Issuu

ISSN 2282-1767

an ipcm magazine

ISSUE 16 OCTOBER 2026

Preventing biofouling at the source:

Assessment of fouling release

FBE linings for industrial valves: market

an ultrasonic approach to hull protection

for PDMS-based coatings

evolution and application expertise

page 30

page 44

page 64

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The most important industry events at your fingertips 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 an ipcm app ®

events of the surface treatment sector.

05 FROM THE EDITOR 06 WHAT'S NEW 10 SUCCESS STORY Carnival Cruise Line pioneers hull cleaning for cruise operations with Jotun

ISSUE 16 - OCTOBER 2026

14 THE BREAKDOWN Why thermoplastic powder coatings are emerging as the smarter choice for wire and tubular applications

20 SCIENCE OUTLOOK Cathodic protection design for ship hulls: beyond anode selection

30 SPOTLIGHT Preventing biofouling at the source: an ultrasonic approach to hull protection

34 THE BREAKDOWN From hand tools to robotics: the evolution of mechanical surface preparation

44 SCIENCE OUTLOOK

CONTENTS

Assessment of fouling release for PDMS-based coatings

52 ADVANCEMENTS Evonik strengthens fast-cure epoxy offering in the Americas with Ancamine® 2868 and Ancamine® 2844 for challenging conditions

54 THE BREAKDOWN Single-coat powder coating solutions: greater efficiency in a single application

56 SCIENCE OUTLOOK Critical comparison of impressed current and galvanic anode cathodic protection in the offshore wind industry

64 THE BREAKDOWN FBE linings for industrial valves: market evolution and application expertise

70 SPOTLIGHT Data-Driven hull performance: connecting hull coatings, fouling control and vessel efficiency

66 56

74 ROAD TO 2050 How VpCI® packaging cuts plant energy use and carbon emissions

77 WHERE WE'VE BEEN 78 MEETING THE INDUSTRY

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FROM THE

EDITOR

orrosion protection should never be

The other recurring theme is the automation

treated as a step to be addressed

and robotisation of surface preparation.

only after a project is complete,

The use of automated platforms and robotic

but rather as a strategic element

systems is one of the most promising avenues

to be incorporated from the earliest design

for the evolution of this process stage: these

stages. Whether it involves organic coatings,

technologies enable operations to be managed

inorganic treatments, cathodic protection

with controlled, repeatable parameters,

systems, or antifouling treatments, the choice

reducing the variability associated with manual

of the right solutions should take into account

intervention. As well as promoting process

the operating conditions, the exposure

standardisation, these solutions help to

environment, the expected service life, and the

improve operator safety by limiting exposure

performance requirements of the structure or

to harsh environments, dust, and potentially

component to be protected.

hazardous substances, and by reducing the

An integrated design approach enables the

need to work underwater or at height. Process

prior assessment of compatibility among

data collection also enables the documentation

materials, protective technologies, and

of operating conditions, verification of

operating conditions, thereby avoiding late,

compliance with specifications, and prompt

costly, and potentially ineffective corrective

identification of any anomalies.

measures. Surface preparation plays a crucial

Underwater robots, remotely operated

role in this regard: the removal of contaminants

vehicles, and autonomous systems take on

and the achievement of the required surface

even greater importance in applications where

profile are essential to ensure the adhesion and

inspections and manual interventions are

durability of subsequently applied coatings.

particularly complex, costly, or risky. This is

Similarly, maintenance planning should

the case with pipelines, offshore structures,

be defined at the design stage. Regular

and the submerged sections of ship hulls,

inspections, performance checks, and

where limited accessibility and environmental

preventive maintenance enable the early

conditions make both surface preparation and

detection of signs of degradation and help to

treatment quality control difficult.

extend the service life of structures.

A further advantage is the ability to integrate

Corrosion protection can thus be viewed as a

sensors and monitoring instruments to collect

process comprising three closely interlinked

data on surface conditions and document the

stages: surface preparation, protective system

work carried out. This information helps to

design and application, and long-term

make maintenance planning more effective and

and maintenance. Only

monitoring and maintenance. Only by taking

to identify any signs of degradation promptly.

by taking a holistic view

a holistic view can costs be optimised over

All these topics, together with the impact of

the life cycle, reliability increased, and the

the crisis in the Middle East and the challenges

sustainability of industrial investments

associated with the Strait of Hormuz, will

ensured.

be central themes at ADIPEC, one of the

That is one of the key concepts addressed in

leading international events for the energy

the numerous articles featured in this issue

sector, taking place in Abu Dhabi from 2 to 5

of Corrosion Protection, which focuses on

November. Corrosion Protection will be there

technologies for the marine and offshore

with its own stand (#16008), distributing this

sectors.

issue to visitors.

Alessia Venturi Editor-in-chief

Corrosion protection can be viewed as a process comprising three closely interlinked stages: surface preparation, protective system design and application, and long-term monitoring

can costs be optimised over the life cycle, reliability increased, and the sustainability of industrial investments ensured.

OCTOBER 2026 | CORROSION PROTECTION

W H AT ’ S

NEW Hempel secures three-year global hull coatings agreement with Maersk for fleet dry dockings

Jotun Yachting highlights 50% lower carbon footprint with Imperial fouling protection

The agreement reinforces a long-standing partnership

New analysis demonstrates the environmental and operational benefits

and demonstrates how high-performance hull coatings

of advanced hull protection for superyachts.

improve fuel efficiency and vessel performance. It also

Jotun has unveiled new analysis showing that its Imperial Fouling

underscores ongoing customer trust in Hempaguard

Protection System can deliver an approximately 50% lower carbon

silicone technology and the strong demand for

footprint over a 30-year service life compared with a conventional

Hempel’s premium hull solutions.

antifouling coating system, reinforcing the importance of effective hull

The paints and coatings supplier Hempel has signed

protection in the superyacht sector.

a three-year global hull coatings agreement with A.P.

Hull fouling remains one of the most significant yet overlooked

Moller - Maersk (Maersk), covering a substantial share

factors affecting vessel efficiency. As marine organisms accumulate

of the company’s 2026 to 2028 dry dock programme.

on the underwater hull surface, drag increases, leading to higher fuel

“Maersk is widely recognised as a global leader in

consumption, greater emissions, and increased operating costs. In some

operational excellence and decarbonisation, setting

cases, a fouled hull can add more than 50% to a yacht’s annual fuel bill.

the standard for our industry. We are very proud to

Designed specifically for the unique operating profiles of superyachts,

work with a partner with such ambitious goals. At

Imperial uses advanced silyl acrylate self-polishing technology to help

Hempel, we believe that trust is earned through proven

maintain a cleaner hull over extended periods, even when vessels

performance, reliable service and long-term results. We

spend significant time at anchor or operating at low speeds. The tailored

are delighted that Maersk’s confidence in our solutions

approach enables coating specifications to be matched to a vessel’s

has led to this agreement, which further strengthens

sailing pattern, voyage factor, and operating environment.

the long-standing partnership between our companies

The reduced carbon footprint is achieved through fewer maintenance

and builds on our successful collaboration in advancing

cycles, lower paint consumption, and reduced waste generation over

hull-performance solutions,” has stated Malgorzata

the life of the vessel. Compared with a business-as-usual coating

Kolton, Executive Vice-President and Head of Marine

specification developed in collaboration with leading paint manufacturers

at Hempel A/S.

and the Water Revolution Foundation, Imperial uses approximately half

Hull coatings are an important factor for vessel

the paint volume while maintaining long-term performance.

efficiency, with hull condition directly influencing fuel

“This is ultimately about giving owners strong performance while

consumption, emissions and operating costs. This

reducing environmental footprint where possible,” said Tracey Warner,

agreement goes beyond hull coatings: Maersk and

Regional Category Manager Yachting, Europe and Central Asia, Jotun

Hempel will further strengthen their collaboration

Performance Coatings.

through joint initiatives, from driving dry docking

Beyond efficiency gains, effective fouling protection also supports marine

excellence to enhancing in-service performance.

biosecurity by helping prevent the transfer of invasive species between

“Hull performance is an important contributor to

regions and reducing the need for underwater cleaning operations.

fuel efficiency and our emission reduction ambitions.

Leah Werner, Executive Director of the Water Revolution Foundation,

Through this new agreement, we ensure that we can

added: “A robust lifecycle assessment considers the full range of impacts,

continue to innovate and optimise vessel performance

from material production and maintenance cycles to waste generation

across our fleet,” has added Kristian Brauner, Head of

and operational efficiency. Transparent lifecycle data enables the industry

Fleet Operations at Maersk.

to make more informed sustainability decisions.”

www.hempel.com

www.jotun.com

CORROSION PROTECTION | OCTOBER 2026

WHAT'S NEW

PPG introduces PPG ONE RANGE portfolio for onboard maintenance PPG launched the PPG ONE RANGE™ portfolio of five one-

Products in the portfolio incorporate technologies that support low

component marine coatings at the SMM 2026 maritime trade fair

volatile organic compound (VOC) compliance and low flame spread

in Hamburg, Germany. Designed to simplify onboard maintenance,

certification,” has added Kahina Ouchaou, PPG product manager,

the ready-to-use coatings eliminate mixing requirements, reduce

Protective and Marine Coatings. PPG’s commitment to simplifying

waste and help crews complete maintenance projects more

onboard maintenance extends beyond coatings. At SMM, PPG

efficiently. The portfolio supports a broad range of applications

will preview the PPG POWERPACK™ application tool, a portable,

while simplifying product preparation, storage and handling.

battery-powered system developed to improve application efficiency

“Coatings maintenance is essential for extending vessel lifecycles,

when used with the PPG One Range portfolio.

but preparation and application can be time-consuming for crews

“The PPG PowerPack tool allows crews to switch easily between

managing other operational responsibilities. With the PPG One

roller and brush application using a single unit, reducing

Range portfolio, we focused on eliminating mixing requirements

equipment changes and helping improve productivity. Together,

and simplifying application to help crews complete projects more

the PPG One Range portfolio and the PPG PowerPack tool

efficiently,” has stated Ewout Bosman, PPG segment director,

demonstrate how we continue to innovate both inside and outside

seastock, Protective and Marine Coatings.

the can,” has concluded Ewout Bosman.

“The portfolio includes waterborne, alkyd and polyurethane technologies for both interior and exterior maintenance applications.

www.ppg.com

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QUALITY AND INNOVATION BEYOND THE SURFACE O.M.SA. s.r.l. Via Cimabue, 16 | Fraz. MONTESIRO 20842 BESANA in BRIANZA (MB) | ITALY info@omsasrl.com | www.omsasrl.com

WHAT’S NEW

Hydrojetting drives demand for coatings that can protect corrosion-prone steel Hydrojetting, also known as water jetting or water blasting, uses

may be difficult to achieve. They require no mixing and can be

ultra-high-pressure water, typically at 700–1,000 bar, to clean,

applied by brush, roller or spray to damp or manually prepared

descale and remove existing coatings from ship hulls, decks, cargo

steel,” has added Andreas Engert.

holds and tanks. The process is increasingly being used as an

The systems can be used at temperatures ranging from -5°C to

alternative to dry abrasive blasting during drydock maintenance,

50°C and at relative humidity levels of up to 98%. The company also

amid greater scrutiny of the environmental impact of spent abrasive

says they adhere to stainless steel, galvanised steel and aluminium,

and contaminated waste. Unlike abrasive blasting, hydrojetting

allowing corrosion-protection work to be carried out during

produces no dust or spent abrasive and can reduce the amount

drydocking or while vessels remain in service.

of contaminated waste generated during surface preparation.

The coatings can be applied to hydrojetted steel prepared to SSPC-

However, the process presents challenges for conventional coating

SP WJ/NACE WJ standards, including WJ-3 to WJ-2, as well as to

systems because it does not create a new anchor profile on the

vapour-blasted and manually or power-tool prepared surfaces.

steel surface. Residual moisture and flash rust can also affect

Hydrojetting has gained particular acceptance where waste-

coating adhesion and curing.

disposal requirements, environmental controls or operational

“These conditions can make it difficult for traditional coatings

constraints make abrasive blasting less practical.

to perform reliably, particularly in hot and humid climates where

“By combining hydrojetting with moisture-cure coating technology,

relative humidity can exceed recommended application limits.

shipowners and offshore operators benefit from an alternative

If conditions are not ideal, such coatings can fail to adhere

corrosion-protection method that can simplify maintenance,

properly, blister, crack or break down,” has stated Andreas Engert,

reduce maintenance costs and extend service life in demanding

technical director at Steelpaint. Single-component moisture-

conditions,” Frank Müller, Director of Steelpaint. The single-

cure polyurethane coatings can offer an alternative in these

component nature of the coatings can further reduce material

conditions. The company cites its Stelpant and Stelcatec systems

waste and packaging requirements. Unlike conventional two-

as examples of coatings designed to tolerate high humidity and

component systems, they do not require mixing and have no limited

damp substrates. According to the company, the coatings can be

pot life, reducing the amount of unused mixed coating that must

applied at relative humidity levels of up to 98% without dew-point

be discarded. Lastly, the combination of hydrojetting and moisture-

restrictions and can be used on damp steel and surfaces showing

cure coatings therefore offers potential benefits in terms of

light to medium flash rust. They are also designed to maintain

environmental impact, labour requirements and material efficiency,

adhesion on partially corroded or relatively smooth steel.

alongside corrosion protection in demanding marine environments.

“The coatings are intended in particular for onboard maintenance applications, where conventional surface-preparation requirements

www.steelpaint.de/en/

Sustainability: Impresa Donelli earns EcoVadis Bronze Medal Following the success of Donelli Alexo, Impresa Donelli has

 Labour & Human Rights

achieved a significant sustainability milestone by being awarded

 Sustainable Procurement

the EcoVadis Bronze Medal. This result places the enteprise in

This achievement confirms Donelli’s commitment to responsible,

the top 35% of all global entities evaluated by the rating agency

transparent business models and minimizing its environmental

over the past 12 months. The EcoVadis assessment evaluates

impact. It is the direct result of the strategic work coordinated

companies with robust management systems aligned with ESG

by the company's ESG Committee, established to drive the

(Environmental, Social, and Governance) criteria. To qualify for the

sustainable transition, integrate environmental and social policies

medal, Impresa Donelli met a minimum threshold of 30 points in

into core decision-making, and chart the course for continuous

each of the four key areas of the assessment:

improvement.

 Environment  Ethics

CORROSION PROTECTION | OCTOBER 2026

www.donelli.it/en

WHAT'S NEW

Svenska Aerogel’s customer launches fire-resistant coating tailored for the marine industry Svenska Aerogel’s customer, a European manufacturer of paints

The fire-resistant coating will be sold on a project-by-project basis,

and coatings, is launching a new industrial and fire-resistant

and the customer has begun its sales activities.

coating for the marine industry. The Company’s aerogel material enhances the coating’s fire performance, thereby contributing to

About Svenska Aerogel

increased safety onboard vessels. The coating is intended for use

Svenska Aerogel manufactures and commercializes the

on interior surfaces, such as walls and ceilings. The customer’s

mesoporous material Naerogel®. Svenska Aerogel’s business

product has been developed for commercial shipping and meets

concept is to meet the market’s need for new materials that are in

the applicable requirements set by the International Maritime

line with global sustainability objectives. Naerogel® is flexible and

Organization (IMO). The maritime sector is subject to stringent

can be tailored to different applications to add essential properties

safety requirements, driving demand for fire-protective solutions.

to an end product. The company’s vision is to be the most valued

Such solutions play an important role in limiting the spread

business partner providing pioneering material solutions for a

of fire and protecting structures and escape routes. “We are

sustainable world.

pleased to see our material, Naerogel®, being used in a product

Svenska Aerogel Holding AB is listed on Nasdaq First North

that addresses a clear market need and, above all, contributes

Growth Market. Certified Adviser is FNCA.

to increased safety for people onboard,” says Tor Einar Norbakk, www.aerogel.se

CEO of Svenska Aerogel.

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SUCCESS

STORY

Carnival Cruise Line pioneers hull cleaning for cruise operations with Jotun 10

CORROSION PROTECTION | OCTOBER 2026

SUCCESS STORY

Carnival Cruise Line (CCL) became the first cruise operator to adopt Jotun’s Hull Skating Solution (HSS), a robotic technology for proactive hull cleaning.

Carnival Cruise Line (CCL) has signed an agreement with Jotun to implement Hull Skating Solution (HSS), becoming the first cruise operator to use this robotic proactive hull cleaning technology. With this commitment, Carnival continues to utilise innovation and technology to reduce emissions and protect biodiversity.

s one of the world’s largest and most influential cruise brands, Carnival’s adoption of Hull Skating Solution (HSS), developed by Jotun, to prevent and remove biofouling from ship hulls, on board

the Carnival Pride marks an important shift for the wider industry. The technology enables proactive hull cleaning, helping vessels maintain a clean hull throughout typical cruise operations. This proactive approach also reduces fuel consumption and carbon emissions while helping to protect marine biodiversity.

OCTOBER 2026 | CORROSION PROTECTION

SUCCESS STORY

First cruise-sector application of Jotun’s Hull Skating Solution

The solution is also supported by high-end technical services.

Jotun Hull Skating Solutions combines proactive cleaning,

antifouling system and implement a comprehensive regime

condition monitoring, high-performance coatings and specialised

for measuring and documenting coating application quality.

technical services to prevent early-stage fouling and maintain a

A certified project manager supervises the overall process,

clean hull during vessel operations. By keeping the hull clean, the

including the installation and set-up of the robotic system.

solution is designed to reduce fuel consumption and greenhouse

HullSkater is remotely operated by trained Skate Operators

gas emissions while helping to limit the spread of invasive species.

working through Jotun’s “follow-the-sun” operating hubs,

HSS comprises five integrated elements. The first is SeaQuantum

providing 24/7 operational support.

Skate, a high-performance antifouling coating specifically

The fifth element is a clean hull guarantee. Jotun provides

developed for use with HullSkater technology. The coating builds

performance and service-level guarantees designed to support

on the performance of Jotun’s SeaQuantum range, developed

the requirements of demanding vessel operations, reflecting the

through more than 20 years of research into silyl acrylate

company’s confidence in the integrated Hull Skating Solutions

technologies. SeaQuantum Skate is specifically tailored for Hull

approach.

Specialised coating advisors oversee the application of the

Skating and has been verified by Lloyd’s Register. A second key element is proactive condition monitoring, which

A new approach to proactive hull maintenance

supports predictive hull maintenance. Jotun’s in-house analysts

"Maintaining a clean hull is essential for efficient ship operations,

use big data trends, algorithms and data analysis to predict fouling

and the Hull Skating Solutions allows us to take a more proactive

development and advise customers on when hull maintenance

approach to hull maintenance," said Jari Oinas, AVP of fuel

should be carried out. Oceanographic assessments are also used

performance and decarbonization at Carnival Cruise Line. "As

to support fouling predictions and determine the most appropriate

we evaluate the technology aboard Carnival Pride, we see strong

timing for HullSkater deployment.

potential to support ship performance while advancing our long-

The third element is inspection and proactive cleaning. HullSkater

term sustainability goals."

is a robotic system specifically designed to inspect and clean the

Carnival’s move is the first introduction of Jotun’s robotic hull

hull proactively, removing early-stage fouling while minimising

cleaning solution in the cruise sector.

the risk of damage to the antifouling coating. The robot remains

“Carnival is demonstrating real leadership by embracing new

onboard the vessel, making it available whenever required,

technology that ensures consistently clean hulls and reduced

including when the vessel is in port or at anchor.

environmental impact,” says Stein Kjølberg, Regional Vice President Americas for Jotun.

