ipcm® Protective Coatings n. 33 - April 2020 by ipcm® International Paint&Coating Magazine

ISSN 2282-1767

Protective Coatings Â®

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THE MAGAZINE ABOUT CORROSION CONTROL AND PREVENTION TECHNOLOGIES 2020 - 9th Year | Quarterly - N.33 April

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in this issue 01 EDITOR’S LETTER

02 ANALYSIS

Factors affecting sealer performance on concrete

10 BRAND NEW 12 HIGHLIGHT OF THE MONTH Women in STEM: shining the light on Danijela Milosevic-Popovich

14 BRAND NEW 16 INNOVATIONS

Intumescent coatings can meet demanding aesthetic and safety standards

20 FOCUS ON TECHNOLOGY

Metal alloy upgrade in corroding process vessels

24 INNOVATIONS Global first as Talga graphene coating begins commercial-scale trial on ocean-going cargo vessel

28 HIGHLIGHT OF THE MONTH The global value chain and the importance of measuring and control tools to guarantee product quality

INSPECTION LOGBOOK Coating inspections – review and preparation of inspection documents (Part 1)

36 FOCUS ON TECHNOLOGY The perfect synergy between coatings supplier and applicator allows to negate vessels’ erosion and corrosion issues

40 BRAND NEW

42 INNOVATIONS Results: anti-corrosion additives for ferrous metals

44 SUSTAINABILITY Five on Five Interview: sustainability according to the industry players - Series 2 - Part I

50 BRAND NEW 52

TRADE FAIRS & CONFERENCES

54 ZOOM ON EVENTS

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EDITOR’S LETTER

In the middle of the health crisis caused by the Covid-19 pandemic, we #stayathome but #wedontstop.

hese days, we are learning even more to work and live in a virtual world, where the importance of digital content is growing by the hour. Luckily, we were far-sighted. For a

long time now, our website, www.myipcm.com, has made all our magazines’ issues and a daily-updated “NEWS” section available for free. This means that even if we were not able to send you your hard copies (but we are sure we will make it happen), you will be reached by our content. ipcm®_Protective Coatings will continue to recount the strength of the European industry

in the world through the tool we know best: information. We will unite the corrosion prevention community through our content, because we firmly believe that providing updated information and tools to take advantage of this period’s slower rhythms can be useful to seize all the opportunities that will surely arise at the end of the health emergency. The issue you are about to read was conceived to be a special edition for several exhibitions and conferences in the field, the OTC 2020 Offshore Technology Conference in Houston, for example, which has been cancelled in the light of the Covid-19 pandemic. Indeed, it is a very rich and stimulating issue. We offer you top-notch articles about great technological innovations, cutting-edge systems, and success stories. Here are some trends in protective coatings that this issue highlights. Waterborne is the future even in protective coatings, once firmly convinced that solvent borne was the only possible choice for anticorrosion coatings or inhibitors or zinc-lamellar technology. The use of water-based products has increased as regulation of volatile organic compounds has restricted the availability and use of solvent-based ones. However, water-based products still show some performance issues in a few application, as for concrete sealers (see page 2). Environmental friendliness remains a hot topic for the protective coatings industry: research & development are focusing on chrome-free anti-corrosion inhibitors for ferrous metals (see page 42), on water-based VPCI and on biobased and biodegradable rust preventatives (see pages 10 and 40). For its exceptional mechanical properties, graphene is catching on in many different coating applications: in this issue, we report about what is believed to be the world’s largest single application of graphene on a cargo vessel’s hull (see page 24). Until now, we read about graphene application mainly as an additive of protective coatings for the general industry. Now, a graphene-based marine coating has been developed and is currently under extensive testing. The future will be graphene additives as an after-market product (ready to be mixed into the coatings on-site by the applicator) and as a component of powder coatings. Last but not least, thermal spray (High Velocity Thermal Spray with next generation alloy materials, in particular) is becoming more and more used as a high performance cladding solution to stop corrosion for without any further maintenance anticipated for at least 15+ years (see an application at page 20).

