select the most appropriate protective coating system and are required to draw up comprehensive tender documents, pre-qualify tenderers to determine their capacity to handle the work, evaluate tenders, and award the contract. They must administer detailed supervision
to ensure the work is carried out in accordance with the tender document and finally bear the risks associated with the long-term performance of the applied coating system.
Alternatively, the coating applicator, in conjunction with the paint supplier, determines the specifications and administers the program, maintaining the coatings system for the duration of the contract period and taking full responsibility for continued performance. However, prior to commencement, any proposed paint system should be independently verified for performance by a recognised material engineer.
Maintenance or general painting requires a disciplined approach if available finances and labour are to be utilised to the best advantage. A program should be formulated to maintain and reinstate any failed areas, maximising efficiency and preventing premature breakdown and possible loss of load-bearing capacity. Protecting individual sections in a non-systematic manner inevitably leads to confusion in the long term, as well as adding difficulty to the functions of inspection and supervision.
The entire program should preferably be under the control of a nominated individual or painting contractor. Any non-systematic approach should be avoided for all the obvious reasons. A coordinated approach ensures that all the money spent is costeffective in relation to the long-term objectives. The cost of
shutdowns due to unforeseen failures should also be considered; these are hidden costs, as only one enforced shutdown due to coating failure would more than compensate for any difference between a planned program and a non-systematic approach on an as-needed basis.
This type of approach enables the principal to achieve maximum value for the money spent on construction and maintenance. The property asset value is enhanced since the condition of the structure can be reviewed and maintained in accordance with a carefully tailored program. All work undertaken can and should be comprehensively guaranteed against premature failure so the principal does not carry any financial risk should the coating system fail.
It is in the best interest of the painting contractor/coating supplier to ensure that the system is kept in good condition throughout the contracted period, as this reduces the yearly workload and relieves the principal of the considerable expense of hidden costs and effort involved in detailed contract supervision. It is also important to emphasise that these arrangements place no obligation on the principal to continue with the program should the circumstances change for any reason; the principal should be able to terminate the agreement without penalty, just by paying any difference that may exist between the value of work undertaken and the sum paid at the time of termination, or any separate agreement between the contracting parties. Payment should be spread annually over the duration of the
contract (a rise and fall clause based on labour and material costs provides for indexation of each year’s payment). The distinct advantage of this deferred payment system is that it enables the principal to budget the cash flow more accurately by eliminating the fluctuating payments that would be involved if work was invoiced on an ad hoc basis.
A typical example of an actual program based on new construction in value terms is illustrated in Table 3. Programs of this nature will, in effect, maximise the total funds invested, not only in terms of plant and equipment but also of possible revenue losses due to unforeseen related shutdowns. It does represent a very cost-efficient approach to maintenance and construction painting.
The example in Table 3 takes into consideration the total cost of the protective system and includes the maintenance component over a 5-year contract period. The premise: the calculation of the delayed payment over 5 years, with the first payment made on completion and followed by equal yearly payments. For simplicity, interest is calculated at 10% (would be subject to prevailing market rates). This is a typical example referring to new construction; however, there are circumstances where the tax implication may or may not be applicable. The advantage is that the initial payment of $ 1.5 M is capitalised, which is subject to yearly depreciation. The remaining payments are expensed each year as maintenance write-off costs. However, this premise would need to be researched by an appropriate taxation consultant.
The effects of inflation can be significant and difficult to determine; this also applies to interest rates on earnings, which are not fixed either, particularly if the economic conditions are volatile. While inflation is unknown cash flow, predictability can be calculated. Inflation will increase the amount of money necessary to perform an operation in the future; therefore, it is imperative to choose the best possible present paint system available to cover future costs. Choosing a low-quality system is not
worth considering, given that the cost of paint protection for new construction represents only 1-2% of the total construction cost. For existing facilities, the paint cost is somewhat higher but still not enough to consider lower-quality materials.
To summarise, cash flow analysis is based on a simple principle: any future sum required can be generated by making a smaller investment today and earning interest up to the future date. By summing present-day investments, the total cost for protection over the contracted period may be determined. A painting program with practical deferred payments is a tangible way to ensure a project receives the best, longest protection available, with the added benefit of cash flow predictability. It is a win-win situation for all parties concerned, including the facility owner, the painting contractor, the paint supplier, and, to some degree, a prospective buyer should the facility be sold at a future date. ‹
To summarise, cash flow analysis is based on a simple principle: any future sum required can be generated by making a smaller investment today and earning interest up to the future date.