CORROSION PROTECTION | OCTOBER 2026

SUCCESS STORY

“With our 100-year long track record in hull performance, and with presence in the US for over 50 years, we are proud to support an American icon that is both ambitious and forward leaning.” In addition to the HullSkater device, the agreement includes compatible hull coating, continuous monitoring and hull inspections, hull performance transparency through Jotun’s digital reporting solutions, and an always clean hull guarantee. Jotun recently received independent verification from DNV, verifying an always clean hull for vessels using HSS, with no measurable speed loss. For cruise operators, the ability to inspect and clean the hull before sailing to the next destination is particularly valuable. By maintaining a clean hull, Carnival can support fuel efficiency, minimise speed loss and reduce the risk of transferring invasive species between various waters and ports.

Jotun Hull Skating Solutions combines proactive cleaning, condition monitoring, high-performance coatings and specialised technical services to prevent early-stage fouling and maintain a clean hull during vessel operations.

Stein Kjølberg in Jotun applauds Carnival’s willingness to challenge and disrupt: “Our Clean shipping commitment is dependent on collaborations with partners who dare to innovate.” ‹

From left to right: The HullSkater robot, part of Jotun’s HSS, an advanced system for the proactive cleaning of ship hulls. Proactive condition monitoring is a key element in supporting predictive hull maintenance. The crew of Carnival Pride with Jotun technicians. Carnival Pride, where Jotun’s Hull Skating Solution is being evaluated for its potential to support ship performance.

OCTOBER 2026 | CORROSION PROTECTION

THE BREAKDOWN

WHY

THERMOPLASTIC POWDER COATINGS ARE EMERGING AS THE SMARTER CHOICE FOR WIRE AND TUBULAR APPLICATIONS Anuj Gupta Rapid Coat Powder Coatings, Noida (Uttar Pradesh) - India anuj.gupta@rapidcoat.com

CORROSION PROTECTION | OCTOBER 2026

THE BREAKDOWN

Thermoplastic powder coatings can provide enhanced protection for outdoor wire and tubular articles, particularly at joints and welded areas where coating coverage is critical. This article examines High Adhesion Polymer Alloy (HAPA), a thermoplastic powder coating developed for demanding outdoor applications, with particular attention to its ability to withstand corrosion, weathering

coating can pass every standard test and still fail where it matters most: at the joint. On wire and tubular workpieces, that’s the

thinnest point in the film, and the first place a changing climate puts real stress on it. The choice between thermosetting and thermoplastic powder coatings determines what happens at this critical point.

and repeated thermal stresses in a warming climate,

The weak point is at the joint

as demonstrated by independent ageing, corrosion,

grilles, and fencing, the joint is one of the most

chemical resistance and adhesion tests.

On wire and tubular articles such as mesh, critical areas for coating performance.

OCTOBER 2026 | CORROSION PROTECTION

THE BREAKDOWN

Figure 1 shows the difference. Because of its nature and particle size distribution, thermosetting powder tends to form a thinner film at weld points and wire intersections, potentially leaving the steel exposed. Thermoplastic powder melts and flows, providing full encapsulation of the joint. Figure 2 shows the result after prolonged use: rust starts at the joint on the thermoset-coated article, while the thermoplasticcoated article shows no signs of rust. This is why thermoplastic is a better choice for outdoor wire articles such as fan grilles, wire racks, and fencing.

High Adhesion Polymer Alloy (HAPA): built for outdoor wire articles This is where High Adhesion Polymer Alloy (HAPA) Figure 1 - Cross sectional view of wire articles using thermoplastic and thermosetting powder coatings.

comes in. HAPA is a thermoplastic powder specially designed for demanding outdoor applications involving UV radiation, rain, and pollution. It offers clear advantages over thermosetting coatings for outdoor articles such as fencing, manhole covers, and outdoor furniture. Beyond the joint-coverage advantage, HAPA offers the properties inherent to thermoplastic chemistry that are particularly relevant for outdoor applications:  Corrosion resistance: the film resists rust even under prolonged exposure to moisture, salt, and chemical agents.  UV resistance: colour and surface integrity are maintained under prolonged exposure to sunlight.  Excellent adhesion: the coating provides strong adhesion to the substrate, helping to maintain film integrity and minimise peeling throughout the service life of the article. Together, these properties contribute to significantly longer service life outdoors for articles coated with HAPA compared with those coated with thermosetting powder. A visual comparison is presented in Figure 2, showing that the HAPA coating remains in good condition and retains its appearance even after prolonged use and exposure (Table 1). HAPA can be applied using the conventional electrostatic spray coating method, as shown in the top image in Figure 3, with only minor adjustments to the process parameters. For complex-shaped and welded steel wire articles, fluidized-bed dip coating is highly

Figure 2 - Results after prolonged outdoor exposure: a) thermoset powder-coated article, showing the onset of rust at the joint; b) thermoplastic powder-coated article, showing no signs of rust.

CORROSION PROTECTION | OCTOBER 2026

recommended. The fluidized-bed dip-coating process is illustrated in the bottom image of Figure 3.

www.montipower.com

• Abrasive blast finish with a hand-held tool • Removes corrosion, mill scale and coatings • ATEX approval for use in Zone 1

www.montipower.com

THE BREAKDOWN

PROPERTIES

SPECIFICATION

Specific Gravity

0.940-0.980

Melting Range

96-102°C

Hardness

42-44 Shore D

Coverage Area

3.00-3.20 m2/kg

Water Absorption

<0.04%

Appearance

Glossy

Adhesion

Excellent

Impact Strength

>27 Joules (0.7mm Plate)

Surface Finish

Smooth

Safe Working Temp.

Up to 60°C

Table 1: Technical data specifications at a glance.

Figure 3 - Application of HAPA by conventional electrostatic spray coating (top) and fluidized-bed dip coating (bottom), recommended for complex-shaped and welded steel wire articles.

The hidden advantage: standing up to a warming climate There is an advantage that may not be immediately apparent but becomes important over the service life of the article: resistance to thermal expansion and contraction. As temperature rises and falls, metal expands and contracts – a movement too small to see or feel, but one that is repeated every day and every season, for years. Over time, this repeated movement places stress on the coating applied to the metal. Thermosetting powder coatings’ rigid, cross-linked film resists this movement rather than accommodating it, which can lead to microcracking and loss of adhesion at points of stress. Thermoplastic powder, being flexible rather than cross-linked, can accommodate the movement of the metal rather than resisting it. This matters increasingly with each passing year. Europe is now the fastest-warming continent on record, with temperatures rising roughly twice as fast as the global average – about 2.3 °C above pre-industrial levels compared with 1.3 °C globally, according to the Copernicus Climate Change Service and the World Meteorological Organization’s European State of the Climate report1. This means greater daily and seasonal temperature variations, and potentially greater thermal stress on outdoor coatings than in the past. An article coated with thermoplastic powder may therefore be better able to withstand this stress than

The increase in temperatures in Europe at a rate roughly twice that of the global average results in greater daily and seasonal temperature variations, and potentially greater thermal stress on outdoor coatings than in the past. An article coated with thermoplastic powder may therefore be better able to withstand this stress than one relying on a coating designed for a more stable climate.

one relying on a coating designed for a more stable climate. Copernicus Climate Change Service (C3S) and World Meteorological Organization (WMO), 2025. European State of the Climate 2024. https://climate.copernicus.eu/esotc/2024

OCTOBER 2026 | CORROSION PROTECTION

THE BREAKDOWN

HAPA: performance under cyclic testing, not just static conditions

Images of the testing are shown in Figure 4, which comprises

Outdoors, a coating rarely faces one stress at a time. Sunlight, heat,

testing, the sample panels after 1680 hours of cyclic corrosion

rain, salt, and cold occur in sequence, season after season. Cyclic

testing, and the pull-off adhesion test performed on the

testing reproduces these conditions by running a programmed

exposed sample panels after cyclic corrosion testing.

three images: the pull-off adhesion test before cyclic corrosion

sequence of UV and heat exposure, moisture, salt spray, and drying, sometimes including a cold step, and repeating the cycle multiple times. Coatings rarely fail as a result of a single stress alone. Failure can occur when different stresses act together over time, and cyclic testing can reveal failure modes similar to those observed in the field, including chalking, blistering, cracking, and loss of adhesion. This provides data that are more representative of actual service conditions. To assess performance under these conditions, HAPA was independently evaluated by IFO Laboratories, Germany (IAS-accredited to ISO/IEC 17025), using a cyclic ageing test in accordance with ISO 12944-6:2018, Annex B, for the C5 category – a high-corrosivity classification under the standard. Each cycle comprised 72 hours of UV weathering, 72 hours of salt spray, and 24 hours of cold storage at -20 °C. The cycle was repeated for 10 cycles, corresponding to a total exposure time of 1680 hours (Table 2)2.

PROPERTY

REQUIREMENT (C5)

RESULT

Blistering

0 (S0)

Rusting

Ri 0

Cracking

0 (S0)

Flaking

0 (S0)

Corrosion at scribe

≤ 3.0 mm

1.50 mm

Adhesion (pull-off), post-ageing

≥ 2.5 MPa

>5.00 MPa

Figure 4a: Pull-off adhesion test before cyclic corrosion testing.

Figure 4b: Sample panels after 1,680 hours of cyclic corrosion testing.

Table 2: HAPA performance after 10 cycles of cyclic ageing testing according to ISO 12944-6:2018 Annex B (C5 category). The most significant result in Table 2 is the adhesion performance: it remained essentially unchanged after 1680 hours of repeated heat, cold, UV, and salt exposure. No detachment was recorded on any sample. This indicates that the film remained bonded and intact under the type of cyclic stress associated with repeated temperature fluctuations – not simply withstanding a single condition in isolation, but maintaining its integrity as conditions repeatedly change. 2 The results characterise HAPA’s performance under these standardised protocols; they are not intended as a direct comparison with a specific thermoset product.

CORROSION PROTECTION | OCTOBER 2026

Figure 4c: Pull-off adhesion test on the sample panels after cyclic corrosion testing.

THE BREAKDOWN

The samples showed good corrosion resistance after 1680 hours,

These tests indicate that the coating maintains its performance

meeting the specified requirements. In addition, the pull-off

under these exposure conditions.

adhesion tests conducted after cyclic corrosion exposure showed

Taken together, the two reports show consistent performance:

no detachment on any of the samples.

whether exposed to individual stresses or subjected to cyclic sequences of heat, cold, UV, and salt, the coating film maintains

Independently confirmed, condition by condition

its adhesion, colour, and integrity.

A second, separate round of testing at Shriram Institute for

The test results and corresponding images presented above

Industrial Research, New Delhi, India (ISO 9001, 14001 and 45001

provide evidence of the coating’s corrosion resistance and

certified), further demonstrates HAPA’s performance when

adhesion performance after prolonged exposure.

individual environmental, chemical, and adhesion properties are

Under the tested conditions, the results indicate that the coating

assessed separately (Table 3).

maintained its performance throughout the cyclic corrosion test. ‹

TEST

DURATION

RESULT

Salt spray (cross-scribe)

1440 hrs

No blistering, rusting, cracking or flaking

QUV accelerated weathering

1440 hrs

No visual change

Chemical resistance (Acid/Alkali)

1440 hrs dip

No blistering or rust spot

Chemical resistance (Urea, DAP)

3000 hrs dip

No blistering or rust spot

Pull-off adhesion

—

7.5 MPa

Table 3: Results of individual tests assessing HAPA’s environmental, chemical and adhesion performance. The colour change remained below 2 ΔE even after 1,440 hours of accelerated UV exposure, indicating good colour retention under prolonged weathering conditions. The 3,000-hour resistance to urea and DAP is also relevant because these coatings are used on fencing installed directly in agricultural environments, where the soil and surrounding air may result in prolonged exposure to urea

The samples showed good corrosion resistance after 1680 hours, meeting the specified requirements. In addition, the pull-off adhesion tests conducted after cyclic corrosion exposure showed no detachment on any of the samples.

and DAP fertilisers used in farming.

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OUTLOOK

Cathodic protection design for ship hulls: beyond anode selection Marco Cattalini Cathodic Protection Specialist – AMPP CP4 - ISO 15257 Level 4M CORE S.r.l., Italy - info@coreconsultancy.it

CORROSION PROTECTION | OCTOBER 2026

SCIENCE OUTLOOK

The opposite conclusion, however, would be equally misleading. Cathodic protection of a ship hull is not simply a matter of selecting the right anodes and installing enough of them. Protection depends on how current is distributed across the hull under changing coating, environmental and operating conditions. Hull geometry, appendages, anode location and, in ICCP systems, dielectric shields, reference electrodes and electrical continuity all influence the actual protection achieved. This article examines these factors and shows why effective cathodic protection must be designed as an integrated electrochemical system, rather than as a collection of individual components.

Rapid consumption does not automatically demonstrate effective cathodic protection, just as limited consumption does not automatically demonstrate poor performance. An anode may consume rapidly because it is delivering substantial useful protective current, but excessive or uneven consumption may also indicate inappropriate sizing, wrong current distribution, coating deterioration, unexpected environmental conditions or other departures from the original design assumptions. Conversely, an anode showing little consumption may simply have been generously sized, or it may have delivered much less current than expected. The amount of anode remaining is therefore useful information, but it is not, by itself, a measure of cathodic protection effectiveness. The relevant question is different: Did the cathodic protection system provide adequate protection where it was required, when it was required, and throughout the intended design period? This

t first glance, designing a cathodic protection system for

apparently simple question changes the nature of the problem.

a ship hull may appear to be a relatively straightforward

Calculating the total current demand of a ship hull is an essential

exercise. Determine the wetted surface area, select

part of cathodic protection design and, once the relevant design

an appropriate design current density, calculate the

parameters have been established, it may not be particularly

required protective current and, finally, determine the number and

complicated. Ensuring that this current reaches different parts of a

size of the anodes. In its simplest form, the process seems almost

real vessel in the required amount and under its relevant operating

reassuringly linear: surface area  current density  required

conditions is another matter entirely. A ship is not a uniform steel

current  anodes.

surface immersed in an infinite homogeneous electrolyte. Hull

The equations are well established, design standards and

geometry, coating condition, propellers, shafts, rudders, thrusters

recommended practices are available, and manufacturers offer

and other appendages, electrical continuity, local shielding effects

extensive catalogues of galvanic and impressed-current anodes.

and variations in operating and environmental conditions all

It may therefore be tempting to regard cathodic protection design

influence the way protective current flows and distributes.

essentially as a matter of selecting the right products and installing

The problem becomes even more evident with impressed current

enough of them. Unfortunately, seawater has never shown much

cathodic protection systems. The availability of higher and

interest in catalogues.

controllable current output does not make current distribution

Over the years, the author has encountered some surprisingly

less important. On the contrary, it makes the consequences of

persistent interpretations of how galvanic anodes should work. On

inappropriate design potentially more significant. Anode location,

one occasion, it was suggested that the anodes should be coated

dielectric shield geometry, reference electrode positioning,

because, in this way, “they would last longer”. Strictly speaking, the

electrical continuity and control strategy become integral parts of

statement is difficult to dispute. A properly coated galvanic anode

the electrochemical design.

would probably last considerably longer. It would simply achieve

The real progression of a cathodic protection project is therefore

this remarkable service life by doing very little of what it had been

somewhat less linear than the simple sequence suggested above.

installed to do.

The question is not merely how much current is required, but also

On another occasion, the excellent quality of a particular anode

where it is required, how it will get there, what electrical paths

alloy was supported by an apparently convincing piece of evidence:

it will follow, and how these conditions will change throughout

after several years in seawater, the anodes were still almost intact.

the operating life of the vessel. Selecting the anodes remains

Again, an impressive result — if preservation of the anodes was the

important. But it is only one step.

objective. It is not. Galvanic anodes are intended to be consumed.

Cathodic protection systems are not simply collections of anodes

Their controlled electrochemical dissolution is the process through

attached to a hull. They are engineered electrochemical systems

which electrons are supplied to the protected structure and

whose performance depends on the interaction between the

protective current is established through the electrolyte. An anode

structure, the coating, the electrolyte, the current sources and

that consumes during operation is therefore not necessarily failing.

the electrical paths connecting them. And this is where cathodic

Consumption is an expected consequence of its function.

protection design really begins.

OCTOBER 2026 | CORROSION PROTECTION

SCIENCE OUTLOOK

The starting point: how much current is required?

But time is not the only variable. The underwater hull should not

The first quantitative question in cathodic protection design is

necessarily be treated as a single homogeneous surface with one

always the same: how much protective current does the vessel

uniform current density. Bow, side shell and stern operate under

require? For an experienced corrosion engineer, estimating the total

different hydrodynamic conditions, while the stern region also

current demand of a ship hull is generally not the most challenging

includes components such as propellers, shafts, rudders and

part of the design. The real issue is that the answer is not a single,

thrusters, often involving different materials and electrochemical

permanent value. A vessel changes throughout its operating

conditions. Appropriate design current densities must therefore

cycle. Coating defects develop, existing damage may progress

reflect the characteristics of the different areas to be protected

and the area of steel effectively exposed to seawater increases.

(Fig. 1). Even the wetted geometry is not constant. Draft changes

The current demand evolves accordingly. The coating breakdown

with loading condition, changing both the total immersed area

factor is therefore much more than a numerical correction used in

and the relative extent of the different hull zones exposed to

a calculation. It represents an assumption about how the condition

seawater. A fully loaded vessel and the same vessel operating

of the coating is expected to evolve during the relevant design

at a substantially lower draft do not present the same cathodic

period. For a conventional ship, this period is closely related to the

protection problem (Fig. 2).

dry-docking cycle. At scheduled dry dockings the underwater hull

Initial, mean and final current requirements should consequently

can be inspected, cleaned and the coating repaired as necessary.

not be regarded simply as three values in a calculation sheet.

From the cathodic protection perspective, each docking therefore

They represent different stages and conditions in the expected

represents an opportunity to restore the coating condition and

operation of the vessel. The situation becomes even more evident

substantially modify the starting conditions for the following

for an FPSO or another permanently moored offshore unit, where

operating period.

dry docking may not be part of the maintenance strategy and

Figure 1 - Vessel zoning for cathodic protection purposes.

CORROSION PROTECTION | OCTOBER 2026

SCIENCE OUTLOOK

coating degradation may have to be considered over a much longer uninterrupted service period. The important question is therefore not simply how much current the ship requires, but how that requirement changes with coating condition, hull area, operating condition and time.