Alessia Venturi Editor-in-chief

We hope that you will enjoy the reading of this issue, both if you are confined at home or still working at full speed. Because, the world doesn’t stop!

ipcm® Protective Coatings - 2020 APRIL - N.33

ANALYSIS

Factors Affecting Sealer Performance on Concrete C. Jim Reader Evonik Corporation – Allentown, USA

jim.reader@evonik.com

Gary Johnson Intertek Allentown – Allentown, USA

web.allentown@intertek.com

Abstract

It is often assumed that solvent-based sealers give better performance

few microns of the open surface. A study has also been carried out

than water-based formulations on concrete because the solvent-based

using a model waterborne acrylic sealer formulation to determine

sealers are assumed to penetrate better into the concrete matrix. In

whether additives might influence the penetration of the sealer into

practice, it can be difficult to measure actual penetration of a sealer

the concrete or other factors that could affect the performance of the

into concrete, as dyes and colorants used to highlight the sealer

waterborne coating. This work has shown that the addition of anti-

may show different migration properties than the polymeric binder.

foaming, coalescing surfactants can improve the protective properties

Confocal Raman spectroscopy mapping has been used to map the

of the coating by improving air release and increasing film network

depth of penetration of solvent-based, 100% solids and water-based

formation at the concrete surface.

sealers that employ acrylic and epoxy binders. This mapping shows that neither solvent-based nor water-based formulations showed any

Introduction

significant penetration into the concrete substrate beyond the first

Sealers are an important part of protecting concrete against surface

N.33 - 2020 APRIL - ipcm® Protective Coatings

ANALYSIS

damage, corrosion and staining. They work by either blocking the pores

cure (Fig. 1). The exact nature of the concrete and concrete surface will

in the concrete to prevent the ingress of water and water-soluble salts

vary, depending on the supplier and local raw materials, although it is

or by forming a polymeric barrier that prevents such materials passing

essentially a porous, mineral substrate for the sealers.

through to the substrate. Penetrating sealers contain reactive species,

Solvent-based sealers are claimed to give better performance

such as silanes, siliconates and silicates that can enter the concrete

than water-based sealers [5], although it is acknowledged that the

matrix and react with minerals present to block the pores and create a

performance of water-based sealers is improving [6-7].

hydrophobic and oleophobic barrier. Penetrating sealers have excellent

One explanation often cited for the improved performance is that

durability but do not change or enhance the surface appearance of the

solvent-based sealers can better penetrate the concrete surface,

concrete surface. They can also make further treatment of concrete

providing some pore blocking and developing enhanced adhesion

difficult. [1,2]

through mechanical interlocking. [2, 8-9]

Topical sealers are coatings that form a polymeric film and barrier

The improved adhesion is also cited as evidence for the improved

at the concrete surface. They are prepared using many different

penetration into the concrete, but in practice, there has been little

chemistries, although acrylic, epoxy and polyurethane binders are most

research on the actual penetration of the sealer into the concrete.

common. Topical sealers may not last as long as penetrating sealers,

Simple dye or colour penetration tests may be misleading as the colour

but they can enhance and decorate the concrete surface and prepare it

spread may not show the real spread of the polymeric binder needed

for additional treatment. Sealers are typically low viscosity coatings and

for performance (Fig. 2 [10]).

contain either solvent or water as a diluent. Solvent-based sealers give

Wood is a porous substrate for which several investigations into

a more glossy, wet-look finish, whereas water-based sealers often give

the penetration of coatings have been conducted. De Meijer, et al,

a more natural looking appearance. Many states now restrict the use

observed that loss of water or solvent into the capillaries between

and sale of solvent-based sealers for environmental, health and safety

wood cells caused a rapid increase in binder viscosity that limited

reasons.

penetration of the coating into the wood capillaries. [11]

Concrete is a highly complex substrate, comprising mineral aggregates

They also noted that the binder particles were too large to penetrate

and fillers like sand bound together in a crystalline, inorganic matrix

the cell walls of the wood itself. Alberdingk and Boley also observed that

based on hydrated calcium and aluminium salts. [3-4]

the penetration of the coating into the wood was effectively prevented

Concrete is also porous, containing many natural air voids as well as

by the cell walls of the wood itself, regardless of diluent, polymer

capillary pores created during the release of water during setting and

chemistry, molecular weight or particle size. [12]

ÂŠ Evonik

Figure 1 - The concrete substrate. [4]

ipcmÂŽ Protective Coatings - 2020 APRIL - N.33

ANALYSIS

Figure 2 - Colour based test for sealer penetration into concrete.