PFP Seminar 2025: the annual event is back with the latest innovations in the intumescent coating sector
On 2 April, Jotun organised a seminar in collaboration with Sames, a partner of WiWa in Italy, to present the latest innovations in the intumescent paint sector and even show their effectiveness through a practical demonstration. The event attracted a large audience who actively interacted with the speakers, confirming the growing interest in these products.
The Passive Fire Protection Seminar organised by Jotun – one of the world’s leading manufacturers of paints and coatings for the offshore, energy, mining, and infrastructure industries – in partnership with Sames, company partner of WiWA in Italy and specialised in the production of application systems of liquid and powder paints, adhesives and sealants – was held on 2 April in Bergamo (Italy) with its now traditional agenda: a first part dedicated to the description and presentation of new products, their formulation and development, and their fields of application and a second part actively engaging participants with a practical workshop. This formula has proven effective not only for presenting product innovations in detail but also for showing how easy it is to apply them and check the results straight away (Fig. 1).
Intumescent paint plays a key role in passive protection against cellulosic fire: it slows down the fire’s spread, allowing people to escape to safety and firefighters to intervene. As with other fire protection products, the PFP coating sector has recently seen a tightening of regulations following the dramatic fire at Grenfell Tower in London in 2017, which highlighted the devastating consequences of using inadequate building materials. Jotun’s Global R&D Intumescent Lab in Flixborough (United Kingdom), part of a more complex structure consisting of 6 other laboratories worldwide, specialises in the research and development of intumescent coatings that are highly effective not only in slowing down the spread of fire in a timeframe of 30 to 180 minutes but also in meeting the demands of applicators (e.g. fast on-site drying times and prolonged resistance properties during the construction phases) while, at the same time, reducing environmental impact. “This event attracts a large turnout every year between applicators and other professionals actively involved in designing structures, such as architects and engineers, fire safety consultants and inspectors, construction companies’ representatives, and project managers,” explains Vaira Vesnaver, Marketing Communication
Manager of Jotun Europe Sales (JES).
“We aim to present our latest SteelMaster solutions for passive protection against cellulosic fire with a series of in-depth analyses on various topics such as fire scenarios, industry regulations, terminology, and application equipment.”
Introduction to fire protection
In the morning session, after a welcome speech and a presentation of the company delivered by Angelo Susani, Sales Manager Energy & Infrastructure at Jotun, the audience listened to an interesting talk by Katie Shelbourne, Senior R&D Chemist at the Flixborough laboratory, who analysed the importance of these paint products. “All materials commonly used in architecture lose part of their resistance when exposed to fire: concrete spalls to expose the reinforcement bars, wood depletes by charring, and steel does not burn but loses structural strength. The latter is the most commonly used material in the construction of commercial and industrial buildings dues to its versatility, constructability, and high strength-to-weight ratio. It will begin to lose its intended design strength at temperatures above 400 °C.
“When a steel structure is exposed to cellulosic or hydrocarbon fires, its temperature will increase rapidly. After 5 to 15 minutes, the structure becomes increasingly unsafe, which puts both lives and assets at serious risk (Fig. 2),” emphasised Shelbourne.
“Let us look at two examples: the case of the Piper Alpha oil platform, which caught fire on 6 July 1988 following the escape of a considerable quantity of gas, triggering countless explosions
that led to the structure’s collapse, and that of the Windsor Tower in Madrid, a 32-storey, 106 metres-high skyscraper devastated by a fire on 12 February 2005, leading to the partial collapse of the building, which was subsequently demolished. All asset owners and operators in the sector are responsible for ensuring adequate safety measures are in place to significantly reduce the risk of fire, including fire prevention, detection, protection, and extinction systems. In terms of protection, our work aims to formulate intumescent products that can prolong the integrity of a structure before it collapses so that the people inside it have the time to evacuate and the building is protected until the fire brigade arrives
When a steel structure is exposed to cellulosic or hydrocarbon fires, its temperature will increase rapidly. After 5 to 15 minutes, the structure becomes increasingly unsafe, which puts both lives and assets at serious risk.
to extinguish the fire.”
The speech continued with an analysis of the characteristics of intumescent paint. “This term comes from the Latin intumescere, which means ‘to swell up’. Indeed, intumescent coatings rapidly expand on heating to form a porous, stable carbonaceous char that thermally insulates steel from the heat. The required thickness varies depending on several factors, including the size, shape, and characteristics of the steel structure, its limiting/ critical failure temperatures, which are determined by the load percentage, and the required period of fire resistance, generally ranging from 15 to 120 minutes.”