Total current is not current distribution Once the total current requirement has been established, it may be tempting to consider the main part of the design complete. If the calculation says that the vessel requires, for example, 200 A, the obvious next step seems to be providing a system capable of delivering 200 A. Unfortunately, the sea does not read the calculation sheet, and neither does the current. Having 200 A available does not mean that 200 A will distribute over the hull in the way the designer expects. Some areas may receive more current than necessary, while others may receive considerably less. Total current balance and adequate protection are therefore not equivalent conditions. The reason is straightforward: current does not distribute according to the designer’s intentions; it distributes according to the electrical and electrochemical characteristics of the available paths. Hull geometry, anode location and distance from the protected surfaces directly influence these paths. Appendages and complex geometries can create very different exposure conditions, while propellers, rudders and thrusters introduce additional surfaces, materials and electrical relationships. Local shielding can further restrict current access to particular areas. The coating adds another level of non-uniformity. Real coating deterioration is rarely perfectly homogeneous. A relatively small area with significant coating damage can attract a disproportionate share of the available current compared with surrounding wellcoated surfaces. The electrical problem represented by the hull can therefore become progressively less uniform during service. In seawater, which is a highly conductive electrolyte, current distribution is governed primarily by the geometry of the system and by the electrochemical condition of the exposed surfaces. The relative position of the anodes, their distance from different parts of the hull, shielding effects and the presence of appendages all contribute to shaping the resulting current field. This is why anode positioning is not merely a construction detail to be decided once the required number of anodes has been calculated. Location is part of electrochemical design. Two systems having the same total installed current capacity may produce very different protection patterns simply because their current sources are differently positioned. Figure 2 - Influence of operating conditions on vessel draft and the extent of the hull area exposed to seawater.

OCTOBER 2026 | CORROSION PROTECTION

SCIENCE OUTLOOK

Figure 3 - Different types and geometries of sacrificial anodes for ship hull cathodic protection.

The design objective is therefore not to make a certain number

service speed experience very different hydrodynamic conditions

of amperes disappear into the sea. It is to obtain appropriate

at the metal–electrolyte interface. Water movement influences

potential and current distribution over the surfaces that require

mass transport, including oxygen transport, and consequently

protection. This distinction becomes particularly important in areas

affects the cathodic processes occurring on exposed surfaces.

where geometry, materials and current demand change rapidly —

Draft changes as well. Loading, unloading and ballast operations

typically around the stern and its appendages — and becomes even

continuously modify the portion of the hull immersed in seawater.

more critical when moving from galvanic anodes to high-output

The wetted surface considered for one loading condition

impressed-current systems. The question is no longer whether

may therefore be different from that associated with another.

enough current is available. It is whether the available current can

Temperature, salinity, speed and draft are not exceptional events.

reach the right places in the right way.

They are normal operating variables, and they may change simultaneously during the vessel’s service.

A ship does not have one operating condition

The purpose of design is not to calculate every possible

A ship does not operate under a single set of environmental and

combination. A vessel operating worldwide could generate an

operational conditions. During its service, seawater temperature

impressive matrix of scenarios — and an equally impressive

may change significantly as the vessel moves between geographical

spreadsheet — without necessarily improving the quality of the

areas and seasons. Salinity may also vary, particularly when moving

design. The engineering task is to identify which variations are

between open sea, coastal waters, estuaries and ports. These

significant, establish the relevant operating envelope and verify

variations affect seawater conductivity and the electrochemical

the cathodic protection system against the conditions that can

behaviour of the cathodic protection system. Speed is another

realistically govern its performance.

variable. A vessel alongside and the same vessel underway at

CORROSION PROTECTION | OCTOBER 2026

SCIENCE OUTLOOK

Galvanic anodes: mass is not enough Galvanic anode design is sometimes reduced to a question of mass: once enough kilograms of the selected alloy have been installed to satisfy the required design life, the job may appear to be complete. It is not quite that simple. Electrochemical capacity and current output are two different design requirements. The first tells us whether sufficient consumable material is available for the intended service period; the second tells us whether the selected anodes can actually deliver the current required by the structure under the relevant design conditions. This distinction may appear obvious, but it has an important practical consequence: An anode may have sufficient electrochemical capacity for the required design life and still be

Figure 4 - Main hull appendages and components considered in cathodic protection design.

unable to deliver the required current under a specific design condition. The opposite situation is equally possible: an anode configuration may provide ample current output while offering insufficient capacity for the required service period. This is where geometry becomes as important as mass. Two anodes containing similar quantities of alloy but having different shapes and dimensions do not necessarily behave in the same way. Commercial availability should therefore follow the design requirements, rather than quietly becoming one of them. In many cases, the capacity and current-output verifications are satisfied at the first iteration. In others, they are not, and the selected geometry, number or arrangement of the anodes has to be reconsidered (Fig. 3).

Anode location is part of the design Selecting the number, size and type of anodes still leaves one apparently simple question unanswered: Where should they be installed? The answer cannot be reduced to finding sufficient space on the hull. From an electrochemical perspective, anode location

Figure 5 – Ship propeller submerged in seawater.

must support an appropriate protection pattern, particularly around geometrically complex or demanding areas such as propellers, rudders and thrusters (Figs. 4, 5 and 6). Moving an anode may change its contribution to the protection of these areas even though its material, dimensions and nominal output remain exactly the same. At the same time, a ship is not designed around its cathodic protection system. Anode positioning has to coexist with hull geometry, appendages, hydrodynamic requirements and practical installation constraints. Accessibility for inspection and replacement must also be considered, particularly when the CP design is linked to scheduled dry-docking activities. This inevitably requires compromise. The most convenient position for installation may not be the most effective electrochemically; the preferred electrochemical position may not be acceptable from a

Figure 6 - Sacrificial anode positioning and distribution on a ship’s underwater hull.

OCTOBER 2026 | CORROSION PROTECTION

SCIENCE OUTLOOK

hydrodynamic or structural perspective. The important point is that

An MMO anode should therefore not be considered simply as a

these compromises should be engineered, rather than discovered

piece of coated titanium capable of delivering a specified number of

during installation. Two vessels — or even two alternative designs

amperes. Its performance cannot be separated from the dielectric

for the same vessel — may carry exactly the same anode alloy,

shield, power supply and control system, reference electrodes,

the same number of anodes and the same total anodic mass, yet

cabling and electrical connections, or from the electrical continuity

achieve different protection performance simply because those

of the structures intended to participate in the protection system.

anodes are arranged differently. Anode location is therefore not

These elements interact continuously. The reference electrodes

the final drafting exercise performed after the cathodic protection

provide the potential information used by the control system; the

system has been designed. It is part of the design itself.

controller regulates anode output; the anode and dielectric shield influence the local current field; and the electrical configuration

ICCP: more current means more responsibility

of the vessel determines which metallic components participate

Moving from galvanic anodes to impressed current cathodic

in the cathodic protection circuit. The design of an ICCP system

protection changes the scale of the problem, but not its

must therefore consider these interactions as a whole. Increasing

fundamental nature. An ICCP system provides something extremely

the available current does not remove the problems of distribution

valuable: controllable current. Output can be adjusted as operating

discussed previously; it makes their proper assessment even more

conditions and protection requirements change, and relatively

important, particularly in the immediate vicinity of high-output

compact anodes can deliver currents far greater than those

anodes and in areas where different metallic components and

normally associated with individual galvanic anodes.

complex geometries coexist (Fig. 7).

This flexibility, however, also increases the consequences of inappropriate design. Poor anode positioning, inadequate shielding,

Dielectric shields are part of the electrochemical design

unsuitable control settings or incorrect assumptions about

Among the components of a hull ICCP system, the dielectric shield

electrical continuity can produce highly non-uniform conditions and

surrounding an impressed-current anode is sometimes regarded

excessive local polarization. Having more current available is useful

as little more than a construction detail or a protective layer around

only if that current can be delivered and controlled appropriately.

the anode installation. Its function is considerably more important.

Figure 7 - Main ship types and their characteristic hull configurations relevant to ICCP system design.

CORROSION PROTECTION | OCTOBER 2026

SCIENCE OUTLOOK

An ICCP anode can discharge a relatively high current from a

understanding of the expected potential distribution rather than

comparatively small surface. In its immediate vicinity, this creates

merely according to installation convenience. The opposite problem

high current densities and steep potential gradients. If the adjacent

is equally important. If the control strategy responds primarily

hull surface were directly exposed to this near-anode field, it could

to a location requiring greater polarization, increasing the anode

be subjected to unnecessarily high local current densities and

output to satisfy that measurement may drive surfaces closer to the

excessive polarization. The dielectric shield deliberately prevents

anodes to unnecessarily negative potentials. Excessive polarization

current transfer to the hull over a defined area around the anode. In

can create conditions detrimental to the coating system and

doing so, it modifies the geometry of the near-anode electric field

may promote premature coating deterioration or disbondment,

and encourages the current to spread into the electrolyte before

depending on coating characteristics and exposure conditions.

reaching the protected metallic surface. Its dimensions therefore

A correctly controlled potential at the reference electrode location

cannot be considered independently of the expected anode

therefore does not, by itself, demonstrate adequate protection

output and installation geometry. A shield suitable for one anode

of the entire hull. The reference electrode arrangement must

configuration or operating current should not automatically be

allow the system to operate within an appropriate potential range

assumed suitable for another simply because the physical anode is

across both the most favourably and the least favourably polarized

similar.

areas. Number, location and redundancy should consequently be

If the shield is inadequately dimensioned for the intended output,

established together with anode arrangement, dielectric shielding

excessive current concentration may occur near its boundary.

and the expected potential field. For complex hull geometries,

Depending on the potential reached, coating characteristics and

multiple reference electrodes may be necessary not only for

exposure conditions, this may result in excessive local polarization

reliability, but also to provide the controller with meaningful

and contribute to deterioration or disbondment of the coating

information from electrochemically different areas of the vessel.

adjacent to the shield. Conversely, unnecessarily extensive

Reference electrode placement is therefore part of the same design

shielding can remove useful cathodic surface from the immediate

problem discussed throughout this article: achieving adequate

area and influence the local protection pattern. The transition

protection in the least favourably positioned areas while avoiding

between the dielectric shield, the surrounding coating and the

excessive polarization elsewhere.

exposed electrolyte is therefore an electrochemically significant region and should be treated accordingly in both design and

Do not forget the propeller shaft and rudder

installation. For this reason, dielectric shield geometry belongs

A final detail deserves explicit attention: the cathodic protection

to the electrochemical design of the ICCP system. It should be

system does not end at the hull plating. Propeller, shaft and rudder

established together with anode location and expected operating

are part of the same electrical and electrochemical system, and

output, rather than treated later as a standard construction detail.

their relationship with the hull must be deliberately considered. Mechanical connection alone should not be assumed to provide

Reference electrodes: what does the control system actually see?

reliable electrical continuity, particularly across rotating interfaces,

Automatic control is one of the major advantages of an ICCP

grounding arrangements may therefore be required to provide

system, but the controller can only respond to the potentials

controlled low-resistance electrical paths and integrate these

measured by its reference electrodes. Their position is therefore a

components correctly into the cathodic protection system.

fundamental part of the electrochemical design.

If continuity is inadequate or intermittent, current may follow

The objective is not simply to maintain the correct potential at one

unintended paths through bearings or other interfaces, creating

convenient point on the hull. The control system must provide

discharge points where localized stray-current corrosion can

sufficient current to protect the more remote or less favourably

develop. The same attention should be given to the electrical

exposed areas, including surfaces that may be partially shielded,

continuity of the rudder and other relevant appendages.

bearings and lubricated surfaces. Appropriate bonding and shaft

without driving other areas into excessive polarization. This balance is particularly important in the vicinity of impressed-

Design life means different things for different vessels

current anodes. A reference electrode positioned where the

Design life is often expressed as a number of years, but in cathodic

hull is strongly influenced by the local anode field may indicate

protection design the number alone says relatively little unless

satisfactory protection while more distant areas remain at less

it is associated with the maintenance philosophy of the vessel.

negative potentials. Its position must therefore be selected with an

For a conventional merchant vessel, the relevant design period is

OCTOBER 2026 | CORROSION PROTECTION

SCIENCE OUTLOOK

Fig. 8 - Flush-mounted sacrificial anodes: main characteristics, applications and coating requirements.

normally linked to the dry-docking cycle: dry dock  operation 

current demand may become substantially more important, and

dry dock.

greater attention must be given to system reliability, redundancy,

At scheduled dry dockings, the underwater hull becomes

monitoring and the consequences of component degradation or

accessible for inspection, cleaning, coating repair and maintenance

failure.

of the cathodic protection system. The next docking therefore

The same distinction is reflected in the different technical

represents a foreseeable opportunity to restore, at least partially,

frameworks used for ships, floating offshore units and other types

the condition of the protective system. This has a direct influence

of marine structures. Although the underlying electrochemistry

on the assumptions used in CP design. Coating breakdown can be

does not change, the design approaches are adapted to different

evaluated over the period between maintenance opportunities, and

operating profiles, inspection possibilities, maintenance strategies

the corresponding evolution of current demand can be considered

and required service lives. This is particularly relevant as the

within that interval. The condition at the end of the cycle is

boundary between traditional ship design and offshore engineering

important, but it is not necessarily assumed to continue indefinitely:

becomes less distinct. Floating production units, permanently

inspection and maintenance are part of the design philosophy.

moored vessels and other long-duration floating assets may

The situation is fundamentally different for an FPSO or another

resemble ships geometrically, while their maintenance philosophy

permanently deployed offshore unit: installation  20–30 years of

is much closer to that of a permanent offshore installation. Applying

continuous operation.

assumptions developed for a conventional dry-docked vessel

Here, periodic dry docking may not be a realistic part of the

simply because the structure floats may therefore be inappropriate.

operating strategy. The cathodic protection system may therefore

Design life should consequently be understood together with

have to remain effective over a much longer uninterrupted

the opportunities available during that life to inspect, maintain

period, while the coating progressively ages and opportunities

and restore the protection system. The expected condition of the

for intervention are considerably more limited. The difference

coating, the required CP performance and the necessary level of

affects much more than the quantity of anodic material. Coating

reliability all depend on that operational context.

breakdown assumptions extend over a different time horizon, final

CORROSION PROTECTION | OCTOBER 2026

SCIENCE OUTLOOK

Verification: design does not end with installation

consumption, reference electrodes, dielectric shields, coating

A cathodic protection design is necessarily based on assumptions.

condition and any localized signs of abnormal behaviour can be

Commissioning is the first opportunity to verify those assumptions

inspected directly. The opportunity should be used not only to

against the actual behaviour of the installed system. For this

maintain the system, but also to verify the original design and,

verification to be meaningful, however, the vessel must be in

where necessary, refine it for the following service period.

conditions reasonably representative of those for which the

A cathodic protection system can only be validated under

system was designed. Draft and immersed hull area are particularly

conditions in which it can actually operate. Commissioning a ship

important. Testing a system under conditions substantially different

with essential components out of the water is, after all, asking

from its intended operating envelope may produce results that are

electrochemistry to cooperate with the test schedule.

technically measurable but of limited value for validating the design. The author has encountered, for example, a commissioning test

Conclusions — Engineering the system

performed with a vessel completely unloaded and without ballast.

The idea of painting galvanic anodes so that they last longer is

The draft was so low that some reference electrodes and part of

obviously an extreme example. The belief that an anode must

the anode system were above the waterline. In another case, only

be performing well because, after years of service, it still looks

a fraction of the design hull area was immersed and the installed

almost new is more subtle. Both, however, point to the same

ICCP system, sized for a much larger wetted surface, rapidly drove

misunderstanding: judging cathodic protection from the condition

the immersed hull towards excessive polarization. Neither situation

or characteristics of a single component rather than from the

represented a failure of the cathodic protection design. The

performance of the system (Fig. 8). Anodes matter, of course. Their

problem was that the system was being asked to demonstrate its

material, geometry, capacity and output are fundamental design

performance under conditions fundamentally different from those

parameters. But even a correctly selected anode tells us relatively

on which that design was based.

little when considered in isolation. Its effectiveness depends on

Commissioning should therefore be planned as an engineering

where it is installed, what it is electrically connected to, which

activity, not simply scheduled when construction work has been

surfaces it is expected to protect and how the complete system

completed. Vessel loading condition, draft, immersion of anodes

behaves under actual operating conditions.

and reference electrodes, seawater conditions and sufficient

The same principle applies to impressed-current systems. Anodes,

time for the electrochemical response of the system should all be

reference electrodes, dielectric shields, power supplies, electrical

considered when defining the test conditions. Where representative

connections and monitoring equipment may all be individually

conditions cannot be achieved, the limitations of the test should

suitable and still fail to produce the intended result if their

be recognized and additional verification performed when suitable

interaction has not been properly considered. Cathodic protection

operating conditions become available.

exists only when these components, the structure and the

This verification should continue during service. Monitoring of

electrolyte operate together as an electrochemical system capable

potentials and system output provides information on how the

of maintaining the required protection throughout the relevant

protection system evolves with time and can reveal departures from

service period. This is ultimately the distinction between selecting

the expected behaviour. Dry docking then offers a different and

cathodic protection equipment and designing cathodic protection.

particularly valuable form of verification: the possibility of comparing

Cathodic protection systems are not purchased. Their components

operating data with direct physical evidence. Anode condition and

are purchased. The system itself must be engineered. ‹

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SPOTLIGHT

Preventing biofouling at the source:

an ultrasonic approach to hull protection Interview with Chris McGlade, Business Development Manager at Cathelco

CORROSION PROTECTION | OCTOBER 2026

SPOTLIGHT

vessel’s hull may look clean from a distance, but even a thin layer of marine growth can have consequences far beyond its appearance. Biofouling increases hull resistance, raises fuel consumption and emissions, and

can turn ships into vectors for the transfer of invasive species across oceans. The problem becomes particularly critical when vessels remain stationary for extended periods in confined or strategically important maritime areas. During these periods, marine organisms can accumulate on the hull and, once vessels resume navigation, travel thousands of kilometres with them. At the same time, the additional resistance created by fouling means that more energy is required to maintain the same speed. Against a backdrop of growing uncertainty, rising fuel costs and

Biofouling increases hull resistance, fuel consumption and emissions, while also contributing to the spread of invasive marine species. Cathelco part of Evac Group, and a specialist in marine water treatment and antifouling technologies, has developed DragGone™, an ultrasonic protection system designed to inhibit the formation of the initial slime layer and prevent further marine growth.

geopolitical tensions affecting international shipping routes, these effects are becoming an increasingly important concern for shipowners. The situation in the Strait of Hormuz is a particularly relevant example: vessels forced to remain stationary for extended periods may be more exposed to the accumulation of marine growth, potentially compounding the challenges associated with fuel consumption, emissions and the spread of invasive species. This combination of environmental and economic pressures is driving interest in technologies capable of preventing biofouling rather than simply removing it once it has formed. Among these solutions is Cathelco’s DragGone™, an ultrasonic protection system developed by Cathelco that uses ultrasonic energy to prevent microorganisms and algae from establishing themselves on the hull surface.

OCTOBER 2026 | CORROSION PROTECTION

SPOTLIGHT

Protecting the hull from the start

The technology is therefore designed to

Emissions and fuel consumption

Cathelco, part of the Evac Group and

reduce fuel consumption and emissions

The impact of biofouling extends beyond

based in Chesterfield, is a leading designer

for shipowners, while also helping to

the spread of invasive species from one

and manufacturer of marine equipment

address the growing environmental

geographical area to another. A fouled hull

designed to protect commercial vessels,

concern surrounding the spread of

creates greater resistance as it moves

superyachts and naval ships from

invasive species through biofouling.

through the water, meaning that the

biofouling and corrosion.