Figure 3 - Penetration of solvent free and water-based epoxy on concrete.

Penetration of coatings into concrete

Raman microscopy couples a Raman spectrophotometer with an

The penetration of two different sealers into concrete substrates was

optical microscope together with a spatial filter, to chemically analyse

studied by two different methods. The first method employed simple

the volume of a sample in three dimensions. The limits of the spatial

UV fluorescence to visualise the depth into which two epoxy sealers

resolution are dependent on the laser and microscope objective, but it

penetrated into the substrate. Simple stoichiometric mixtures of liquid

is possible to identify individual particles smaller than 1µm. [13]

epoxy resin (EEW 190) with either a liquid amidoamine hardener or

Raman spectroscopy is similar to infrared spectroscopy in so far as it

a water-based hardener (Evonik – Anquawhite® 100) were prepared,

measures the internal molecular vibrations via a different mechanism.

and applied by roller onto cleaned, shot blasted concrete panels. The

Infrared and Raman spectra often provide complementary information,

coated panels were allowed to cure for seven days under ambient

but Raman spectroscopy is suitable for aqueous samples and

conditions and then carefully cut in half to expose the concrete

samples containing high water content that can interfere with infrared

substrate. The cut surfaces were illuminated with short wave, UV

spectroscopy.

radiation (“black light”), and the resulting fluorescence from the

Two commercial acrylic sealers were used (Behr Premium Low-Lustre Sealer

aromatic epoxy binder was photographed (Fig. 3). The two panels look

Water-based masonry sealer and Increte Clear Seal 400 Solvent-based

almost identical with only limited fluorescence at the coated surface,

masonry sealer) and they were applied by both roller and brush onto

indicating minimal penetration of the concrete itself by the sealer.

cleaned, shot blasted concrete panels. The coated panels were allowed

Unfortunately, not all binders fluoresce, so an alternative method was

to cure for seven days under ambient conditions before the coated

needed to measure penetration of acrylic based sealers. Confocal

concrete plates were fractured into manageable pieces and one face

Integration

5s x 2

Grating

600 line/mm

Confocal Aperture

200µm

Spectral Bandwidth

6cm-1

Slit

100µm

Detector

Synapse 1024 x 256 CCD

Laser

532nm, 20mW

Objective

50X uwd

Laser Filter

1 O.D.

DUO Scan Pixel

1 x 1µm

Table 1 - Operating conditions for confocal Raman microscopy of sealed concrete panels.

N.33 - 2020 APRIL - ipcm® Protective Coatings

ANALYSIS

Figure 4a - Micrograph of the concrete surface sealed with a water-based sealer.

Figure 4b - Raman map of the same area. The green rectangle indicates area mapped with 1x1µm pixels. Intensity of hydrocarbon band at 2391Rcm-1 represented by green colour saturation.

Figure 5a - Micrograph of the concrete surface sealed with a solvent-based sealer.

Figure 5b - Raman map of the same area. The green rectangle indicates area mapped with 1x1µm pixels. Intensity of hydrocarbon band at 2936Rcm-1 represented by green colour saturation.

on each section was polished using 600-grit abrasive film.

coatings on the concrete cross sections, together with a second sharp

Raman spectra were obtained using a Horiba LabRAM HR Raman

shoulder marked at 2881 Rcm-1, assigned to C-H stretching in a linear

confocal microscope system and the operating conditions shown in

hydrocarbon chain. The C-H stretching band marked at 2936 Rcm-1 was

Table 1. Spectra of the coating/concrete interface cross sections were

the strongest feature in the spectrum of the solvent-based sealer and

obtained in a x = 19μm by y = 24μm grid, with 1μm steps using a

it was selected to monitor the solvent-based coatings on the concrete

1 X 1μm pixel for complete overlap between steps. A small portion of

cross sections.

each liquid coating sample was allowed to air dry onto a glass slide and

A sample image of a cross section of the roller applied, water-based

Raman spectra of the resulting films were obtained.