“Primers and topcoats are critical elements of intumescent coating systems,” concluded Katie Shelbourne. “During a fire, the primer helps the carbon layer adhere to the steel substrate, whereas the topcoat seals and protects the intumescent paint from adverse environmental conditions without negatively affecting its performance (Fig. 3).”
The following speech, by Mattia Cristofoli, Area Sales Manager Yard/Fabricator/Applicator at Jotun, described the Norwegian company’s broad portfolio of intumescent products. “Our SteelMaster range, specifically designed to offer the most suitable protective solutions, includes water-based, solvent-based, and solvent-free two-component epoxy-based products. The SteelMaster 600, 900, and 1200WF series of water-based coatings are ideal for delaying the spread of fire for 30 to 180 minutes, depending on the product used. These paints are characterised by a low VOC content and can be applied in small quantities to steel structures, thus helping reduce environmental impact.
“The solvent-based products 90SB and 90SB QD, applied in one coat to a thickness of 1,500 microns, can guarantee up to
120 minutes of protection in different environments and a high aesthetic yield, an important aspect for both property sellers and residents. These products allow for excellent performance both in-shop and on-site, where they can be exposed without a topcoat for 9 months during the construction phase, provided they have reached adequate drying and reasonable hardness before exposure. However, whether topcoated or not, the coating must be protected from condensation, ponding/pooling water due to rainfall, running water, or snow and ice during construction and in
IT‘S THE PROCESS THAT BECOMES YOUR SOLUTION.
We supply you with individualized finishing lines for e.g. pipes, monopiles etc.
service (Fig. 4).”
The latest product developed by Jotun’s laboratories is the 100% epoxy intumescent coating 1200HPE, which can be exposed in any environment up to C5 class (ISO 12944-2) and immersed in water, guaranteeing a fire protection time of 15 to 180 minutes. “Solvent-free and coming with an EPD1, this is a superior coating solution, resistant to weathering, impact, and damage and ideal for latest-generation cellulose fire protection, with or without a sealing topcoat. A component treated with this product can be overcoated after 4 hours and handled after 16 hours at 23 °C. It can be easily applied in two coats of 3 mm each within the same day, for a total thickness of 6 mm.”
After the coffee break, the morning session continued with a talk by Stefano Sgualivato, Area Sales Manager YFA at Jotun, who described the activities of the Jotun Fire Engineering Services division, emphasising the importance of value engineering for project optimisation. “Jotun Fire Engineering Services is our team of structural fire protection engineers offering unique expertise
by combining engineering with intumescent coating know-how to provide expert advice for our customers and partners around the globe. It analyses customer specifications and project details and supports with calculating and optimising all fire protection aspects. The team also provides project marked-up drawings that make it easy to identify which SteelMaster product and dry film thickness (DFT) to apply on each steel section according to requirements, enhance application quality and efficiency, enable the most efficient use of multiple SteelMaster products in one project, and ensure cost-saving benefits.
“That is also guaranteed by Structural Fire Design practices that start from the existing design, which generally assesses the capacity of steel in normal conditions (cold state) to define its overcapacity in fire and thus customise the products and volumes needed. Using specialised engineering software solutions, we identify cellular beams from building drawings and analyse cellular beam members to pinpoint compliant coating products and thicknesses, thus devising a suitable coating schedule for each specific project. Through collaboration on design and engineering from the early stages of a project, Jotun Fire Engineering Services can contribute with valuable expertise to find smart solutions
for every need. For example, we apply value engineering to identify optimisation targets for steel and/or the coating without comprising the structure’s fire rating and the structural integrity in a fire.”
The series of speeches ended with images of the numerous architectural projects in which SteelMaster intumescent coatings have been used, such as the Oasis Theme Park in Qatar, the Eskişehir Museum in Turkey, the Granada Mall in Saudi Arabia, the Ferrari World theme park and Abu Dhabi International Airport in the United Arab Emirates, the Equatorial Tower in Malaysia, and the Changsha Xiangjiang Fortune Financial Center in China, to name a few (Fig. 5).