“The current situation in the Strait of

engine has to work harder to maintain the

“Our main product line is MGPS (Marine

Hormuz is showing us just how relevant

same speed. As a result, fuel consumption

Growth Prevention Systems) & ICCP

this issue can be, and our technology can

increases, along with the emissions

(Impressed Current Cathodic Protection),

help shipowners prevent what is already

generated by the vessel.

which is used across a wide range of

happening. Not every shipping company

“If a hull is kept completely clean, a

vessel installations, from oil rigs to

can afford to clean a vessel before it

shipowner can expect to save about

yachts,” explains Chris McGlade, Business

leaves the area, as the process can be very

25% in fuel per year. Now, that’s quite a

Development Manager at Cathelco. “Two

expensive. DragGone™ was developed as

bold statement, and it relies on the hull

years ago, we launched DragGone™, an

a preventative measure: instead of waiting

being absolutely pristine, which is never

ultrasonic technology designed to prevent

for biofouling to develop and then having

achievable. So what DragGone™, our

the formation of the slime layer on the hull.

to clean the hull, the aim is to prevent

system, does is save up to 13%. That’s sort

By preventing this initial layer from forming,

marine organisms from attaching to it in

of indicative of some of the preliminary

the system helps maintain the vessel’s

the first place. This preventative approach

reports that we’ve had back already,”

hydrodynamic performance, allowing it to

has already taken DragGone™ from the

continues Chris McGlade.

maintain the same speed while using the

R&D stage to more than 60 installations

The potential savings become particularly

same amount of fuel – or to achieve the

over the last two years.”

significant for cruise ships, which

same speed with less fuel.”

operate continuously and consume large quantities of fuel. Even a relatively modest reduction in fuel consumption can therefore translate into substantial savings over the course of a year, while also contributing to lower emissions.

Strategic development for an intelligent system Cathelco spent 10–12 years developing the DragGone™ technology. “We originally looked into the technology as possible alternative to the copper used in sea chests and pipework, however it soon became apparent that this technology wouldn’t have the same preventative measures in these areas that copper dosing could provide,” explains McGlade. We soon realised that the solution could have a much broader application: protecting the hull itself. This marked the beginning of the development of the relevant patents and the adaptation of the technology to a much larger surface area than pipework, ultimately leading to the DragGone™ system as it is today.”

CORROSION PROTECTION | OCTOBER 2026

SPOTLIGHT

Beyond the technology: a partnership approach

company works with its customers. Unlike

Cathelco’s work on biofouling also

essentially installed and then operated by

extends beyond the technology itself,

the vessel, DragGone™ is presented as a

encompassing regulatory developments,

long-term partnership between Cathelco

legislation, certification and the wider

and the shipowner. “You just switch it

management of biofouling. “One of the

on,” explains McGlade, highlighting the

key areas of focus is helping shipowners

simplicity of the system from an operational

understand the importance of effective

perspective.

biofouling management. At present, the

However, ensuring that it continues to

IMO’s guidelines do not make a Biofouling

perform at its optimum level requires

Management Plan mandatory for ships;

ongoing monitoring and communication.

rather, they provide recommendations for

Customers provide monthly log sheets,

preventing and managing the accumulation

which Cathelco uses to track performance,

and transfer of marine organisms. However,

while annual inspection visits and regular

as more shipping companies adopt formal

dialogue with the crew and shipowner

Chris McGlade,

management plans and practices, we

allow the company to identify any issues

believe this could contribute to a future in

and optimise the system over time. “In this

Business Development Manager at Cathelco

which such measures become regulatory

sense, DragGone™ is not simply a product

requirements”.

that is installed on board, but part of a

This educational and collaborative

broader approach to continuous biofouling

approach is also reflected in the way the

management,” concludes McGlade. ‹

more conventional systems, which are

The perfect mix for blast cleaning Ervin has been providing customers with the best blasting solutions since 1920. Whatever your needs, we can provide the ideal abrasive and technical support for perfectly clean and prepared surfaces. Amasteel shot & grit • High quality martensitic steel abrasives for cleaning, surface preparation and peening Stainless shot & grit • Produces high gloss, rust free surfaces • For cleaning, surface preparation and peening Amapure • New mineral degreasing additive • Improved productivity and coating performance • Combine with Ervin Amasteel and Stainless abrasive for the ideal blasting solution

Ervin Germany GmbH T +49 30 6780 4940 info@ervin.eu www.ervin.eu

THE BREAKDOWN

FROM HAND TOOLS TO ROBOTICS:

THE EVOLUTION OF MECHANICAL SURFACE PREPARATION Drs. JF (Frits) Doddema, Group CEO of MontiPower and Founder of Allter B.V. for visco-elastic pipeline coatings frits.doddema@montipower.com

Are there alternatives to conventional abrasive blasting for surface preparation? MontiPower presents a range of manual and mechanical technologies, from hand and power tools to bristle blasting, cordless equipment, and emerging robotic solutions, describing their characteristics, applications, and potential advantages for coating maintenance.

CORROSION PROTECTION | OCTOBER 2026

THE BREAKDOWN

Blast cleaning typically requires compressors, blast pots, hoses, abrasive media, containment and substantial logistical support. The final clean-up requirement can also be considerably lower when mechanical power tools are used in field applications because there is no loose abrasive media to collect, remove and dispose of. Powered surface preparation requires a source of compressed air, electricity or battery power, whereas basic manual cleaning can be performed using little more than a hand wire brush or scraper. Increasingly, however, high-performance cordless tools are entering the pipeline, energy and industrial maintenance markets, changing the practical limitations traditionally associated with power-tool surface preparation.

Surface preparation and coating performance Manual and mechanical cleaning are not always the most efficient methods for removing tightly adherent rust, mill scale or heavy coating systems. However, surface preparation should never be considered independently from the coating system that follows. The condition of the substrate after preparation, the coating technology and the environmental exposure all influence the expected service life of the completed protective system. A coating applied to manually prepared steel inside a controlled building environment, for example, may provide a significantly longer service life than the same coating applied to manually prepared steel exposed to a severe coastal or offshore environment. For most coating systems, a useful principle remains: the cleaner

and better prepared the substrate, the better the foundation for coating performance.

brasive blast cleaning is widely recognised as an

There are, however, important differences between coating

effective method for removing existing coatings,

technologies. Certain PIB-, viscoelastic- or wax-based corrosion

corrosion and mill scale and for preparing steel

protection systems can tolerate significantly lower levels of

surfaces prior to the application of new protective

surface preparation than conventional liquid-curing coating

coating systems. Nevertheless, there are many situations in which

systems and may not require a conventional primer.

conventional open abrasive blasting is impractical, uneconomical

Manual and power-tool cleaning have nevertheless been used

or simply not permitted. For this reason, alternative surface

successfully for many decades. Coating manufacturers have

preparation technologies—including grinders, abrasive tools,

consequently developed a range of surface-tolerant coating

laser and induction systems, wire brushes, needle scalers and

systems specifically intended for manually or mechanically

specialised mechanical surface preparation equipment—continue

prepared substrates.

to play an important role in industrial maintenance.

This provides asset owners and maintenance contractors

Although grinders, rotary wire brushes, abrasive discs and similar

with another option: combining manual or mechanical surface

tools can be more labour-intensive when measured against the

preparation with a suitably qualified surface-tolerant coating

area treated, they require significantly less supporting equipment

system, rather than automatically specifying open abrasive

than conventional abrasive blasting.

blasting for every maintenance intervention.

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THE BREAKDOWN

Comparing surface preparation methods This article follows the general approach of the MontiPower Surface Prep Guide, developed in cooperation with Corrodere UK, and considers manual and mechanical surface preparation alongside conventional loose-abrasive blast cleaning. The comparison should not focus solely on visual cleanliness. Important parameters include:  surface cleanliness;  surface profile and anchor pattern;  productivity;  ergonomics;  accessibility;  containment and clean-up;  occupational health and safety; and  suitability for the specified coating system. Surface preparation is therefore more than simply achieving a visual cleanliness grade. The objective is to create a substrate condition appropriate for the coating system, environment and required service life.

Hand tools Manual cleaning uses non-powered tools to remove loosely adherent material from a substrate and prepare the surface for subsequent treatment. Materials that can be removed include loose rust and poorly

Bristle blasting introduced a new category of handheld mechanical surface preparation: a power tool capable of producing a surface texture comparable to that associated with abrasive blast cleaning without using loose abrasive media.

adherent protective coatings. Tightly adherent corrosion products and mill scale, however, are difficult or impossible to remove effectively using conventional hand tools alone. Typical hand tools used in the corrosion protection and coating industries include:

Because different bristle materials are available, hand brushing

 hand wire brushes;

can be used on both ferrous and non-ferrous substrates, provided

 scrapers;

the correct brush material is selected to avoid contamination.

 hammers;  abrasive pads; and

Scrapers

 abrasive paper.

The scraper is one of the most universal tools used by industrial painters and coating applicators. It can be used to remove flaking

Hand wire brushes

paint, loose rust, overspray, dry spray between coating layers and

The hand wire brush has been used in the coating industry

particles embedded in a dried coating film.

for generations. Early designs often incorporated steel or iron

Scrapers can also remove thick deposits of grease and

bodies, whereas modern brushes generally use wooden or

oil, although residual contamination will remain and must

polymer handles. The bristles are commonly manufactured from

subsequently be removed by appropriate cleaning methods.

carbon steel, although stainless steel, aluminium, brass, zinc and

They may be used in combination with chemical paint removers

synthetic materials are also available depending on the substrate

and, in day-to-day coating work, are also useful for numerous

and application.

practical tasks. A scraper alone, however, will generally not

Manual wire brushing remains widely used in maintenance

prepare steel to a condition suitable for the application of a high-

coating work, but it represents a relatively basic level of surface

performance coating system. Additional abrasive treatment using

preparation.

hand or powered tools is normally required.

CORROSION PROTECTION | OCTOBER 2026

THE BREAKDOWN

The Aeroblaster integrates MontiPower’s Bristle Blaster® and MBX® technologies into an aerial payload compatible with the Voliro T platform for mechanical surface preparation of steel substrates.

Smaller deburring scrapers can be particularly useful on existing

 mains electricity; or

coatings because their sharp blades can remove isolated surface

 high-performance battery systems, including the Cordless

defects or contamination from a cured coating film.

Alliance System (CAS). Electric and pneumatic tools can operate considerably faster than

Abrasive pads

hand tools and generally reduce physical effort for the operator.

Abrasive pads consist of non-woven nylon fibres bonded together

Operator exposure nevertheless remains an important

with synthetic resin and containing abrasive particles.

consideration. Vibrating handheld equipment can present

Different abrasive materials and grades are available, ranging from

occupational health risks, particularly through prolonged exposure

micro-fine to coarse. These pads are commonly used for cleaning

to hand-arm vibration (HAV) and the associated risk of Hand-Arm

and conditioning surfaces before coating. The embedded abrasive

Vibration Syndrome (HAVS). Powered equipment is used both

can lightly roughen an existing coating surface, creating a more

for preliminary cleaning and for final surface preparation before

suitable substrate for adhesion of the subsequent coating layer.

coating application. Common technologies include:  rotary wire brushes;

Power-tool surface preparation

 sanding machines;

As the name implies, powered surface preparation equipment

 angle grinders and abrasive discs;

requires an external energy source.

 needle scalers;

Modern equipment can operate using:

 chipping hammers; and

 compressed air;

 Bristle blasting tools.

OCTOBER 2026 | CORROSION PROTECTION

THE BREAKDOWN

Rotary wire brushes

Bristle blasting

Powered wire brushing is widely used throughout the corrosion

Bristle blasting differs fundamentally from conventional rotary wire

protection industry, particularly for maintenance coating, local

brushing.

repairs and transition areas during new construction—for example

The process removes corrosion, existing coatings and

in shipbuilding and offshore oil and gas structures.

contaminants while simultaneously generating an anchor profile

Rotary wire brushes are also frequently used on construction

on the substrate.

sites where abrasive blasting of small areas would be difficult or

It uses a specially engineered, self-cleaning rotary bristle belt.

impractical, such as around welds.

Forward-curved wire tips are dynamically tuned to the handheld

A powered wire brush is considerably faster and more productive

power tool, which operates at approximately 2,400 rpm.

than manual wire brushing. Brushes are available in different

The principal distinction is that the process does not simply brush

materials, including carbon steel, brass, copper, stainless steel

the surface: it generates a surface profile.

and synthetic materials.

During operation, the wire tips first engage an accelerator bar

One of the most common configurations is the cup brush, with

incorporated into the tool. The interaction with the Accelerator Bar

typical diameters ranging from approximately 50 to 150 mm. Both

retracts and accelerates the bristle tips before they are released

electric and pneumatic versions are widely available.

towards the substrate.

Although rotary wire brushing is considerably more effective than

The tips subsequently strike the surface with kinetic energy,

manual brushing, an important limitation is its tendency to smooth

removing corrosion products, existing coatings and contaminants

or burnish the steel surface.

while simultaneously creating microscopic impact craters.

The same phenomenon can occur when brushing tightly adherent

Because the bristles repeatedly retract and strike the surface

mill scale or corrosion products. A polished or burnished substrate

rather than simply wiping across it, bristle blasting differs

can provide an inadequate mechanical key for a subsequently

substantially in both operating principle and resulting surface

applied coating and may therefore adversely affect coating

condition from conventional rotary wire brushing.

adhesion.

The resulting surface contains a continuous pattern of peaks and valleys rather than the comparatively smooth or burnished surface that may result from conventional wire brushing. This makes bristle blasting particularly relevant for smaller steel areas, maintenance and repair work, weld seams, local coating repairs and pipeline field-joint preparation where the mobilisation of conventional abrasive blasting equipment may be disproportionate to the area requiring treatment.

Bristle blasting is particularly relevant for smaller steel areas, maintenance and repair work, weld seams, local coating repairs and pipeline field-joint preparation where the mobilisation of conventional abrasive blasting equipment may be disproportionate to the area requiring treatment.

Bristle Blaster® Bristle Blaster® equipment is available in electric, cordless and pneumatic configurations. The bristle belts use spring-steel or stainless spring-steel wire. The geometry and condition of the bristle tips are important because they determine the impact mechanism and consequently influence cleaning performance and the resulting surface profile. Bristle blasting introduced a new category of handheld mechanical surface preparation: a power tool capable of producing a surface texture comparable to that associated with abrasive blast cleaning without using loose abrasive media. The patented technology can therefore be described as “blasting without loose abrasive media.” Under appropriate operating conditions, bristle blasting can produce a visual surface cleanliness comparable to ISO 85011 Sa 2½ and SSPC-SP 10/NACE No. 2 Near-White Metal Blast

CORROSION PROTECTION | OCTOBER 2026

THE BREAKDOWN

Cleaning, while simultaneously generating a measurable anchor

 Bristle Blaster Subsea – developed for underwater surface

profile. This distinction is important. Removing a coating is not

preparation; and

necessarily the same as preparing a surface for a new coating.

 PREPPER® Q4 – a customised robotic configuration for pipeline

For many high-performance liquid-curing coating systems, the

field-joint surface preparation.

substrate requires not only cleanliness but also an appropriate roughness, profile and anchor pattern.

Operating principle

The Bristle Blaster® range has developed substantially since its

Bristle blasting simultaneously removes corrosion and creates

introduction and today includes several configurations for different

a new anchor profile using specially designed rotating belts

field applications:

manufactured with spring-steel or stainless spring-steel bristles.

 Bristle Blaster Pneumatic Single & Double – including

Each belt contains forward-curved wire tips dynamically matched

configurations for use in ATEX environments;

to the operating characteristics of the tool.

 Bristle Blaster Electric Single – available for standard mains

The tips are geometrically formed and sharpened so that, after

power applications;

interacting with the Accelerator Bar, they strike the substrate with

 Bristle Blaster Cordless – battery-powered for remote and

considerable kinetic energy. Immediately after impact, the bristle

mobile field operations;

tips retract from the steel surface.

 Bristle Blaster Double / DUO – using two 23 mm Bristle Blaster

This repeated impact-and-retraction process removes mill scale,

belts to increase working width and productivity;

corrosion and existing coatings while simultaneously generating

 Bristle Blaster Axial – designed for difficult-to-access areas

a new surface profile. The resulting peaks and valleys form a

including welds, corners and flange geometries;

continuous anchor pattern without the broad smooth areas

Stop Corrosion Before It Starts. Protect your assets with next-generation, eco-friendly VpCI® coatings that break the corrosion cycle.

VpCI® coatings protect a wide range of metal assets, providing fast and economical preservation for both interior and exterior surfaces. Our technical experts are ready to help you select the ideal solution for long-lasting, complete protection of your corrosion-sensitive products.

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THE BREAKDOWN

Consequently, bristle blasted surfaces can exhibit both a

The next generation: PREPPER®, AeroBlaster and robotics

texture and visual cleanliness resembling those produced by

The next stage in industrial surface preparation will increasingly

conventional abrasive blast cleaning.

involve automation, robotics and cordless technology.

typically associated with conventional rotary brushing.

This does not necessarily mean replacing conventional abrasive

Training and correct application

blasting or handheld tools. Rather, the industry is developing a

As with any surface preparation technology, correct application

broader toolbox in which the preparation method can be matched

is essential. Operators should be trained by qualified personnel

more precisely to the geometry, accessibility, coating system,

in the appropriate working technique, tool configuration

safety requirements and economics of the project.

and operating parameters for the application concerned.

Monti is consequently developing its technologies beyond the

Understanding tool angle, contact pressure, movement, belt

conventional handheld power tool.

condition and working speed is important for achieving consistent results.

PREPPER®: from handheld tool to automated surface preparation

Correct operation also improves belt utilisation and productivity

With the PREPPER® platform, Monti is transferring established

while providing the best possible substrate for adhesion of

mechanical surface preparation principles into automated

subsequent coatings, adhesives or sealants.

applications. The objective is to perform cleaning and surface profiling in a controlled and repeatable manner while reducing

Combining specialised robotic platforms with surface preparation and coating application technologies makes it possible to automate progressively larger areas of industrial structures.

CORROSION PROTECTION | OCTOBER 2026

THE BREAKDOWN

the amount of manual intervention required. This includes technologies for both external and internal pipeline applications. For pipeline construction and rehabilitation, automation is particularly attractive because the geometry is relatively repetitive. A robotic or automated system can therefore control parameters such as travel speed, contact pressure, tool position and surface coverage more consistently than purely manual operation. The objective is not simply to make the process faster. It is to make surface preparation measurable, repeatable and scalable. AeroBlaster: taking surface preparation into the air Another development direction is the AeroBlaster, combining surface preparation technology with aerial robotics. Together with Swiss robotics company Voliro, Monti is working on

The industry is developing a broader toolbox in which the preparation method can be matched more precisely to the geometry, accessibility, coating system, safety requirements and economics of the project. Monti is consequently developing its technologies beyond the conventional handheld power tool.

solutions in which flying robots can establish controlled physical contact with industrial structures. This creates new possibilities for mechanised and, ultimately,

 improve consistency and reproducibility of surface preparation;

increasingly automated surface preparation on assets that are

 reduce worker exposure to dust;

traditionally difficult and expensive to access.

 reduce exposure to noise and vibration;

Potential applications include:

 minimise work at height;

 storage tanks;

 reduce dependence on scaffolding and rope access;

 large steel structures;

 improve data collection and process documentation; and

 offshore structures;

enable work in locations that are difficult or hazardous for

 wind-energy assets;

- Combining specialised robotic platforms with surface preparation and coating application technologies makes it possible to automate progressively larger areas of industrial structures.

personnel.

 elevated pipework; and

In this respect, robotics should be viewed not simply as labour

 other structures traditionally requiring scaffolding, mobile

replacement but as an extension of the surface preparation

elevated work platforms or rope access.

toolbox.