sealers is shown in Fig. 4a. The green rectangles in the images indicate

Both sealers had Raman spectra characteristic of acrylic polymers. The

the area mapped by Raman spectroscopy. The intensity of the C-H

C-H stretching band marked at 2931 Rcm was the strongest feature

stretching band at 2931 Rcm-1 (integrated from 2818 – 3054 Rcm-1

in the spectrum of the water-based sealer and selected to monitor the

with baseline correction) is shown in Fig. 4b by imposing saturation of

-1

ipcm® Protective Coatings - 2020 APRIL - N.33

ANALYSIS

Raw Material

Function

Supplier

Mass

Water

Carrier

Carboset CA600

Binder

Lubrizol

58.2

Wetting Agent

Various

0.9

Defoamer

Various

0.1

Dowanol DPnB

Coalescent

Dow

1.2

Dowanol PPh

Coalescent

Dow

1.0

Benzoflex 50

Plasticizer

Eastman

0.8

Ammonia

Buffer

Acrysol RM-8W

Thickener

37.3

0.1 Dow

0.4

Table 2 - Guide formulation for water-based concrete sealer (Lubrizol).

green superimposed on expanded scale micrographs. The green areas

sealers, more study is needed. Most sealers are unpigmented or only

on the images end at the visible boundaries between the coating and

contain low levels of pigments and fillers, so improved resin technologies

concrete, indicating the coating is concentrated on the surface of the

will be key to bridging the performance gaps, [14-16] but other

concrete. The almost identical results with the solvent-based sealer are

formulation components can also affect sealer performance.

shown in Figs. 5a-5b. This limited study suggests that there is limited sealer penetration into

Effect of additives on water-based sealers

the concrete substrate, beyond the initial surface roughness and open

Water-based coatings often have higher surface tensions than

capillary structure at the surface. Therefore, to address the real or

solvent-based formulations due to the higher surface tension of water.

perceived performance gaps between water-based and solvent-based

Flow into capillary pores can occur when the adhesive forces of the

ÂŠ Evonik

Figure 6 Surface tension of water-based sealer containing different surfactants.

N.33 - 2020 APRIL - ipcmÂŽ Protective Coatings

ANALYSIS

Figure 7 - Micrograph of the concrete surface sealed with the water-based sealer containing a coalescing surfactant (left) or non-ionic, alkyl phenol ethoxylate surfactant (right). The green rectangle indicates area mapped with 1x1µm pixels. Intensity of hydrocarbon band at 2931Rcm-1 represented by green colour saturation.

liquid to the pore material are greater than the cohesive forces of the

was measured using a Krüss BP2 Bubble Pressure Tensiometer and the

liquid to itself, so low surface tension is desirable for capillary flow and

results are shown in Fig. 6. The sealer without additives has a relatively

penetration. [2, 11]

low surface tension, but many of the surfactants tested lowered this

Wetting agents (surfactants) are additives used to lower the surface

considerably. The most effective products for reducing surface tension

tension of aqueous coatings; therefore, a number of different

were the advanced Acetylenic Glycols.

surfactants were tested in a water-based sealer formulation (Table 2) to

The different sealer formulations were also applied by both roller and

determine whether they could improve performance and penetration

brush onto cleaned, shot blasted concrete panels and the panels tested

into the concrete substrate.

for substrate penetration using the Confocal Raman Mapping method

The surface tension of formulations containing different surfactants

described above. However, the results from the Raman mapping were © Evonik

Figure 8 Effect of different surfactants (0.9% w/w/ use level unless stated) on water spot resistance of concrete sealer formulation.

ipcm® Protective Coatings - 2020 APRIL - N.33

ANALYSIS

almost identical to the previous results, with almost no penetration into

Conclusions

the concrete substrate regardless of the surfactants used (Fig. 7).