Sames Italy and WiWA enter a strategic partnership for application equipment
The Sames speakers’ session began with a presentation of the company by Andrea Sanchini, Area Sales Manager Northwest Italy & Business Development Italy, and continued with a talk by Technical Manager Michele Troilo. He explained the terms of the agreement between Sames Italy and German company WiWA Wilhelm Wagner GmbH & Co. KG – specialising in spraying and industrial protection solutions and, in particular, passive fire protection systems since 1950 – and then illustrated the application devices that would be used in the afternoon during the practical demonstration.
“Our two companies have actively collaborated for years in terms of both sales and production: some WiWA equipment is completed with components produced by Sames, such as the pump heater that we will see in operation this afternoon. About a year ago, we had the idea of joining forces to offer combined solutions for the anticorrosion and fire protection sector, to be distributed on the Italian market.
All WiWA products for passive protection against cellulosic fire are especially characterised by high flow rates. For example, the Herkules GX pump, ideal for applications in small areas and for repairs, has a flow rate of about 16 litres/hour with guns that can exceed 400 bar of pressure.”
Two pumps from this series, together with the new Duomix GX PFP system, were indeed chosen for the live demonstration scheduled for the afternoon. “The new Duomix GX device, equipped with three hydraulic pumps (two for the base component and one for the catalyst), enables to work with intumescent material in an even more fluid, efficient, and simple way. Characterised by safe and intuitive operation and a modular configuration fitting different customer needs, it is
Duomix GX device is characterised by safe and intuitive operation and a modular configuration fitting different customer needs, and it is perfectly suited to the offshore, oil & gas, and architectural industries.
perfectly suited to the offshore, oil & gas, and architectural industries. Lloyd’s Register has certified that a Duomix 333 GX PFP unit meets the requirements for operation in a Zone 1 hazardous area as per EN 60079-10-1:2009 (ATEX designation CE II2Gc IIB T 3). WiWA Duomix 333 GX PFP Zone 1 is based on the Duomix 333 model, but the electrical components have been minimised. The electrical controller and the level gauge for the water tanks are protected by pressure-encapsulated control boxes.” The last device presented by Sames was Fleximix GX PFP. “With this system, we are introducing a new multicomponent device in the field of passive fire protection, offering significantly high flow rate values for the application of highthickness films with a variably adjustable and precisely maintained mixing ratio.” The audience was very interested and actively involved. They asked numerous questions, particularly about the new products’ application process, certification, and compliance with Italian building regulations.
After the lunch break, the participants moved on to the practical demonstration at the premises of Lena Anticorrosione, a company specialising in corrosion protection treatments since 1950. Under the supervision of Alessandro Formenti, Senior Coating Advisor at Jotun, and Nicolay Dinspel, Regional Sales Manager – Fire Protection ECA – Europe & Central Asia, three types of Jotun intumescent paints were applied: the water-based SteelMaster 900WF, the solvent-based 90SB QD, and the epoxy-based 1200HPE. “We know that industry professionals appreciate this type of seminar because they have the opportunity to ask technical questions and take a closer look at the
The last application phase during the practical demonstration.
applied coatings,” stated Vaira Vesnaver. “To make this event even more effective and worthwhile for all participants, we will send them a survey to assess their degree of satisfaction and the practical scope that this seminar will have in their daily work. This, too, demonstrates Jotun’s reliability, care, and respect for its users. I would like to take this opportunity to thank all the participants, our employees, and MarieAnne Guilldou, the Marketing Manager for Italy & Middle-East - area of Sames, who actively collaborated with us in organising this event, which has become an annual tradition that will certainly come back in the future.” ‹
During the practical demonstration, three types of Jotun intumescent paints were applied: the water-based SteelMaster 900WF, the solvent-based 90SB QD, and the epoxy-based 1200HPE.
3-5 JUNE
INTERNATIONAL TRADE FAIR FOR PUMP SYSTEMS, VALVES AND EQUIPMENT FOR INDUSTRIAL PROCESSES
By Sherwin-Williams Protective & Marine
The new Global Core coatings include an inorganic zinc primer, epoxy primer, epoxy intermediate coat and urethane topcoat. These versatile coatings can be used in various combinations and with other products to create multi-layer coating systems for corrosion protection and aesthetics for a wide range of applications in the commercial infrastructure, bridge and highway, energy, manufacturing and processing, water and wastewater, and other markets. Each product is easy to apply while meeting the requirements of local, regional and global customers who expect consistency no matter the location. The four additions to the Sherwin-Williams Global Core product line each meet the strict requirements of the ISO 12944:2018 and NORSOK M501 standards. These global standards
define the minimum performance characteristics of coatings in an array of service environments, including the most severe C5 and higher conditions noted in ISO 12944:2018. Adhering to these international standards enables the third-party validated coatings to be specified and used around the world, as they will feature the same chemistry, technical data sheet information, coating performance data, standard colours and application characteristics regardless of where they are manufactured or sold. These characteristics make the Global Core coatings particularly advantageous for use in multiregional projects.