Access can represent a substantial proportion of the total cost of industrial maintenance. A relatively small area of corrosion located

Cordless technology changes field preparation

high on a tank or steel structure may require extensive scaffolding

At the same time, battery technology is changing what is possible

or specialist rope-access operations before surface preparation

with handheld equipment.

can even begin. Flying robotic systems have the potential to

Historically, industrial power-tool surface preparation required

change that equation.

either compressed air or mains electricity. Both introduce

Rather than bringing the worker to the surface, the surface

practical limitations in remote pipeline, tank, offshore and

preparation technology can increasingly be brought to the work

maintenance environments.

location robotically.

Modern high-performance battery systems increasingly remove this dependency.

Ground-based and magnetic robotics

Monti is a member of the Cordless Alliance System (CAS), allowing

Monti also sees considerable potential in ground-based and

its mobile equipment to operate within a broader professional

magnetically attached robotic platforms.

battery platform.

For robotic blasting and coating applications, Monti works with

For field operators, cordless technology means that high-

Robot++ from Beijing, China.

performance surface preparation can increasingly be deployed

Combining specialised robotic platforms with surface preparation

without a compressor, generator or lengthy electrical connection.

and coating application technologies makes it possible to

This is particularly relevant for:

automate progressively larger areas of industrial structures. The

 remote pipeline locations;

purpose is not productivity alone.

 field joints;

Automation can potentially:

 local coating repairs;

OCTOBER 2026 | CORROSION PROTECTION

THE BREAKDOWN

 inspection and maintenance campaigns;

Another internationally established Monti application is the Vinyl

 offshore structures;

Zapper®. The technology is used in the automotive, transport

 wind turbines;

and signage industries to remove decals, vinyl films, graphics

 tanks and elevated steelwork; and

and adhesive residues from cars, buses, trains, aircraft and other

 locations where conventional blasting equipment would be

coated surfaces while protecting the underlying paint system

disproportionate to the area being repaired.

when correctly applied. From approximately 2006 onwards, Monti became increasingly active in the international pipeline and

From the brush to robotic surface preparation

corrosion-protection industries.

The history of Monti illustrates how dramatically mechanical

The development of bristle blasting represented an important

surface treatment has evolved over the past four decades. Monti

step in this evolution because it enabled a mechanical handheld

was founded in 1987, with its origins in Bonn, Germany, based on

tool not only to remove corrosion and existing coatings, but also

an idea developed by Werner Montabauer and Detlef Thomas.

to generate a new surface profile suitable for subsequent coating

The original application was relatively simple: specialised brushes

application. The technology therefore evolved from its origins

driven by a conventional drilling machine were used to structure

in wood and automotive surface treatment into a method for

the surface of oak timber.

demanding industrial surface preparation.

From this mechanical principle, applications were subsequently

Today, the Monti Group operates its own manufacturing activities

developed for the automotive industry, particularly under the

in Hennef, Germany, together with additional activities in Ratingen.

MBX® – Metal Blasting Xperience brand.

In North America, Great Lakes Gages and M-Testco expand

The technology evolved from a specialised brush system into a

the group’s activities into coating inspection, measurement

controlled method for treating and cleaning different surfaces.

and testing equipment—an important complement to surface

CORROSION PROTECTION | OCTOBER 2026

THE BREAKDOWN

preparation because the quality of the prepared substrate

The emerging surface-preparation toolbox extends from the

ultimately has to be verified. The group also has operations and

simplest hand scraper through conventional powered equipment

companies across Europe, North and South America, and Asia-

to bristle blasting, cordless systems, PREPPER® automation,

Pacific. What started with a brush for structuring oak has therefore

pipeline robots and flying AeroBlaster platforms.

developed over almost four decades into an international

The common objective remains unchanged: to create the right

technology platform for surface treatment and surface

surface for the protective system that follows.

preparation.

As battery technology, automation, robotics and inspection technologies converge, surface preparation is moving from

The surface preparation solutions of the future

a predominantly manual operation towards an increasingly

There will not be one universal method of surface preparation.

controlled and measurable process.

Large, accessible areas may continue to favour abrasive blasting

The long-term vision is therefore a surface preparation

because of its productivity. Small repair areas may favour compact

environment in which the same fundamental objective can be

mechanical tools. Field joints may increasingly be prepared using

achieved manually, cordless, mechanically assisted, automated

cordless or automated equipment. Difficult-to-access structures

or autonomously—outside or inside a pipeline, on the ground,

may eventually be treated by climbing or flying robots.

underwater or in the air.

The future is therefore not a competition between abrasive

For an industry facing increasing pressure to improve safety,

blasting and power tools.

productivity, environmental performance and coating reliability,

It is about selecting the right technology for the substrate,

that evolution may prove to be as important as the development of

geometry, coating system, environmental conditions and required

the coatings themselves. ‹

service life.

The long-term vision is a surface preparation environment in which the same fundamental objective can be achieved manually, cordless, mechanically assisted, automated or autonomously—outside or inside a pipeline, on the ground, underwater or in the air.

Left photo: The HighMate Prepper is a robotic platform designed to automate surface preparation on large steel structures. Right photo: Bristle Blaster Subsea Q4 Demo.

OCTOBER 2026 | CORROSION PROTECTION

SCIENCE

OUTLOOK

CORROSION PROTECTION | OCTOBER 2026

SCIENCE OUTLOOK

ASSESSMENT OF FOULING RELEASE

FOR PDMS-BASED COATINGS E. Tubaro, L. Fedrizzi, F. Andreatta University of Udine, Polytechnic department of engineering and architecture, Udine, Italy

This study investigates the influence of formulation parameters on the fouling release performance of polydimethylsiloxane (PDMS)-based coatings. The effects of crosslinker content and catalyst type on surface roughness and marine fouling behaviour were evaluated, demonstrating the importance of coating formulation in determining fouling release performance.

he most effective strategy currently available to mitigate marine biofouling relies on the use of biocide-based antifouling coatings. These systems can either completely inhibit or partially limit the growth of fouling organisms on

submerged surfaces. Biocides are inherently toxic substances and their use is therefore strictly regulated in terms of both toxicity and solubility in seawater. In response to increasingly restrictive environmental regulations, growing attention has been directed towards more sustainable alternatives, among which fouling release coatings represent one of the most promising solutions.

OCTOBER 2026 | CORROSION PROTECTION

SCIENCE OUTLOOK

Fouling release coatings are typically characterised by a low

surface characteristics, including chemical composition, texture,

elastic modulus, low surface energy and low surface roughness.

colour, structure and wettability, also influence fouling attachment

These coatings are generally obtained through hydroxylation or

[3,5]. The formulation of fouling release coatings directly affects

condensation curing reactions. In condensation-cured systems,

their surface properties. Parameters such as crosslinker

a polysiloxane precursor bearing silanol end groups reacts with

concentration, ambient humidity during curing, catalyst content

a silicone crosslinker based on alkoxysilane functionalities.

and the presence of hydrophilic additives influence surface

Polydimethylsiloxane-based (PDMS) fouling release coatings

roughness, chemical heterogeneity and coating reactivity upon

present several intrinsic limitations, including reduced antifouling

exposure to water. In addition, the incorporation of silicone oils

effectiveness under static conditions, low mechanical resistance

is known to enhance fouling detachment by increasing surface

and susceptibility to failure in the presence of brown slime, which

lubricity and reducing adhesion strength [6]. The objective of this

preferentially adheres to hydrophobic surfaces [1].

paper is to investigate the formulation variables that govern and

In marine environments, fouling development is often

enhance fouling release performance. In addition to their fouling

oversimplified as a linear process, whereby the formation

release performance, the barrier properties of the coating system

of a bacterial biofilm is assumed to precede the settlement

were evaluated by electrochemical impedance spectroscopy

of macroalgae spores and, subsequently, the attachment

(EIS) after immersion in artificial seawater. This preliminary

of invertebrate larvae such as barnacles. However, this

electrochemical characterization was performed to verify the

representation is misleading. Fouling processes are neither

integrity of the multilayer coating system before investigating

strictly sequential nor causally linked, and the inhibition of one

the effects of formulation parameters on surface morphology

type of fouling does not necessarily prevent the development

and marine fouling behaviour. For these systems, given the

of others, while the presence of a biofilm can influence the

intrinsic complexity of the marine environment, the antifouling

settlement of spores and larvae [2,3].

effectiveness can only be reliably assessed through real seawater

The design of effective antifouling surfaces therefore requires

immersion tests, which represent the most accurate validation

resistance to a wide range of marine organisms, spanning

method.

from microorganisms at the micrometre scale, such as bacteria, diatoms and algal spores, to macro-organisms including larvae and invertebrates. Antifouling coatings aim to minimise the adhesive forces between the biological adhesive secreted by organisms and the coating surface. This task is particularly challenging due to the vast diversity of marine species, which employ different adhesion mechanisms and chemical compositions. Only a limited number of organisms, such as mussels, have been extensively studied, and even in these cases investigations have often been conducted under simplified laboratory conditions [4]. Consequently, laboratoryscale optimisation does not guarantee improved antifouling performance under real service conditions. Surface roughness and topography play a significant role in fouling adhesion and distribution. Although biofilm growth itself is not strongly affected by surface smoothness, smoother surfaces generally facilitate fouling removal. Surface irregularities such as microcracks, crevices and pores increase the available surface area and provide sheltered sites where organisms can more easily attach and withstand hydrodynamic forces. When the dimensions of these irregularities are comparable to or larger than those of the fouling organisms, adhesion is further promoted. In addition to roughness, other

CORROSION PROTECTION | OCTOBER 2026

The objective of this paper is to investigate the formulation variables that govern and enhance fouling release performance. In addition to their fouling release performance, the barrier properties of the coating system were evaluated by electrochemical impedance spectroscopy (EIS) after immersion in artificial seawater.

However, immersion testing requires long

Samples characterization

exposure times, often spanning months or years,

EIS

which limits the number of formulations that can

Coated panels were characterized by

be practically evaluated. For this reason, this

electrochemical impedance spectroscopy

research aims to correlate variations in fouling

(EIS) to evaluate their barrier properties.

release coating formulations with their antifouling

The EIS measurements were performed on

performance by combining long-term sea trials

a representative coating system consisting

with surface characterisation techniques,

of the epoxy primer developed in previous

including AFM analysis.

studies [7] and a PDMS-based fouling release topcoat. Electrochemical measurements were

MATERIALS AND METHODS

carried out in artificial seawater (NaCl 23 g/l,

Fouling release coating formulations

MgCl 9.8 g/l, Na2SO4 8.9 g/l, CaCl2 1.2 g/l) at

The organic coating examined in this study is a

room temperature using a three-electrode

silicone-based topcoat commercially known as

cell with an Ag/AgCl (3 M KCl) reference

‘Velox Sil’ (Marlin S.r.l., Muggia, Italy). It is a one-

electrode, a graphite counter electrode,

component PDMS formulation

and a working electrode area of 15.89 cm²,

The variables investigated in this work are

connected to an Autolab PGSTAT30 (Metrohm,

multiple, as shown in Table 1, including

Switzerland). EIS measurements were

crosslinker content and catalyst chemistry. The

performed after 10 min of open circuit potential

crosslinker concentration was varied at three

(OCP) stabilization, using a 20 mV sinusoidal

levels, defined as low (L), medium (M), and high

perturbation over the frequency range 0.01–10

(H), to evaluate its effect on surface topography

kHz. The representative coating system was

and on the extent of oil migration to the coating

characterized before immersion and after 24

surface. The catalyst system was modified by

h of exposure to artificial seawater. Besides,

using two compounds derived from tin: dibutyltin

EIS measurements were repeated after 24 h of

dilaurate (1) and dibutyltin dicarboxylate-based

polarization at -1.8 V with respect to Ag/AgCl (3

catalyst (2).

M KCl) reference electrode for 24 h to evaluate

These systems are PDMS-based elastomers,

the effect of cathodic polarization on the barrier

which crosslink through condensation reactions.

properties of the coated panels.

MATERIALS TESTING FOR ASSET INTEGRITY Materials testing, corrosion expertise, and engineering insight to support critical assets

They are extremely complex, as they are composed of several components in addition

AFM

to the crosslinker, such as catalysts to increase

An atomic force microscope (AFM) was

the curing reaction rate, solvents, thixotropics,

employed in this work for the acquisition of

adhesion promoters, silicone oils to improve the

topographic maps of the PDMS topcoat to

fouling release effect, and other additives (Table 1).

investigate the Fouling Release properties of the coating. The measurements were carried out using a Nanoscope III multimode atomic

Sample

Crosslinker quantity

Catalyst

force microscope (AFM). The topographic maps were recorded in tapping mode. All measurements were performed using n+ silicon tips coated with PtIr5 at room temperature with a relative humidity of 40–65%. The scan frequency was 0.1 Hz (256 × 256 lines), and the scan height in lift mode was 250 nm. The scan size was 20 x 20 µm.

element.com

SCIENCE OUTLOOK

Field immersion tests

Impedance measurements were carried out immediately after

The field immersion tests were carried out by exposing coated

immersion in artificial seawater, repeated after 24 h of exposure

panels to marine shallow waters, checking periodically the

and after 24 h of polarization at -1.8 V. Figure 1 shows the EIS

coverage over time. Surface coverage was assessed after

spectra of a representative coating before and after immersion

exposure by means of image analysis. The immersion tests were

and cathodic polarization.

performed in the port of Trieste. Immersion tests started in June

The Nyquist plots display large, well-defined capacitive loops,

2025, in which biofouling reaches its peak and were completed

with no significant change in shape or diameter after 24 h of

in October. During the field immersion tests, the coated panels

immersion, indicating that short-term electrolyte exposure

underwent periodical inspection. PMMA coated panels were

does not induce measurable degradation of the coating system.

immersed in the same harbour position, at the same level of

After 24 h of polarization the Nyquist plots display again large

depth and light exposure, to ensure repeatability of the tests.

capacitive loops, with a small increase in loop diameter.

RESULTS AND DISCUSSION

At 0.01 Hz, the sample exhibits an increase in |Z| from 2.17 × 10¹¹ to 2.43 × 10¹¹ after 24 h of immersion. Furthermore, the impedance

Barrier properties

modulus at low frequency is 3.49 × 10¹¹ Ω·cm² after 24 h of

Electrochemical Impedance Spectroscopy (EIS) was employed

cathodic polarization.

to assess barrier properties of the coating system. The EIS

These results indicate that the barrier properties are fully

investigation was conducted on coated panels representative

preserved. Furthermore, the small increase of impedance values

of the behaviour of the samples presented in this research,

may be related to further curing or post-curing processes of the

consisting of an epoxy primer and a fouling release topcoat.

PDMS-based topcoat, as well described in [7] .

Figure 1: EIS measured at 0 h, after 24 h of immersion and after 24 h of polarization at -1.8 V, in artificial seawater for coated panels.

CORROSION PROTECTION | OCTOBER 2026

SCIENCE OUTLOOK

This multi-layer system (epoxy primer + PDMS topcoat) prevents effectively corrosive substances from reaching the metal substrate, avoiding corrosion and interfacial degradation over the investigated time. Surface topography The fouling release coatings were analysed by atomic force microscopy (AFM) to characterize surface topography and roughness. Figure 2 shows the 3D AFM topographic maps (20 μm × 20 μm) of samples (a), (b), (c), and (d). The corresponding mean roughness values (Ra) were 34.44 nm for (a), 16.99 nm for (b), 40.71 nm for (c), and 7.56 nm for (d). Sample (b) displays a substantial reduction in surface roughness as compared to sample (a), with a reduction of Ra of about 50%. This can be related to the change of the catalyst while maintaining the same crosslinker for coating (a) and (b). To investigate the effect of the crosslinker concentration, sample (c)

Figure 2: 3D topographic maps obtained by AFM of the samples a, b, c, d.

was formulated with a higher crosslinker content than sample (b). This led to a pronounced increase in surface roughness, as evident from both the Ra value and the AFM maps in Figure 2. The increase of the amount of crosslinker in the topcoat formulation causes marked oil leaching on the coating surface, as shown in Figure 3. By increasing the density of the polymer network, the oil contained in the formulation (low molecular weight methyl-phenyl silicone oil) is rapidly pushed outwards by capillary action. This is associated with the high roughness of the coating. Therefore, this formulation (c) was not considered for sea immersion testing.

Figure 3: Oil leaching after 8 days of coating application for sample (b) and (c).

OCTOBER 2026 | CORROSION PROTECTION

SCIENCE OUTLOOK

Sample (d), which contains a lower amount of crosslinker as

CONCLUSIONS

compared to sample (a) exhibits a smooth surface, with Ra of

In this work, different fouling release coating formulations were

7.56 nm. The roughness values of the coatings, together with their

investigated to assess their antifouling performance and to

standard deviations, are reported in Table 2.

identify key formulation parameters for coating optimization. EIS measurements showed that the epoxy primer-PDMS topcoat reference system maintained a high barrier performance

AFM Sample

after 24 h of immersion in artificial seawater and after 24 h of cathodic polarization, providing evidence of good short-term

Mean Ra [nm]

Standard deviation

34.44

3.63

conducted in the port of Trieste for exposure times ranging from

16.99

1.92

one to four months. These tests were complemented by surface

40.71

4.89

7.56

0.06

electrochemical stability in the investigated conditions. The coated surfaces were evaluated through sea immersion tests

characterization using Atomic Force Microscopy (AFM), allowing correlations to be drawn between antifouling behaviour and surface topography. A reduction in crosslinker content leads to smoother surfaces, likely as a consequence of improved polymer chain reorganization during the curing process. This reduction in surface roughness corresponds to improved

Immersion tests

fouling release behaviour during marine exposure.

The immersion tests in the sea were carried out by immersing

Conversely, increasing the crosslinker content results in higher

painted panels and periodically monitoring them to verify the

surface roughness, which is associated with a decrease of the

antifouling action of the coating, taking into account that the static

antifouling performance.

immersion of a fouling release coating is equivalent to the worst possible hypothesis for a painted boat propeller being parked in port for long periods, especially in the summer season when the vegetative power is very high. Samples (a), (b), and (d) were immersed in the port of Trieste for four months and periodically monitored starting from mid-June 2025. Their antifouling effectiveness was evaluated by comparison with an uncoated reference panel (U-C). The results are shown in Figure 4. After one month of immersion, no appreciable differences were observed among the coatings. After four months of immersion, Sample (a) showed poor antifouling performance, being almost completely covered by vegetation, including encrusting bryozoans, algae, tubeworms, and barnacles. Sample (b), formulated using a different catalyst, exhibited significantly improved fouling release properties. The surface was largely free of encrusting bryozoans and tubeworms, with a reduced presence of barnacles. The visible stripe on sample (b) corresponds to a cleaning test performed after two months of immersion to assess fouling removability. Sample (d), which has a formulation similar to (a) with a reduced crosslinker content, also showed improved performance compared to both the uncoated reference and (a). In this case, fouling was mainly limited to calcareous encrusting species, with reduced slime and algal growth.

CORROSION PROTECTION | OCTOBER 2026

These results indicate that the barrier properties are fully preserved. Furthermore, the small increase of impedance values may be related to further curing or postcuring processes of the PDMS-based topcoat. This multi-layer system (epoxy primer + PDMS topcoat) prevents effectively corrosive substances from reaching the metal substrate, avoiding corrosion and interfacial degradation over the investigated time.

SCIENCE OUTLOOK

The nature of the catalyst was also found to play a significant role. Although catalysts are both tin-based compounds, their substitution induces measurable changes in surface morphology, leading to a decrease in surface roughness and a corresponding improvement in antifouling effectiveness. In conclusion, fouling release coatings investigated in this work display antifouling properties that depend on surface roughness and coating topography. Nevertheless, the roughness is not solely controlling the antifouling behaviour of the coatings, as a careful selection of the type of catalyst and amount of crosslinker is necessary to optimize the anti-fouling performance in sea immersion tests. ‹ This research activity was carried out in cooperation with Marlin S.r.l. via Caduti sul Lavoro 4, 34015, Muggia - Trieste (Italy).

References [1] A.J. Ruiz-Sanchez, A.J. Guerin, O. El-Zubir, G. Dura, C. Ventura, L.I. Dixon, A. Houlton, B.R. Horrocks, N.S. Jakubovics, P.A. Guarda, G. Simeone, A.S. Clare, D.A. Fulton, Preparation and evaluation of fouling-release properties of amphiphilic perfluoropolyether-zwitterion cross-linked polymer films, Prog. Org. Coat. 140 (2020). https://doi.org/10.1016/j.porgcoat.2019.105524. [2] Z. He, X. Lan, Q. Hu, H. Li, L. Li, J. Mao, Antifouling strategies based on super-phobic polymer materials, Prog. Org. Coat. 157 (2021). https://doi. org/10.1016/j.porgcoat.2021.106285. [3] D. Howell, B. Behrends, A review of surface roughness in antifouling coatings illustrating the importance of cutoff length, Biofouling 22 (2006) 401–410. https://doi.org/10.1080/08927010601035738. [4] J.A. Callow, M.E. Callow, Trends in the development of environmentally friendly fouling-resistant marine coatings, Nat. Commun. 2 (2011). https:// doi.org/10.1038/ncomms1251. [5] M. Barletta, C. Aversa, E. Pizzi, M. Puopolo, S. Vesco, Design, manufacturing and testing of anti-fouling/foul-release (AF/FR) amphiphilic coatings, Prog. Org. Coat. 123 (2018) 267–281. https://doi.org/10.1016/j. porgcoat.2018.07.016. [6] Tariq Aziz, Hong Fan, Framan Ullah Khan, Muhammad Haroon, Li Cheng, Modified silicone oil types, mechanical properties and applications, Polymer Bullettin (2019). [7] E. Tubaro, A. Rondinella, M. Pesle, A. Bontempi, L. Fedrizzi, F. Andreatta, Effect of silane content on barrier properties and adhesion of fouling release

Figure 4: Field immersion tests of coated panels (a), (b), (d), with respect to the uncoated panel, immersed in Trieste Harbour for 1 and 4 months, starting from July 2025.

coatings for naval applications, Prog. Org. Coat. 219 (2026) 110367. https:// doi.org/10.1016/j.porgcoat.2026.110367.

OCTOBER 2026 | CORROSION PROTECTION

ADVANCEMENTS

Evonik strengthens fast-cure epoxy offering in the Americas with Ancamine® 2868 and Ancamine® 2844 for challenging conditions Edited by Evonik Industries AG Essen - Germany

CORROSION PROTECTION | OCTOBER 2026

ADVANCEMENTS

Ancamine® 2868 and Ancamine® 2844 advance coating performance by enabling rapid thin‑film cure and fast property development — even at low temperatures and high humidity — while increasing formulation flexibility for demanding protective and marine coatings applications.

return to service while providing excellent surface appearance, high chemical resistance, and long‑term corrosion protection in cold‑climate and winter application scenarios. Ancamine® 2844 also demonstrates strong carbamation resistance under cold and damp conditions, along with excellent adhesion and resistance to chemicals and corrosion, including up to 3,000 hours of salt spray performance. These attributes make it particularly well suited for winter coatings, fast‑cure protective systems, and other applications where downtime must be minimized. “From a technical perspective, achieving fast cure, particularly

vonik has strengthened its epoxy curing agent offering for

at low temperatures without sacrificing durability or corrosion

the Americas region to address challenging application

resistance is a complex balancing act,” said Dr. Raghuraman

conditions with Ancamine® 2868 and Ancamine®

Govindan Karunakaran, Advanced Technology Manager,

2844. Both solutions are designed to support epoxy

Crosslinkers at Evonik. “Ancamine® 2844 delivers exceptional

formulators in protective, marine, and industrial coatings

low‑temperature performance as a stand‑alone hardener, while

requiring rapid cure, productivity, and reliable performance under

Ancamine® 2868 adds formulation flexibility as a crosslinkable

demanding temperature and humidity conditions.

accelerator, enabling formulators to fine‑tune cure speed and

Ancamine® 2868 is a modified cyclic polyamine designed to

performance. Together, they give customers powerful options

function as a highly efficient, crosslinkable accelerator for epoxy

to design robust, fast‑curing epoxy systems tailored to specific

systems. When used as a co‑curing agent with polyamides,

applications and challenging conditions.”

amidoamines, and cycloaliphatic amine curing agents, it enables

These fast-cure solutions were showcased at the latest edition

rapid thin‑film cure while maintaining key physical and barrier

of the American Coatings Show (ACS) as part of Evonik’s broader

properties, surface appearance, and corrosion protection. By

epoxy portfolio for the Americas, reinforcing the company’s

significantly accelerating cure speed, Ancamine® 2868 allows

commitment to high-performance, productivity-driven coating

epoxy formulators to fine‑tune performance and formulation

solutions tailored to real-world application challenges, including

response, while supporting efficient processing and broad

seasonal, climatic, and regulatory demands. ‹

formulation flexibility. These attributes make it well suited for industrial maintenance, protective coatings, and civil engineering applications where fast return to service is critical. “Coating applications under challenging temperature and humidity conditions often force customers to choose between speed, appearance and durability,” said Svetlana Ivanova, Marketing Director, Epoxy Curing Agents at Evonik. “With Ancamine® 2868, we are expanding the formulation options available to customers in the Americas by offering an efficient accelerator that delivers very fast cure together with a strong EH&S profile. Combined with proven solutions like Ancamine® 2844, these technologies help customers address real‑world application challenges while supporting productivity and responsible product stewardship.” Ancamine® 2844 complements this accelerator technology as an ultra‑fast cure, high‑functionality aliphatic amine hardener developed for plural component spray applications. Engineered to deliver reliable curing and rapid property development at temperatures as low as 5 °C, this powerful hardener enables faster

OCTOBER 2026 | CORROSION PROTECTION

THE BREAKDOWN

Single-coat powder coating solutions: greater efficiency in a single application Edited by

Europolveri Spa

Sandrigo (Vicenza), Italy

Europolveri’s R&D team has developed a single-coat powder coating system that replaces the traditional multi-layer coating cycle by combining corrosion protection and decorative finishing in a single application.

CORROSION PROTECTION | OCTOBER 2026

he metal corrosion protection market is currently undergoing a profound transformation. Manufacturers are increasingly required to balance the need to reduce processing times and

production costs while maintaining the high performance of their coating systems. In this context, Europolveri’s Research and Development activities are focused on developing innovative solutions that redefine the very concept of anti-corrosion primers, combining sustainability, production efficiency, and long-term reliability. At the core of this innovation are high-performance single-coat systems, a technological solution that replaces the traditional multi-layer coating cycle by combining corrosion protection and decorative finishing in a single application.

THE BREAKDOWN

Simplifying the coating process delivers tangible benefits

Simplified processes, lower energy consumption, and performance

throughout the entire production line, including:

comparable to that of traditional multi-coat systems provide a practical

 significant reductions in gas and electricity

answer to the needs of modern industry.

consumption;

The future of corrosion protection is no longer limited to preserving metal

 lower CO₂ emissions;

surfaces—it also plays a key role in making the entire manufacturing

 increased productivity, with throughput potentially

process more efficient, sustainable, and competitive. ‹

reaching up to twice the number of parts processed compared with conventional two-coat systems. Outdoor performance is equally impressive. The coating retains more than 50% of its gloss after 600 hours of QUV-B exposure, achieving results equivalent to the performance of a Qualicoat Class 2 product. The effectiveness of the system has also been confirmed through laboratory corrosion testing. After 6,000 hours of exposure to neutral salt spray, coating delamination on zinc phosphated steel panels remained below 1 mm. The single-coat system was also evaluated on steel surfaces prepared exclusively by sandblast cleaning (Sa 2½) to assess its performance under particularly demanding conditions. Compared with a conventional polyester powder coating, the single-coat system demonstrated a substantial improvement in corrosion resistance: while maintaining coating delamination below 3 mm, the standard polyester coating achieved approximately 150 hours of neutral salt spray resistance, whereas the single-coat system reached up to 720 hours, meeting the requirements for Corrosivity Category C4 High (C4H).

OCTOBER 2026 | CORROSION PROTECTION

SCIENCE

OUTLOOK

Critical comparison of impressed current and galvanic anode cathodic protection in the offshore wind industry B. Refraschini Independent consultant T. Caglioni, P. Marcassoli Cescor Srl, Via Maniago 12, 20134 Milan, Italy

xtensive experience gained in the offshore industry over the past few decades has established cathodic protection (CP) as the primary corrosion mitigation strategy for protecting

immersed areas of marine structures. Jackets of platforms, pipelines and other subsea assets are generally protected using sacrificial aluminium alloy anodes installed at the fabrication lifeyard, whereas impressed current cathodic protection (ICCP) systems have historically been employed primarily for life-extension and retrofit applications on medium- to large-sized structures rather than on newly constructed installations. The rapid expansion of offshore renewable energy, particularly offshore wind farms, has renewed interest in the environmental footprint of corrosion protection technologies. In fact, in principle, galvanic anode systems progressively release metallic corrosion products into seawater during service life, while ICCP systems may generate chlorine at inert anodes, resulting in localized biocidal effects. This paper presents a comparative assessment of galvanic anodes cathodic protection (GACP) and impressed current cathodic protection systems for offshore wind structures, with a particular focus on their environmental impact. Analysis also examines their respective technical advantages and limitations, with particular emphasis on protection effectiveness, operational reliability, installation constraints and other aspects. The paper aims to provide a balanced assessment of both technologies and support informed decision-making during the design of offshore wind assets.

CORROSION PROTECTION | OCTOBER 2026

OCTOBER 2026 | CORROSION PROTECTION

SCIENCE OUTLOOK

Figure 1 – Sheringham Shoal offshore wind farm, North Sea, United Kingdom. Photograph by Pontificalibus (2019), released under CC0 1.0 Public Domain Dedication.

Cathodic protection has long been recognized as a mature and

must therefore ensure long-term reliability while minimizing

reliable corrosion control technology for offshore infrastructures.

inspection and maintenance requirements. Furthermore, CP

Fixed offshore platforms, subsea pipelines and other subsea

equipment should not complicate transportation, fabrication

assets are predominantly protected through galvanic anodes

or installation activities and should be readily replicated across

cathodic protection systems based on aluminium alloy, or less

multiple foundations.

often zinc. ICCP systems are also widely established, although

Current market trends indicate continued growth in offshore

their use has traditionally been more common in retrofitting and

wind developments located in relatively shallow waters, generally

life extension projects.

approximately 60 m or less deep. In some regions, wind farms

In recent years, the accelerated deployment of offshore renewable

are installed near major river estuaries, where favourable wind

energy installations has introduced new considerations in the

resources coincide with complex environmental conditions. In

selection of corrosion protection systems. In particular, ICCP

deeper offshore locations, floating concepts are increasingly

systems are increasingly being proposed for offshore wind

preferred over fixed monopile or jacket foundations. At the

foundations, often on the basis of their perceived environmental

same time, increasing attention is being directed toward the

benefits. Such claims, however, warrant a comprehensive

environmental sustainability of all components contributing to

technical and environmental assessment.

renewable energy generation, including corrosion mitigation

Selecting an appropriate CP strategy for offshore wind farms

systems. From an environmental perspective, galvanic anodes

requires consideration of several interrelated factors, including

gradually consume and release metallic ions and corrosion

foundation type, installation location, power availability,

products into seawater, whereas ICCP systems generate oxidizing

maintenance requirements, and environmental constraints.

species, predominantly chlorine, that may exert localized biocidal

Offshore wind foundations can take a variety of structural

effects. The following sections provide a detailed comparison of

configurations, including monopiles, jackets, gravity-based

GACP and ICCP technologies, addressing their environmental

structures (GBS) and floating systems. Among these, monopile

implications, as well as technical performance, in the context of

foundations currently represent the dominant solution in the

offshore wind applications (Figure 1).

European market due to their relative simplicity, scalability, and cost-effectiveness.

GACP and ICCP

Unlike conventional offshore platforms, wind farms typically

Cathodic protection of offshore structures can be achieved

consist of dozens of unmanned structures distributed across

through two principal approaches: galvanic anode cathodic

large sea areas. Consequently, maintenance interventions may be

protection (GACP) and impressed current cathodic protection

logistically challenging and costly. Corrosion protection systems

(ICCP).

CORROSION PROTECTION | OCTOBER 2026

SCIENCE OUTLOOK

In galvanic anode systems, corrosion control is achieved by

Oxygen evolution

electrically coupling the protected structure to galvanic anodes,

2H2O = O2 + 4e– + 4H+

(Eq. 1)

typically manufactured from aluminium-based alloys and, less frequently, zinc alloys. The electrochemical potential difference

Chlorine evolution

between the anode, which is the less noble metal, and the carbon

2Cl– = Cl2+ 2e- (Eq. 2)

steel structure, which is the more noble metal, naturally drives the protection current. This technology has demonstrated sound

For commercially available mixed metal oxide (MMO) titanium

reliability in offshore service due to its simplicity, absence of

anodes, oxygen evolution predominates only at current densities

external power requirements, and inherent ability to self-regulate

below approximately 10 A/m². At higher current densities,

output current according to the current demand of the structure.

chlorine evolution becomes the dominant anodic reaction. These

The primary limitation of GACP systems is the large quantity

thresholds may vary for next-generation anodes incorporating

of anodic material often required, particularly for bare steel

improved MMO formulations. For simplicity and to maintain a

structures. This may result in significant additional weight and

conservative assessment, chlorine production is calculated

associated structural implications.

assuming that chlorine evolution accounts for 100% of the

Conversely, ICCP systems rely on an external DC power source to

electrochemical reaction at anodes.

deliver protection current through inert anodes, often consisting

Representative current demand values for ICCP systems

of mixed-metal-oxide (MMO) coated titanium or other alternative

protecting monopile foundations are summarised in Table 1,

materials. These systems can provide equivalent protection

based on the current density values reported in Ref. [1].

with substantially lower installed mass, yielding advantages in fabrication, transportation, and installation. However, ICCP

IP,INITIAL (A)

IP,MEAN (A)

bare

200

100

coated

systems require power supply, electrical cabling, control units and monitoring equipment, introducing additional complexity and potential reliability concerns. The environmental impact of the two technologies will be analysed in the following sections. However, a meaningful comparison of GACP and ICCP for offshore wind foundations must also consider

Table 1: Expected current demand values for the reference monopile used as an example in this paper.

other key criteria, including design life, dependence on an external power supply, weight and hydrodynamic loading, uniformity of potential and current distribution, inspection and maintenance requirements, safety, and decommissioning.

Environmental impact of cathodic protection The environmental impact of the two cathodic protection technologies is primarily associated with metal release (GACP), chlorine evolution (ICCP), and issues related to system decommissioning and disposal. The analysis presented here considers a monopile foundation approximately 7 m in diameter and 35 m in length as a reference case, representing dimensions typical of currently installed structures. Impressed current cathodic protection ICCP systems installed on offshore structures generate chlorine as the main anodic by-product from chlorides present in seawater. At the surface of activated titanium anodes, two principal anodic reactions may occur:

In addition to environmental impact, a meaningful comparison of galvanic anode cathodic protection (GACP) and impressed current cathodic protection (ICCP) for offshore wind turbine foundations must also consider other key criteria, including design life, dependence on an external power supply, weight and hydrodynamic loading, uniformity of potential and current distribution, inspection and maintenance requirements, safety, and decommissioning.

OCTOBER 2026 | CORROSION PROTECTION

SCIENCE OUTLOOK

Assuming that the entire anodic current translates into chlorine

Assuming very low current velocities (approximately 0.01 m/s), the

evolution, the chlorine release rate, RCl₂ (g/h), can be determined

residual chlorine concentration can be estimated as:

according to Faraday’s law:

(Eq. 4)

(Eq. 3)

where pmCl₂ is the molecular weight of chlorine (70.90 g/mol), F

In the present case, the water exchange time required to renew

is Faraday’s constant (96,485 C/eq), n is the number of electrons

the control volume (5,655 m³) is approximately 0.14 h. This value

involved in the anodic reaction (2 eq/mol), and 3,600 is the

was calculated for a radius of 5 m around the monopile and a flow

number of seconds per hour.

velocity of 0.01 m/s. Under these conditions, residual chlorine

The calculated chlorine generation rates are presented in Table 2.

concentrations range from approximately 0.0010 ppm for the coated monopile to 0.0065 ppm for the bare monopile.

RCl2-INITIAL (kg/day)

RCl2-MEAN (kg/day)

bare

6.3

3.3

coated

0.3

0.9

Table 2: Chlorine discharge rate.

In several industrial applications, chlorine is deliberately dosed into seawater as a biocide for biofouling control and sterilisation purposes. Typical minimum dosing concentrations are around 0.5 ppm (Refs. [6] and [7]). Compared with these values, the amount of chlorine generated by the ICCP system of a single monopile is extremely low, although it depends on structural dimensions and

To convert the calculated chlorine release rates into dissolved

coating condition. Rapid dispersion in the marine environment

concentrations in seawater, a simplified approach similar to

further reduces the resulting concentrations.

that proposed in Ref. [5] was adopted. A control volume of

Potential environmental concerns may arise in large offshore wind

seawater surrounding the monopile and extending 5 m from

farms comprising numerous monopiles located in shallow waters,

its surface is considered. Water exchange within this volume is

where cumulative effects could become more significant. In

driven by horizontal flow, replacing the enclosed volume over a

principle, chlorine generation may produce adverse environmental

characteristic time t.

effects, as occasionally observed in harbour areas where vessels equipped with permanently operating ICCP systems remain moored for extended periods. Under such conditions, local

In several industrial applications, chlorine is deliberately dosed into seawater as a biocide for biofouling control and sterilisation purposes. Typical minimum dosing concentrations are around 0.5 ppm. Compared with these values, the amount of chlorine generated by the ICCP system of a single monopile is extremely low, although it depends on structural dimensions and coating condition. Rapid dispersion in the marine environment further reduces the resulting concentrations.

CORROSION PROTECTION | OCTOBER 2026

chlorine accumulation may occur and could ultimately lead to sterilisation of the surrounding water volume.