“Consistency enables uniformity – which are both key characteristics customers look for in coating systems when operating around the globe,” said Sean Grady, Senior Global
Product Director, Sherwin-Williams Protective & Marine. “For example, a project featuring structural steel may be engineered in one region with the steel fabricated and coated in another region before being shipped elsewhere to be erected. Along the way, the initial specifiers, original coating applicators and final touch-up crew must be able to select the same coatings regardless of their location. Our Global Core products offer the same formulations and performance characteristics worldwide, allowing us to service projects wherever materials are needed.”
The new coatings offer enhanced productivity and greater ease of application. On the productivity front, the coatings all have fast drying times, enabling the prompt application of subsequent coats and rapid handling of assets for delivery to job sites. This faster job throughput is further enhanced by application ease, including easy sprayability and tolerance, as well as standard mixing ratios, which minimize the potential for errors. The coatings’ broad performance versatility also enables applicators to stock fewer additional products, helping optimize their inventory operations.
The new Sherwin-Williams Global Core high-performance coatings can be written into specifications or maintenance programs throughout the world without concern for formulation quality or consistency, and include the following products1:
Zinc Clad® 2500 – Inorganic Zinc Primer: faster priming, handling and delivery of new construction assets is possible with Zinc Clad 2500. The inorganic zinc primer is heavily loaded with zinc silicate and is applied to bare-blasted steel in a fabrication
1 https://industrial.sherwin-williams.com/na/us/en/protective-marine/why-us/global-core-products.html
SHERWIN-WILLIAMS PROTECTIVE & MARINE IS DELIVERING SUPERIOR COATING SYSTEM CONSISTENCY AND SPECIFICATION EFFICIENCY WITH AN EXPANDED LINE OF GLOBAL CORE PRODUCTS THAT ARE AVAILABLE AT THE SAME QUALITY AND PERFORMANCE STANDARDS ANYWHERE IN THE WORLD. THESE UNIVERSAL PRODUCTS OFFER ASSET OWNERS, ENGINEERS, SPECIFIERS AND APPLICATORS PEACE OF MIND IN ENSURING COMPATIBILITY, COLOUR MATCHING AND PERFORMANCE ON PROJECTS SPANNING MULTIPLE REGIONS.
shop environment. It provides excellent protection against corrosion (all the way up to ISO 12944 CX environments) and also meets the requirements of slip B for bolted connections. Superior application characteristics provide greater transfer efficiency, less waste and less time spent cleaning up dry spray. The thin-film coating cures quickly, with a 45-minute dry-to-handle time and a dry-to-recoat time of as little as four hours, both of which enable shops to accelerate throughput, maximize productivity and rapidly ship coated assets. This fast delivery pace also helps to accelerate construction schedules for enhanced builder productivity.
Macropoxy® 4600 – Corrosion Inhibitive Epoxy Primer: approved for ISO 12944 service environments of up to C5, Macropoxy 4600 offers a cost-effective anti-corrosion primer option for protecting carbon steel. The high-solids, multi-functional epoxy zinc phosphate coating enables fast applications, cures and asset handling – with no sweat-in time, dry-to-handle times of just three hours and a minimum recoat window of two hours –to enhance productivity. It also features a low-temperature cure, which means the product will dry faster at lower temperatures and will continue to cure even if it is moved outside during the winter months.
Macropoxy® 2600 – Epoxy: in a traditional three-coat system, a high-build intermediate coat is a necessity to build film thickness as a barrier to protect the anti-corrosive layer below. Macropoxy 2600 offers just that, along with notable application efficiencies. The high-solids epoxy has a simple 4:1 mix ratio with no sweatin time; it also dries fast, cures at low temperatures and has a rapid minimum recoat time of two hours, enabling applicators to move quickly to the final top coating step. Adding to the ease of application, both Macropoxy 2600 and Macropoxy 4600 share the same catalyst, enabling applicator inventory efficiencies, as shops only need to stock one hardener. Designed to withstand the most aggressive ISO 12944 C5 environments and higher in its original form, Macropoxy 2600 is also available in a formulation featuring micaceous iron oxide flakes for enhanced overcoating properties and barrier protection.
Acrolon® 7700 – Urethane Topcoat: a durable finish coat of Acrolon 7700 over a high-performance anti-corrosion system offers both enhanced aesthetics and additional protection for steel assets. This two-component, high-solids acrylic polyurethane has excellent resistance to atmospheric exposures and maintains gloss and colour, even in highly corrosive environments. With reduced dry times, Acrolon 7700 allows applicators to rapidly move assets through shops for accelerated throughput. Acrolon 7700 also offers applicators ease of application with lower operating pressures, a wider range of film build requirements with no reduction needed and a simple 4:1 mix ratio to minimize opportunities for errors. ‹
Building on the success of the worldrenowned Pipeline Technology Conference (ptc) in Berlin1, the EITEP Institute announces the launch of its first regional spin-off event, the Pipeline Technology Conference Asia (ptc Asia).
Scheduled to take place in Kuala Lumpur, Malaysia, from November 11-13, 2025, this highly anticipated event will serve as a premier platform for addressing the unique opportunities and challenges facing Southeast Asia’s rapidly evolving pipeline industry.
ptc Asia is designed to bring together key pipeline stakeholders, including operators, EPC contractors, engineers,
1 https://www.pipeline-conference.com/
and technology providers, for an intensive two-day technical conference and exhibition, preceded by a day of specialised training courses. The event aims to foster meaningful discussions on regional challenges, such as new offshore developments, implementing carbon capture and storage (CCS) technologies, and enhancing sustainability in energy infrastructure.
Malaysia, with its strategic location and important role in Southeast Asia’s energy landscape, is the ideal host for ptc Asia. The region is poised for growth, driven by the shift from coal to natural gas, significant offshore gas discoveries, and increasing investments in sustainable technologies.
All conference materials will be published on an open-access basis, fostering knowledge exchange and supporting local academia. ptc Asia will also place a strong focus on empowering students, young professionals and women in the industry, ensuring that the event contributes to building a diverse and skilled workforce. With the backing of the globally respected ptc brand and an international advisory committee, ptc Asia is set to become a cornerstone event for the region’s pipeline industry.
The Euro Institute for Information and Technology Transfer in Environmental Protection, EITEP, was originally founded by the German technical and scientific associations on energy and water. The main objective of the EITEP Institute is to foster the international information and technology transfer in the water, energy, environment, and infrastructure sector.
www.pipeline-conference.asia and www.eitep.de
The 16th edition of the Giornate Nazionali sulla Corrosione e Protezione (National Conference on Corrosion and Protection) will take place in Ancona, Italy, on June 25, 26, and 27, 2025, at the Faculty of Engineering of Università Politecnica delle Marche.
The conference is the leading national event dedicated to the discussion and exchange of scientific, technological, and industrial developments in the field of corrosion and materials protection. The programme will include the presentation of research results by various study groups and numerous companies operating in the sector.
The event, featuring over 80 presentations and a dedicated exhibition area for sponsoring companies, is organised by the key national associations in the corrosion protection field: AIM – Associazione Italiana di Metallurgia (Italian Association for Metallurgy), APCE (Association for Electrolytic Corrosion Protection), and AMPP Italy Chapter. For this edition, they will be joined by the Università Politecnica delle Marche as a partner.
The scientific coordination will be overseen by Professor Tiziano Bellezze.
A special focus will be placed on students, with a dedicated award named in memory of Professor Cecilia Monticelli, which will recognise the most outstanding student presentation during the event.
Registration for the event is now open. Attendees who complete their registration by May 12, 2025, will benefit from a reduced participation fee. Further details can be found in the “General Information” section of the event programme, available for download from the official website.
www.aimnet.it/eng/
Tiziano Bellezze and a panoramic view of Ancona, venue of the event.
The organizers of Maritime Industry are preparing for the upcoming edition on May 20, 21, and 22, 2025, at Evenementenhal Gorinchem in the Netherlands. This year, the focus will be not only on technological innovations and sustainable solutions, but also on knowledge sharing, career development, and supporting a special charity. New features at Maritime Industry include a Belgian Pavilion and a Startup Pavilion.
The first day of the exhibition kicks off with knowledge sharing as the main focus. The event opens with a high-quality knowledge program, where leading experts from the maritime sector share their insights on current and relevant topics. From technological innovations to sustainable initiatives, visitors will have the opportunity to stay up-to-date with trends and new technologies driving the maritime industry at Next Level, the upper floor of Evenementenhal Gorinchem.