Galvanic anode cathodic protection For Al-Zn-In sacrificial anodes, the primary anodic oxidation reactions involve the dissolution of aluminium and zinc: Al  Al3+ + 3e–

(Eq. 5)

Zn  Zn2+ + 2e–

(Eq. 6)

Under conditions of uniform dissolution, the contribution of each electrochemical reaction to the overall anodic process is proportional to the concentration of the corresponding element within the alloy. This relationship should be expressed using mole fractions, although weight percentages provide an adequate approximation for practical calculations. The generation rate of metal ions, RMn+ (g/h), resulting from

SCIENCE OUTLOOK

sacrificial anode dissolution is directly proportional to the

detected; however, no significant environmental consequences

protection current according to Faraday’s law:

have been documented. In the case of galvanic anodes, only the anodes require disposal

upon decommissioning. With impressed current systems, there

(Eq. 7)

are more components to dispose of: anodes, cables, reference electrodes, junction boxes, and the transformer-rectifiers. where I is the current associated with the equivalent fraction of

Consequently, disposal is more complex, as it involves various

each alloying element, awM is the atomic weight of the metal (g/

materials (including potentially polluting ones, such as the cooling oil found in certain types of transformer-rectifier units).

mol), F is Faraday’s constant (96,485 C/eq), n is the number of electrons participating in the electrochemical reaction (eq/mol), and Table 3 reports the dissolution rates of the principal metallic

Other technical comparisons between GACP and ICCP systems

species released by galvanic anodes protecting a representative

Both galvanic and impressed current systems are capable of

monopile structure operating at a protection current of 100 A.

supporting design lives of approximately 25 to 30 years, which

3,600 is the number of seconds per hour.

aligns with typical offshore wind project requirements.

Element, M

Atomic weight, M

Alloy %

eq.M/100 g

xeq.M

eq/mol

g/day

Although ICCP systems may theoretically operate for significantly

26.98

95.6325

10.6331

0.9864

98.635

794.4

longer periods, their long-term effectiveness depends on the

65.38

4.1250

0.1262

0.0117

1.171

34.265

durability and reliability of multiple components, including anodes,

114.82

0.0275

0.0005

0.0000

0.004

0.228

cables, power supplies, and monitoring devices. Consequently,

55.65

0.0900

0.0032

0.0003

0.030

0.748

112.41

0.0020

0.0000

0.000

0.017

the practical service life of the system is frequently governed by

28.09

0.1200

0.0171

0.0016

0.159

0.997

63.55

0.0030

0.0001

0.0000

0.001

0.025

10.7802

1.0000

100.000

Table 3: Dissolution rate of galvanic anode metal ions.

Galvanic anode systems are generally designed conservatively and often retain residual capacity beyond the intended service life.

component reliability rather than electrochemical capacity. A significant advantage of galvanic systems lies in their complete independence from external energy sources. Protective current remains available as long as sufficient anodic material remains. By contrast, ICCP systems are entirely dependent on power availability. Current is supplied through transformer-rectifier units

To estimate dissolved metal concentrations in seawater, the same

connected to the wind farm electrical infrastructure. Therefore,

methodology used for the ICCP assessment was applied. Assuming

interruptions in the power supply directly affect corrosion

a protection current of 100 A and a seawater flow velocity of 0.01

protection performance unless suitable redundancy measures are

m/s, the predicted aluminium concentration is approximately

implemented.

0.00081 ppm, whereas the corresponding zinc concentration is

One of the most significant distinctions between the two

approximately 0.00004 ppm.

technologies concerns system weight.

From the perspective of human health, aluminium is generally

ICCP installations require only a limited number of lightweight

regarded as non-toxic at such concentrations. In drinking water

inert anodes and therefore exert negligible influence on structural

regulations, aluminium concentration limits are commonly set

loading. Galvanic systems, in contrast, may require substantial

between 0.1 and 0.2 ppm, primarily to prevent the formation and

quantities of sacrificial material distributed around the monopile.

deposition of aluminium hydroxide flakes rather than because of

Additional support brackets and mounting frames further increase

direct toxicity concerns. Similar considerations apply to zinc ions,

the total installed weight.

the second most abundant metallic constituent in aluminium-based

Concentrated anode assemblies may also affect fatigue loading

sacrificial anode alloys.

and increase hydrodynamic drag forces generated by marine

Furthermore, ISO 24656 (Ref. [3]) reports that no conclusive

currents, factors that must be considered during structural design.

evidence is currently available regarding adverse environmental

Galvanic anode systems inherently limit the risk of

effects caused by aluminium sacrificial anodes in open-water

overprotection because the lower value of the steel potential is

conditions. In relatively sheltered environments, such as harbour

constrained by the electrochemical potential of the sacrificial

basins, elevated aluminium concentrations have occasionally been

anodes. However, inadequate anode distribution may result in

OCTOBER 2026 | CORROSION PROTECTION

SCIENCE OUTLOOK

localized under-protection, particularly on large structures.

equipment and submerged anodes. Although risks to personnel

ICCP systems offer greater flexibility and control but introduce

are generally limited due to the unmanned nature of most

the possibility of both under-protection and overprotection if not

offshore wind installations, specific precautions are required

properly designed or monitored. This phenomenon becomes

during underwater inspections and diving operations, including

particularly relevant on bare steel structures, where excessive

temporary de-energisation of the cathodic protection system

current densities may develop near the anodes while remote

(Figure 2).

areas may receive insufficient protection. Excessive cathodic polarization can produce undesirable side effects, including

Discussion and conclusions

coating disbondment and hydrogen embrittlement of susceptible

In light of the considerations discussed in the preceding sections,

metallic materials. Appropriate system design therefore requires

both cathodic protection approaches can be regarded as

careful optimisation of anode positioning and current output.

technically sound and viable solutions, each presenting specific

ICCP systems require continuous monitoring of structure-

advantages and limitations.

to-electrolyte potentials as well as periodic inspections of

Galvanic anode systems are generally straightforward to

transformer-rectifier units, junction boxes, cabling, reference

implement, as they operate without the need for an external power

electrodes and anodes. Modern systems generally incorporate

supply or routine maintenance. In addition, they provide a reliable

remote monitoring capabilities that allow operational adjustments

and well-distributed protective current throughout the entire

from onshore facilities. Nevertheless, field inspections remain

service life of the structure.

necessary throughout the service life. Galvanic systems require

Impressed current cathodic protection (ICCP) systems, by

substantially less maintenance. Their simplicity eliminates the

contrast, are capable of delivering significantly higher current

need for active control equipment, and periodic verification of

outputs while requiring substantially less anode mass than

protection levels can be performed either remotely or during

galvanic systems. However, this benefit is often accompanied by

scheduled inspections. From a safety viewpoint, sacrificial anode

greater complexity and potential concerns regarding long-term

systems involve minimal operational safety concerns apart from

reliability. The issue of environmental impact, which is frequently

conventional installation and welding activities. ICCP systems

cited in support of impressed current systems, appears less

introduce additional electrical hazards associated with power

decisive than is often assumed. Although galvanic anodes release

Fig. 2 – Radar diagram with qualitative comparison GACP vs ICCP for offshore wind industry.

CORROSION PROTECTION | OCTOBER 2026

SCIENCE OUTLOOK

considerable quantities of metallic ions into the surrounding environment, the continuous action of marine currents promotes their dispersion, resulting in relatively low local concentrations. Furthermore, ICCP systems are not entirely free from environmental concerns, as the generation of oxidising species may produce biocidal effects, and the systems themselves give rise to a variety of materials that must be managed and disposed of during decommissioning. The previous considerations indicate that both GACP and ICCP systems have a certain level of environmental impact, which must be assessed on a case-by-case basis. From a technical standpoint,

Bibliography [1] Deep water. The next step for offshore wind energy – A report by the European Wind Energy Association (2013) [2] DNV-RP-B401:2021 General Principles of Cathodic Protection [3] ISO 24656:2022 Cathodic Protection of Offshore Wind Structures [4] Wind energy in Europe: 2022 Statistics and the outlook for 2023-2027 [5] US Environmental Protection Agency. “Phase I Final Rule and Technical Development Document of Uniform National Discharge Standards (UNDS). Appendix A, Cathodic Protection: Nature of Discharge”, published in April 1999. Reference number:

one technique may be preferable to the other depending on the

EPA-842-R-99-001

application conditions. Engineering calculations and assessments

[6] World Health Organization. Guidelines for Drinking-water Quality.

can be performed for both scenarios, taking into account the

Fourth Edition. 2022 – pag.361

specific context, such as water depth, currents, water exchange

[7] Council Directive 98/83/EC on the quality of water intended for

rates, and expected concentrations.

human consumption

In summary, the choice of cathodic protection system for offshore structures should be based on technical and economic considerations tailored to the specific case and its conditions, without ruling out either option based on preconceived notions regarding environmental impact. ‹

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FLAME SPRAY TECHNOLOGY

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Resistance to extreme weathering, UV and salt spray protection

Working pressure adjustable from 0.2 to 7.5 bar

Immediate use of coated items

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MARINE

OIL & GAS

INDUSTRIAL

THE BREAKDOWN

FBE linings for industrial valves:

market evolution and application expertise Alessio Trisolino Donelli - Cuggiono (Milan), Italy trisolino@donelli.it

CORROSION PROTECTION | OCTOBER 2026

THE BREAKDOWN

Donelli Alexo has developed its expertise in internal fusion bonded epoxy (FBE) linings for industrial valves, combining specialised application technologies, process control and dedicated production capacity. Its experience spans major infrastructure and offshore energy projects, demonstrating the company’s ability to handle both exceptionally large components and high-volume production programmes while meeting demanding technical and quality requirements. Donelli Alexo’s CX plant in Cuggiono (Milan).

n the industrial valve sector, material selection is increasingly

the same time, the Italian and European valve supply chains have

shaped by the need to reconcile cost competitiveness with

needed access to specialist application expertise capable of

operational safety and service life. The expansion of energy

keeping pace with these changes.

projects and major water infrastructure has made this

Donelli Alexo has developed its activities within this environment,

challenge particularly evident: even very large components must

drawing on the Donelli Group’s long-established experience in

withstand aggressive fluids and demanding operating conditions,

protecting industrial assets against corrosion, a field in which

while manufacturers are expected to control overall supply costs.

the Group has worked for more than a century. Its expertise in

Against this background, internal fusion bonded epoxy (FBE)

FBE linings for valves forms part of a technical journey built over

linings have acquired growing importance over the years.

many years and progressively reinforced as demand increased.

Valves manufactured from carbon steel and protected with

The market’s stronger interest did not signal the introduction

appropriately selected anticorrosion systems can, for certain

of an entirely new activity for Donelli; it called for greater efforts

services, provide an alternative to components made entirely

to expand know-how, upgrade technologies, reinforce the

from corrosion-resistant alloys or fitted with metallic cladding. The

organisation and address increasingly specialised application

economic implications can be considerable, especially as valve

requirements.

diameters, weights and quantities increase. Special alloys and

Italy’s industrial valve manufacturing sector plays an important

cladding naturally remain essential where operating conditions

role in the international supply chain. Alongside the design and

require their specific properties. FBE offers a different engineering

mechanical engineering capabilities of valve manufacturers,

option, to be assessed against the process fluid, temperature,

reliable internal coating services can be a decisive competitive

valve configuration and expected performance. Its industrial value

factor. Donelli has directed its investments towards making

depends on achieving a more competitive material cost without

this expertise available in Italy, also in support of European

compromising the reliability required of the finished component.

manufacturing. The resulting service extends beyond coating

This trend did not result from a single innovation or a sudden

execution, bringing knowledge of materials, applications and

market shift. Interest in FBE solutions has grown through the

technical specifications into the discussions that help define the

progressive development of valve markets, alongside advances

most appropriate protection system at the outset of a project.

in coating materials and application technologies. Manufacturers

For valves intended for critical duties, FBE cannot be treated

have faced increasingly detailed specifications, larger production

as an interchangeable finish. The lining must be suited to the

programmes and more demanding durability requirements. At

component’s behaviour, its operating environment and the stages

OCTOBER 2026 | CORROSION PROTECTION

THE BREAKDOWN

involved in manufacture. Available product families differ in their characteristics and application fields; selecting a suitable system requires a clear understanding of those differences and a technical assessment that reconciles the needs of the valve manufacturer with those of the end user. A correctly selected and applied lining helps maintain the continuity of corrosion protection over time, which is essential if the cost advantage of a more economical substrate is to be realised in service. A significant part of Donelli’s technical development has focused on the interaction between FBE linings and the machining operations involved in valve manufacturing. Internal valve surfaces are not merely areas requiring protection: they can include seats, sealing regions and mating surfaces that must meet precise dimensional and functional requirements. Some of these areas may be machined after coating. Understanding how the lining behaves at that stage is essential. Even a correctly applied coating may no

to identify unsuitable combinations before

In parallel, the company has worked on

longer provide the intended protection if

they become problems on the finished

the evolution of its application methods.

subsequent operations alter the continuity

component.

Valves present passages, cavities,

or functional properties of the barrier in

The significance of this work extends

changes in section and internal surfaces

the finished component.

beyond individual operations. Where the

whose accessibility varies considerably

Donelli has examined these issues

selected product and component design

from one design to another. Experience

by comparing the characteristics of

permit controlled post-coating machining,

with different components has informed

different FBE systems and assessing

the manufacturer has greater flexibility

the development of powder-deposition

their compatibility with the complete

to integrate corrosion protection into the

methods, application arrangements and

manufacturing sequence. Not all materials

production process. Lining selection can

equipment suited to complex geometries,

can be machined in the same way; the

be considered alongside the definition of

always in relation to the selected product

possibility of carrying out a subsequent

machining and assembly operations rather

and required coating performance.

finishing operation must not be mistaken

than being addressed only once those

Advances in powder-spraying technologies

for an automatic guarantee that

stages are complete. For Donelli, expected

and the availability of different application

impermeability, adhesion and protective

durability must therefore be assessed

solutions have supported this continuous

performance will remain unchanged. The

against the valve as it will actually enter

refinement. In this field, consistency

behaviour of the specific system must be

service, not solely against the condition of

depends in part on the ability to adapt the

understood, and the surfaces involved,

the coating immediately after application.

method to the component rather than

machining sequence and acceptable limits

This approach reflects an accumulated

applying an identical process configuration

considered from the outset. This work

understanding of the relationship between

to every valve.

connects coating expertise more closely

materials, mechanical requirements and

Heating and preheating have formed

with valve engineering, making it possible

real-world protection.

another important area of process

CORROSION PROTECTION | OCTOBER 2026

THE BREAKDOWN

From left to right: Internal FBE coating application for the oil and gas industry. FBE coating application on a valve for drinking water service.

development. As valve size, mass and wall thickness change, so does the way heat is transferred through the component. Donelli has therefore focused on defining appropriate thermal cycles, understanding the uniformity of heating and assessing heating arrangements suited to different applications. The development of specially designed ovens, systems for handling demanding loads and improved process monitoring has accompanied this technical work. Achieving a set temperature is not, by itself, the objective: understanding the thermal behaviour of a complex component is essential to establishing repeatable application conditions compatible with the chosen FBE system. The development of this specialisation has followed a clear technical and managerial direction. Alessio Trisolino, who leads Donelli Alexo, has overseen the growth of its FBE activities by connecting market requirements with technical choices and the corresponding industrial investments. Luca Calore has made a particularly important contribution through his years of experience with FBE systems, his detailed knowledge of coating products and his understanding of markets and the requirements of the principal application sectors. This combination of product, market

Valves present passages, cavities, changes in section and internal surfaces whose accessibility varies considerably from one design to another. Experience with different components has informed the development of powder-deposition methods, application arrangements and equipment suited to complex geometries, always in relation to the selected product and required coating performance.

and application expertise supports informed decisions across a wide range of technical requests.

OCTOBER 2026 | CORROSION PROTECTION

THE BREAKDOWN

Marco Malandra’s contribution has been closely linked to quality

wishes to acknowledge the professionalism and commitment of

management and international standards, both fundamental

everyone involved in coating operations and inspection, whose

in projects where compliance with technical requirements and

work has contributed to the company’s technical and industrial

supporting documentation are integral parts of the supply. The

development.

close interaction between product and market expertise, technical

As volumes and production complexity increased, industrial

direction and quality management has allowed Donelli to build

infrastructure also had to evolve. The opening of the CX facility

an integrated approach in which application decisions, industrial

in Cuggiono (province of Milan) in June 2022 addressed this

capacity and specification compliance are closely connected.

need, adding dedicated capacity for powder and liquid coating

The knowledge developed by these specialists is not confined

operations and introducing advanced technologies for handling

to individual roles. Over the years, the Group has invested in

complex components. The investment supported a more effective

training and transferring technical expertise to its application

organisation of activities requiring consistent application results

and inspection teams, allowing experience to become part of

and close coordination between production, planning and quality

the organisation’s shared working methods. The consistent

management.

quality expected in international programmes depends on

The same factors guided the subsequent investment in the MXP

this process: turning specialist understanding into established

facility in Ferno (province of Varese), which resumed operations in

practices that can support expanding production. Donelli also

March 2023 after substantial reorganisation and modernisation.

FBE-coated components.

CORROSION PROTECTION | OCTOBER 2026

THE BREAKDOWN

Additional space and equipment, including capacity for large and

selection, application expertise and dedicated production

heavy valves, extended Donelli’s ability to handle demanding

capacity.

production programmes. The progressive development of its

Growing demand continues to shape the Group’s development.

Cuggiono and Ferno sites therefore reflects two closely related

New materials, changing needs within the manufacturing

forces: rising market demand and continued advances in the

supply chain and increasingly sophisticated expectations all

technology required to serve it. Industrial investments have

require continuous updates to technical knowledge, production

accompanied the growth of expertise, enabling it to be applied

technologies and working methods. The ability to respond comes

across a wider range of components and international-scale

from sustained interaction between those who understand

contracts.

the market, those who assess coating systems and those

For European valve manufacturers, access to nearby specialist

responsible for quality. This balance characterises Donelli Alexo’s

coating facilities offers advantages beyond logistics. Technical

development: application expertise progressively deepened over

requirements can be discussed during coating system

the years and supported by industrial investments consistent

definition; design-related issues can be assessed promptly; and

with the evolution of the technology and its markets.

coating schedules can be better coordinated with mechanical

Today, Donelli provides the industrial valve sector with FBE

manufacturing. Above all, lining selection can be considered as

application capabilities developed in Italy for European

part of the overall valve engineering solution rather than as an

and international markets. Their value lies in the combined

isolated subcontracted operation.

understanding of coating materials, practical applications,

Applications for Middle Eastern markets have provided an

international standards and industrial organisation. Built up as

important stimulus to this development. The requirements

market requirements have evolved, these capabilities enable

associated with major energy infrastructure, including those

manufacturers to pursue technically appropriate and competitive

of the Saudi Aramco APCS-102 coating specifications, and the

coating solutions with a clear focus on the service durability of

water-sector applications historically associated with SWCC,

the finished valve. ‹

demand thorough materials knowledge and an organisation capable of meeting stringent technical conditions and verification requirements. For Donelli, these projects have been opportunities to strengthen experience with international standards and expectations, while continuing to serve a broader market beyond Saudi Arabia. The scale and variety of the programmes undertaken illustrate how its production capabilities have developed. For a major water transport infrastructure project in the Makkah area, Donelli coated 53 valves with a nominal diameter of 100 inches. In a separate programme for a large offshore energy development, 1,400 valves were lined over four months. The two examples represent very different industrial requirements: exceptionally large components in one case and high production volumes within a defined schedule in the other. Both rely on the combination of application expertise, coordination and manufacturing reliability. Such work also demonstrates an important opportunity for the competitiveness of the Italian valve supply chain. Carbon-steel valves protected with FBE systems selected for their intended service can enable manufacturers to evaluate more cost-efficient solutions while maintaining demanding protection requirements, wherever operating conditions and specifications permit. A specialist such as Donelli helps make that option technically and

New materials, changing needs within the manufacturing supply chain and increasingly sophisticated expectations all require continuous updates to technical knowledge, production technologies and working methods. The ability to respond comes from sustained interaction between those who understand the market, those who assess coating systems and those responsible for quality. This balance characterises Donelli Alexo’s development: application expertise progressively deepened over the years and supported by industrial investments consistent with the evolution of the technology and its markets.

industrially viable through product knowledge, coating system

OCTOBER 2026 | CORROSION PROTECTION

SPOTLIGHT

Data-Driven hull performance:

connecting hull coatings, fouling control and vessel efficiency From an interview with Barry Kidd, Vessel Performance Manager, AkzoNobel

CORROSION PROTECTION | OCTOBER 2026

SPOTLIGHT

Understanding vessel performance requires more than selecting the right hull coating. By combining operational data, underwater inspections and coating performance analysis, ship operators can gain a clearer overview of how biofouling affects hull resistance, fuel consumption and emissions. Through its coating expertise, vessel performance analysis capabilities and Intertrac® Vision application, AkzoNobel supports ship operators in managing hull performance and improving vessel efficiency.

he hydrodynamic performance of a ship is governed by a range of interconnected factors, including hull geometry, operating parameters, sea state and the condition of the underwater surface. Among these, biofouling can

progressively increase hydrodynamic drag by adding surface roughness and frictional resistance, resulting in higher power requirements for a given speed and, consequently, increased fuel consumption. Corrosion and corrosion-related surface deterioration can also affect surface characteristics and contribute to changes in resistance. Quantifying the contribution of the coating system and the condition of the hull to overall vessel performance is, however, a complex task. Operational parameters such as speed, shaft or engine power and fuel consumption need to be considered alongside information on fouling progression and the condition of the underwater surface. Correlating these different data sets can provide a more robust basis for identifying changes in vessel efficiency and assessing the potential contribution of fouling and coating performance. Barry Kidd, Vessel Performance Manager at AkzoNobel, has been working on fouling control and vessel efficiency since 2012. His work focuses on the relationship between coating performance, hull condition and operational data. Together with his team, he works with ship operators to analyse data collected from vessel sensors, including speed, power and fuel consumption, and interpret it alongside information on hull and propeller condition and fouling. AkzoNobel's vessel performance analysis capability is independently class-verified and aligned with ISO 19030 principles, providing operators with confidence that performance assessments are based on a recognised and robust methodology.