The Career Event – in collaboration with Scheepvaartkrant – is the main focus on the second day of the exhibition. Job seekers will have the opportunity to connect in an accessible way with leading companies and explore opportunities for internships and jobs in the maritime sector. Employers, in turn, can engage with ambitious professionals looking to accelerate their careers. A direct match between supply and demand is at the heart of this day. The Career Event will be held on May 21, from 1:00 PM to 6:00 PM, at Next Level.
On the third and final day of the exhibition, the SailWise Foundation takes centre stage; a charity that offers people with physical or intellectual disabilities the opportunity to go out on the water and experience ultimate freedom. For over 50 years, SailWise has been organizing adventurous holidays, ranging from sailing and canoeing to water skiing, specifically for people with disabilities.
Thanks to adapted boats and accommodations, along with the support of dedicated volunteers, all participants can enjoy the water without worry. SailWise proves that water sports are accessible to everyone, with the slogan “together, unlimited enjoyment” guiding the way. On this final day of the exhibition, visitors and exhibitors can not only explore the course towards the future of the maritime industry, but also contribute to a world where everyone has the freedom to enjoy water sports, regardless of their limitations.
The upcoming edition promises to be innovative and inspiring. This year, the exhibition organization introduces two brand-new pavilions: the Belgian Pavilion and the Startup Pavilion. The Belgian Pavilion brings the Dutch and Belgian sectors closer together. Visitors can discover the latest developments and innovations within the Belgian inland navigation sector, while enjoying Belgian hospitality, complete with Belgian (craft) beer and authentic Belgian waffles.
The Startup Pavilion provides a platform for young, ambitious companies to present their creative and innovative ideas alongside established names from the industry. Here, visitors will find the future of the inland navigation sector: innovative concepts and promising growth opportunities that offer valuable networking possibilities.
Maritime Industry 2025 will take place on Tuesday, May 20, Wednesday, May 21, and Thursday, May 22, at Evenementenhal Gorinchem and will be open daily from 1:00 PM to 9:00 PM. Admission is free, and visitors can reserve a ticket in advance via the website.
www.maritime-industry.nl/en
The Chemtec Lab Experience event of 20 February 2025 was a great success. Addressed to professionals in the sector, the meeting focused on the innovative ACET method, an advanced technique for measuring the corrosion resistance of coatings. In the morning, at Italiana Hotels in Rho (Milan, Italy), the event’s participants learned more about the advantages of the ACET method, an accelerated testing system ensuring that precise results are obtained in just twenty-four hours, thus significantly reducing the required time compared with traditional salt spray tests while still guaranteeing scientifically valid results. The presentation highlighted the potential of this electrochemical method regulated by ISO 17463, which is establishing itself as an innovative solution to meet the industry’s growing quality requirements.
The morning began with an introduction from the moderator, who greeted the participants and presented the event. Beatrice Turri, head of communication & marketing and sales support at Chemtec, introduced the company and its mission, emphasising the key role of environmental sustainability in every corporate
decision and innovation. Carlo Guidetti, the CEO of Chemtec, greeted all participants by highlighting the ACET method’s high degree of innovation. Gianmaria Guidi from Germedia Srl opened the series of speeches with a detailed analysis of contractual relationships complying with ISO 12944, exploring crucial aspects for operators in the sector. Carlo De Alessandri from Chemtec presented the ISO 17463 standard and explained how the ACET test works, offering a complete overview of its practical application. The presentation continued with Daniele Bottacci from METROHM, who illustrated the instrumentation used for ACET tests, fundamental for guaranteeing measurement precision. Subsequently, Tommaso Giovenzana from Chemtec shared some case histories, comparing ACET with the conventional salt spray test and demonstrating the new method’s effectiveness. Nicolò Trevisan from Metalplast presented a concrete industrial application of ACET, attesting to its usefulness in coating protection. Finally, Stefania Muto from Chemtec illustrated the activities of the company’s laboratory, focussing on the technological resources available for corrosion analysis.
In the afternoon, the event participants visited Chemtec’s headquarters in Corbetta (Milan), including the laboratory and production plant, where they witnessed a sample preparation process. In fact, to complete the experience, each participant was given a voucher to conduct a series of comparative tests within twelve months of the event for an in-depth assessment of the corrosion resistance achieved on their own samples. “We would like to thank all the participants for their interest and enthusiasm,” stated Chemtec’s CEO, Carlo Guidetti. “The Chemtec Lab Experience event was a unique opportunity to emphasise the importance of the ACET method, showing its potential to industry experts. We will continue to pursue our goal of joining forces within the surface treatment sector to promote technological progress, focusing on increasingly sustainable solutions that can meet the challenges of the future.”
The event also provided an opportunity for networking and exchanging ideas with other industry experts, confirming Chemtec as a point of reference in the innovation of industrial finishing technologies.
www.chemtec.it/en
myFAIR is a free web app that can be accessed from both desktop and mobile devices, which allows you to stay up-to-date with the leading events of the surface treatment sector.
From June 24th to 26th 2025, Lille (France) will host the 14th edition of SIFER, the International Exhibition of Railway Technology, the only B2B event in France entirely dedicated to the rail sector.
Held every two years since 1999, SIFER brings together the entire rail ecosystem under one roof: rolling stock manufacturers, railway operators, infrastructure developers, technology providers, equipment suppliers, engineering firms, maintenance specialists, regulatory bodies, research institutions, and industry innovators. The previous edition in 2023 welcomed over 7,000 visitors to Lille Grand Palais — a record that reflects the strategic role of this event within the French rail industry and the dynamism of the sector. In 2025, over 300 exhibitors from 14 countries – including around 100 newcomers – will showcase their latest innovations in a market buzzing with momentum.
At SIFER, innovation comes to life. Over three days and across nearly 5,500 m², visitors will discover:
Indoor tracks: where vehicles and rail equipment can be viewed in live operating conditions.
Innovation Hub: a dedicated space for startups reshaping the future of rail through digitalisation, cybersecurity, AI, decarbonisation and automation.
FIF Village: co-organised with the French Railway Industry Association (FIF), featuring member companies and a dedicated forum space.
International B2B meetings: connecting French and international stakeholders for business development across borders.
A programme of conferences and technical seminars focused on key sector transitions: energy, industrial sovereignty, competitiveness and supply chain resilience.
Networking Event: a relaxed evening gathering with drinks and live music to extend conversations in a convivial setting, taking place after the first day of the show.
New for 2025: Tunnelling Area – a dedicated area to present the latest innovations in the construction and equipment of tunnels.
www.sifer-expo.com
The European Union’s FuelEU Maritime, which entered into force on 1st January 2025, sets targets to drastically reduce the greenhouse gas (GHG) intensity of the European shipping sector. Applying to vessels over 5,000 gross tonnage, the regulation specifies a two-per cent reduction factor in 2025 against a 2020 baseline, increasing in five-year intervals to reach 80% in 2050.
While measures such as voyage optimisation and the use of energysaving devices will help ship owners to meet FuelEU Maritime’s shortterm emissions-reduction targets, achieving its medium- and long-term goals will require the adoption of clean energy sources. Against this background, the number of alternative-fuelled ships on order grew by more than 50% in 2024, with the existing alternative-fuelled fleet increasing by almost 20% in the same period.
Meanwhile, the regulatory framework surrounding the safe implementation of alternative fuels continues to take shape. The International Maritime Organization (IMO)’s 109th Maritime Safety Committee (MSC 109), which took place from 2nd to 6th December 2024, saw the adoption of amendments to the IGC Code to enable the use of ammonia cargo and the approval of draft interim guidelines for ammonia as fuel. Plans were also laid out for a gap analysis regarding fourth-generation nuclear power. Elsewhere, BIMCO recently adopted its FuelEU Maritime Clause for Time Charter Parties 2024 «to help stakeholders align their contractual frameworks”.
Crucial to FuelEU Maritime’s short-to-medium-term goals is shore power. From 2030, passenger and container ships greater than 5,000GT berthed at Trans-European Transit Network ports in the EU for more than two hours and not using zero-emissions technology are required to connect to an onshore power supply (OPS). From 2035, the rule will apply to all EU ports with available shore connections. FuelEU Maritime’s consideration of shore power promises to significantly reduce GHG emissions in and around portside areas while contributing towards its wider targets. Encouragingly, the EU leads the way in providing OPS. While only 3% of global ports currently offer shore connection points, more than half of European ports are equipped with such facilities at one or more berths. The energy transition will be the main topic discussed, along with many others, at the upcoming Europort 2025, which will take place from November 4th to 7th in Rotterdam, Netherlands.
www.europort.nl
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