OCTOBER 2026 | CORROSION PROTECTION

SPOTLIGHT

This helps distinguish genuine performance deterioration from

The appropriate system is selected according to the vessel’s

normal operational variability and supports more informed

characteristics, service conditions and the requirements identified

maintenance and intervention decisions.

for that application, rather than on the coating alone. “Our approach also highlights the importance of balancing

Matching the coating to the vessel’s operating profile

performance expectations with the available dry-docking budget.

The selection of an antifouling coating cannot be separated from

Selecting the right product is only the first step: the quality of

the way a vessel operates. Route profile, trading areas, port calls,

surface preparation and application during dry docking, followed

environmental conditions and the specific challenges encountered

by appropriate monitoring once the vessel returns to service,

during service all contribute to defining the level of fouling and

are equally important in achieving the expected results. Coating

mechanical stress that the hull may experience. As a result, no

selection can be viewed as part of a broader strategy, in which

single coating solution can provide the same level of performance

the characteristics of the product, the vessel’s conditions and the

across all vessels.

quality of its application all contribute to the final result.”

“The starting point is therefore a detailed understanding of the

While underwater inspections are an important component of

ship and its expected service conditions,” explains Barry Kidd.

hull performance management, the quality of findings can vary

“Vessels operating in particularly challenging environments may

significantly depending on the inspection methodology, video

require specific performance characteristics. For example, ships

quality, reporting approach and the experience of the inspector.

transiting the Panama Canal can be exposed to mechanical

Many operators do not have the specialist expertise required to

damage, while vessels operating regularly in ice regions may

independently assess and validate inspection evidence, making it

experience significant damage around the waterline. These factors

difficult to determine whether reported levels of fouling or coating

need to be considered alongside the expected fouling exposure

condition accurately reflect the vessel's true condition. This is

when selecting the coating system.”

where AkzoNobel's expertise in coating performance, inspection

International® offers a range of fouling control technologies

validation and vessel performance analysis can provide additional

designed to address different operational profiles and risk

value. By reviewing inspection evidence alongside operational and

exposures. The most appropriate solution depends on the vessel's

performance data, operators can gain greater confidence in the

characteristics, service conditions and performance objectives

findings and ensure maintenance decisions are based on a robust

rather than the coating itself.

and objective assessment.

Barry Kidd. 72

CORROSION PROTECTION | OCTOBER 2026

This data-driven approach can also help operators understand differences in efficiency across a fleet. Even vessels of the same type may operate on different routes, encounter different environmental conditions, undergo different dry-docking processes or face different levels of fouling risk. For this reason, performance needs to be considered in relation to each vessel’s specific operating profile rather than assessed through a single parameter or a standardised approach.

SPOTLIGHT

“Reliable information is therefore essential to avoid unnecessary

tool can also help estimate potential impacts on fuel consumption

interventions and protect coating integrity,” Kidd explains.

and emissions.”

This data-driven approach can also help operators understand

The same approach extends beyond the initial coating selection.

differences in efficiency across a fleet. Even vessels of the

Once a vessel is in service, monitoring its behaviour and identifying

same type may operate on different routes, encounter different

changes at an early stage can help operators make more informed

environmental conditions, undergo different dry-docking

decisions. Factors such as extended idle periods, changes in

processes or face different levels of fouling risk. For this reason,

operational patterns or uncertainty about future vessel activity

performance needs to be considered in relation to each vessel’s

can influence the risk of deviations and therefore need to be

specific operating profile rather than assessed through a single

considered when managing the hull.

parameter or a standardised approach.

“This process is ultimately based on cooperation rather than simply providing instructions. Our role, as coating supplier, is to support

From operational data to active management

operators by interpreting the available evidence and providing

Analysing a vessel’s previous and expected routes, including the

an additional perspective on ship performance. Building this

ports and harbours it regularly visits, provides a more detailed

relationship requires transparency and trust, particularly when the

picture of the environmental conditions which the hull will be

analysis shows that a deviation may not be related to hull fouling or

exposed to. AIS (Automatic Identification System) data can

coating condition.

reveal trading patterns, idle periods and environmental exposure,

This makes the use of operational data not only a tool for assessing

helping operators understand why seemingly similar vessels

current performance, but also a means of anticipating potential

can experience markedly different fouling risk and performance

issues and making more informed decisions throughout the

outcomes.

vessel’s operating life”.

“This information can then be combined with previous

Ultimately, managing hull performance is not simply a matter of

observations and performance records from vessels with similar

selecting the right coating. It requires a continuous understanding

characteristics. Our team uses these data to support coating

of how the vessel operates, how its condition evolves and how

selection and to assess how different solutions may perform under

different factors can affect efficiency. By combining coating

specific conditions. The Intertrac Vision application allows different

technology, class-verified performance analysis, inspection

coating and dry-docking scenarios to be compared, modelling the

validation and operational data, operators can take a more

potential development of hull resistance over time,” explains Barry

proactive approach to fouling control, helping to maintain vessel

Kidd. “By linking resistance development to vessel efficiency, the

performance while reducing fuel consumption and emissions. ‹

OCTOBER 2026 | CORROSION PROTECTION

ROAD TO

2050 How VpCI® packaging cuts plant energy use and carbon emissions Ana Juraga, Cortec Advertising Agency - ana.juraga@ecocortec.hr ®

VpCI® packaging protects metal components from corrosion while reducing the need for conventional washing and degreasing processes, helping manufacturers lower energy and resource consumption.

ROAD TO 2050

ndustrial facilities are facing relentless pressure to cut

It also eliminates chemical solvent baths, removing harmful VOCs

energy bills and carbon footprints. Big capital projects

from the shop floor and improving worker safety. Without the delay

like solar arrays or new machinery take time and serious

of washing and drying parts, production lines run faster, boosting

budget, but there’s a far simpler place to start: cutting out

overall production speed.

the washing and degreasing line altogether. Standard practice has long been to coat raw metal parts in heavy oil or grease for

Manufacturing in Croatia with global standards

transit. The problem is that before painting, welding, or assembly,

EcoCortec®, Cortec® Corporation’s European manufacturing plant,

plants have to heat up massive chemical baths and run high-

operates on a closed-loop model with its own recycling system

powered blowers to dry everything off. That process burns

to eliminate waste. Located in Beli Manastir, Croatia, the facility

through gas and power while leaving behind tanks of hazardous

produces environmentally safe VpCI® anti-corrosion packaging for

waste. Switching to Cortec® VpCI® packaging lets plants bypass

global export. VpCI® technology forms a microscopic vapor layer

the washing stage altogether. Parts arrive clean and ready for

on metal surfaces to block corrosion inside the package. Upon

production, which immediately cuts energy use and waste.

unpacking, the vapor dissipates completely without leaving any film or

Turning off heated wash tanks and forced-air drying ovens

residue. Parts arrive clean and ready for immediate welding, painting,

removes thousands of kWh in monthly gas and electricity usage.

or assembly, eliminating the need for chemical washing lines.

EcoCortec’s production facility in Beli Manastir, Croatia. The plant focuses on lowering Scope 1 and 2 emissions through clean processing and energy-efficient manufacturing.

OCTOBER 2026 | CORROSION PROTECTION

ROAD TO 2050

To meet different applications and shipping requirements, EcoCortec® offers this wide range of packaging materials:  VpCI® Films and Bags - Manufactured using advanced processing technologies, EcoCortec’s recyclable plastic films and bags come in various sizes, from small top-seal bags for nuts and bolts to heavy-duty sheeting for large industrial equipment. To help plants meet strict sustainability targets, the lineup also includes options made with PCR (post-consumer recycled) content, as well as fully biodegradable and compostable films.  VpCI® papers- offer recyclable and fully repulpable protection for single-item packaging, parts interleaving, and layer separation. Options include creped, reinforced, grease-resistant, and ESDsafe paper, as well as moisture barrier alternatives to traditional wax or polyethylene coatings.  Specialty Products & Emitters – For added protection in compact or harsh environments, VpCI® emitters and foam inserts provide localized corrosion inhibition alongside cushioning and desiccant action. Options like the USDA-certified BioPad® deliver high-performance protection using biobased non-woven materials. Switching to VpCI® packaging gives manufacturing plants a direct way to lower energy costs, manage less hazardous waste, and meet corporate carbon targets. Replacing traditional rust oils with VpCI® technology changes everyday shop floor operations for the better. When VpCI® materials are built right into the packaging By eliminating part washing, assembly lines operate without delays and are safer, allowing operators to move clean components straight into production.

step, facilities can skip the wash and dry stages altogether. That means shutting down heated chemical baths and high-volume air blowers, which cuts electricity and gas usage while removing toxic solvent waste from the floor. It›s a simple process upgrade that keeps operators safer, reduces unit production costs, and makes daily manufacturing much simpler. ‹

VpCI® papers provide recyclable and fully repulpable corrosion protection for packaging and parts separation.

CORROSION PROTECTION | OCTOBER 2026

Switching to VpCIR packaging gives manufacturing plants a direct way to lower energy costs, manage less hazardous waste, and meet corporate carbon targets. Replacing traditional rust oils with VpCIR technology changes everyday shop floor operations for the better.

WHERE

WE'VE BEEN

OCTOBER 2026 | CORROSION PROTECTION

MEETING

THE INDUSTRY Cathodic protection at the centre of the fifth “Pietro Pedeferri” Study Day Who was Pietro Pedeferri? Pietro Pedeferri (1938–2008), born in Delebio, in the province of Sondrio, graduated in Chemical Engineering from Politecnico di Milano in 1963. Appointed Full Professor in 1983, he initially taught Electrochemistry and subsequently Corrosion and Materials Protection. He served on the university’s Board of Directors and Academic Senate and was a full member of the Istituto Lombardo – Accademia di Scienze e Lettere. His scientific career began in electrochemistry before focusing on corrosion and metal protection. His research interests ranged from the fundamental aspects of corrosion and passive materials to cathodic protection and reinforced concrete. In the latter field, he devised and developed

a corrosion control method that he termed “cathodic prevention”, he fifth edition of the “Pietro Pedeferri” Study Day, dedicated

which was subsequently incorporated into several international

to corrosion and materials protection in memory of the

standards.

founder of the Corrosion and Protection of Metallic Materials

From the late 1970s onwards, he also devoted himself to the

school at Politecnico di Milano, will take place on 27 November at

study of titanium oxidation, combining scientific rigour with

the university’s Conference Hall.

artistic sensibility to achieve distinctive colour effects. This work

Held every two years, the event has addressed different areas

earned him several awards, including the “Science pour l’art”

of corrosion science and engineering over the years, fostering

prize, presented to him in Paris in 1988.

dialogue between academia, research and industry on scientific and technological advances in these fields. Previous editions have

Event organisation

covered topics ranging from new frontiers in corrosion engineering,

The event is organised by PoliLaPP – the “Pietro Pedeferri”

the focus of the inaugural event in 2018, to the durability of reinforced

Corrosion Materials Laboratory at Politecnico di Milano, part

concrete structures in 2020, stress corrosion cracking and hydrogen

of the Department of Chemistry, Materials and Chemical

embrittlement in 2022, and the anodising of light alloys in 2024.

Engineering “Giulio Natta”. It is held under the patronage of

This year’s edition, entitled “Cathodic Protection: Science,

APCE (Association for Protection against Electrolytic Corrosion),

Engineering and Industrial Applications”, will bring together experts

AIMAT (Italian Association for Materials Science and Technology),

from academia and industry to explore the state of the art in

AMPP Italy, AIM (Italian Association for Metallurgy), INSTM

cathodic protection, with particular attention to the latest research,

(National Interuniversity Consortium of Materials Science and

new applications and practical experience gained in the field.

Technology), ATE (Association of Building Technologists), Centro

The programme will feature contributions from academia and

Inox (Italian Stainless Steel Development Association), CTA

research institutions, alongside presentations by industry experts

(College of Steel Construction Engineers), and AICAP (Italian

and professionals. As the organisers explain, the aim is to bridge

Association for Reinforced and Prestressed Concrete).

advances in corrosion science and their engineering applications,

Participation is free of charge, subject to registration via the

with a particular focus on the principles, methodologies and

online form: Giornata di studio “Pietro Pedeferri” 5a edizione.

practical experience associated with cathodic protection and cathodic prevention for buried structures, structures exposed to

www.cmic.polimi.it/en/department/eventi/giornata-di-

seawater and reinforced concrete elements.

studio-pietro-pedeferri-5a-ed/

The full programme is available at this link: https://www.cmic.polimi.it/media/14035/dcmc_giornatapedeferri-2026.pdf

CORROSION PROTECTION | OCTOBER 2026

MEETING THE INDUSTRY

World Maritime Forum 2027 will unite maritime decision-makers in Copenhagen on February 23-24

he World Maritime Forum will

evolve over the coming years. Topics

provide an opportunity to compare the

return to Copenhagen in 2027,

will include IMO measures, EU ETS

advantages presented by suppliers with

welcoming the maritime community to

and FuelEU Maritime, alternative fuels

the costs, integration requirements and

the AC Bella Sky Convention Center for

and bunkering infrastructure, retrofit

operating realities examined throughout

two days of discussions and industry

performance, transition finance, sanctions

the conference.

engagement. Organised by IGGS Group,

and shadow-fleet risks, cyber and GNSS

Copenhagen provides a fitting location

the forum will bring together shipowners,

security, crew skills, AI, vessel design,

for an event representing a diverse

ship managers, shipbuilders, ports,

and remote and autonomous operations.

range of maritime interests, while the

authorities, maritime suppliers and

These discussions will consider the

AC Bella Sky Convention Center allows

service providers. The event comes

impact of regulatory requirements and

the conference, exhibition and business

as the sector navigates important

operational risks on investment across

meetings to be held under one roof.

decisions related to fleet investment,

fleets, ports, infrastructure, people and

Beyond the number of participants, the

operational continuity, workforce

technology.

forum will create a space where policy

preparedness and the implementation

An exhibition area alongside the

developments, vessel operations, capital

of digital technologies across everyday

conference will provide suppliers with

allocation and supplier expertise can be

operations.

a platform to display their products,

assessed together. These exchanges may

Approximately 800 attendees, 70

services, expertise and emerging

help maritime businesses identify which

speakers and 50 exhibitors are expected,

innovations. The showcased solutions

fleet, technological and organisational

with more than 300 buyers projected

will span propulsion, fleet-performance

solutions are ready for wider adoption

to participate. The audience will include

systems, maintenance, safety,

before the end of the decade.

professionals working in fleet, project,

connectivity, cybersecurity, ship repair,

procurement and technical management,

vessel design, interior solutions and

alongside specialists in sustainability,

shipbuilding. For buyers, the exhibition will

www.worldmaritime-forum.com

crewing, port operations, finance and IT. This broad representation reflects how decisions concerning vessels increasingly rely on cooperation across multiple departments, budgets and shore-based systems. New speakers from established shipping companies, ports and influential maritime organisations will join the 2027 programme. Through their direct industry experience, they will provide practical insights into fleet investment, port strategy, cybersecurity, the adoption of artificial intelligence, vessel efficiency and the evolving capabilities required from the maritime workforce. The programme will offer twelve new panel discussions and two on-stage conversations covering the key strategic and operational issues affecting maritime companies. The sessions will also examine how investment needs could

OCTOBER 2026 | CORROSION PROTECTION

EDITOR IN CHIEF ALESSIA VENTURI venturi@ipcm.it

an ipcm® magazine

EDITORIAL OFFICE redazione@ipcm.it

EDITED BY

PAOLA GIRALDO giraldo@ipcm.it MONICA FUMAGALLI fumagalli@ipcm.it MATTEO SOTTI sotti@ipcm.it ILARIA PAOLOMELO paolomelo@ipcm.it

Eos Mktg&Communication srl Via Pietro Mascagni, 8 - 20811 Cesano Maderno (MB) - Italy Tel. +39.0362.503215 www.eosmarketing.it - info@eosmarketing.it | www.myipcm.com - info@ipcm.it

MARTINA STUCCHI mstucchi@ipcm.it

EDITORIAL DIRECTOR

MEDIA SALES

Marco Ormellese, Politecnico of Milan

FRANCESCO STUCCHI stucchi@ipcm.it

EDITORIAL BOARD

ILARIA PAOLOMELO paolomelo@ipcm.it MARTINA STUCCHI mstucchi@ipcm.it NICOLE KRAUS kraus@ipcm.it

GRAPHICS

Annalisa Acquesta, University of Naples

Marina Delucchi, University of Genoa

Francesco Andreatta, University of Udine

Francesco Di Franco, University of Palermo

Mehdi Attarchi, Senior Materials & Corrosion Specialist

Sergio Lorenzi, University of Bergamo

Andrea Balbo, University of Ferrara

Tullio Monetta, University of Naples

Hadi Beirami, Cathodic Protection Certified Specialist

Tomáš Prošek, University of Prague

Maria Bignozzi, University of Bologna

Edoardo Proverbio, University of Messina

Stefano Caporali, University of Florence

Stefano Rossi, University of Trento

Marco Cattalini, AMPP Italy Chapter Chairman

Monica Santamaria, University of Palermo

Jérôme Crouzillac, BAC Corrosion Control

ELISABETTA VENTURI grafico@ipcm.it Questa testata è associata a

TRANSLATIONS CHIARA FOPPA PEDRETTI chiara.foppapedretti@gmail.com

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