There are many different types of concrete sealers available, but

The water sensitivity of the sealed panels was also tested using a simple

the two most commonly used are film forming acrylic sealers and

water spot method that measures the time for water to penetrate

penetrating sealers. Although they both seal concrete, they do so in

through the sealer and become visible by a darkening of the concrete

different ways. Film forming sealers work by forming a protective film

below the coating. A minimum of five tests per panel were used and

atop the concrete and, whether water-based or solvent-based, do not

the tests were repeated with different panels, and the averaged results

appear to penetrate the concrete substrate.

are summarised in Figure 8. The best results were obtained with the

The use of water-based sealers has increased as regulation of volatile

formulations containing non-ionic, coalescing surfactants, although

organic compounds has restricted the availability and use of

these did not give the lowest surface tension. The formulations

solvent-based sealers; however, some concern remains about the

containing the non-ionic, coalescing surfactants also gave the best

performance of water-based sealers. This performance is primarily

appearance, both visually and under the microscope.

affected by choice of resin, but the choice of additives can also affect

The choice of defoamer also affected the water sensitivity of the sealer.

the sealer performance. De Meijer noted that significant amounts of

Both strongly incompatible defoamers that were highly effective at

water can be lost to the substrate when coatings are applied to porous

reducing foam and highly compatible defoamers (less effective at

substrates and this can affect both rheology and viscosity build, but

controlling foam) produced sealers that had poor water resistance. The

potentially also film formation. Coalescing surfactants can help lower

strongly incompatible defoamers gave very poor surface appearance

the surface tension of water-based sealers as well as aid film formation

(craters or dewetting) when the sealer was applied over Leneta charts)

at the concrete surface to improve film properties. â&#x20AC;š

and it is thought that these might also disrupt the film on the concrete surface allowing water to penetrate. However, it was not possible to confirm this visually. Similarly, defoamers that were too compatible left residual foam and bubbles in the dry films when the sealer was applied onto Leneta charts, and these bubbles are likely to remain when applied onto concrete; however, these also could not be seen visually or under a microscope. The optimum defoamers gave significantly

The authors wish to thank Paul Marcella for helping to create the data

improved water resistance (Fig. 9).

and Ingrid Meier and Maria Nargiello for editorial assistance.

ÂŠ Evonik

Figure 9 - Effect of different defoamers on water spot resistance of concrete sealer formulation. The left image shows the concrete darkening as water penetrates through the sealer formulated with a compatible defoamer. The right image shows the sealer formulated with an optimized defoamer where the water does not penetrate through the sealer.

N.33 - 2020 APRIL - ipcmÂŽ Protective Coatings

ANALYSIS

References 1 https://en.wikipedia.org/wiki/Concrete_sealer 2 Understanding Concrete Sealers and Chemicals, Seminar TH140, WoC2011 3 https://www.understanding-cement.com/hydration.html 4 http://www3.imperial.ac.uk/concretedurability/researchprojects/ predictingmasstransport 5 Comparison of Waterborne and Solventborne Resins for Concrete Sealers, Wexler, ACA Coatings for Concrete, January 2014 6 https://waterbasedsealers.com.au/water-based-concrete-sealersvs-solvent-based-concrete-sealers/ 7 https://www.concretecamouflage.com/ water_based_concrete_sealer.cfm 8 Understanding High Performance Coatings for Decorative Concrete, Seminar WE27, WoC2011 9 http://indecorativeconcrete.com/?page_id=644 10 Image taken from http://www.amshieldcorp.com/ capillaryWaterproofing.htm 11 A Rheological Approach to Understanding Capillary Penetration of Coatings into Wood by M. de Meijer, B. van de Velde and H. Militz, 5th Nurnburg Congress (1999) 12 Alberdingk and Boley, Lignocure VP2010 Product Information 13 http://www.horiba.com/us/en/scientific/products/ raman-spectroscopy/raman-academy/raman-faqs/ what-is-confocal-raman-microscopy/ 14 Development and Properties of a Waterborne Wet-Look Sealer at 50 g/L VOC, Flecksteiner, Matranga and Lawhorn, ACA Coatings for Concrete, January 2014 15 A Unique Acrylic Latex for Improved Chemical and Hot Tire Resistance in Low VOC Garage Floor and Masonry Applications, Goldslager, Coatings Trends and Technologies, September 2016 16 https://www.epscca.com/opencms/export/sites/epscca/galleries/ pdfs/articles/ECS-Garage-Floor-Paint-Andrew-Hearley.pdf

́ ́ ́ ́ ́

BRAND-NEW

Go Water-Based and VOC Compliant with DTM Coating Powered by NANO VpCI® VpCI®-386 is a fast drying, water-based acrylic one coat system

without altering vehicle appearance, while still providing protection

(topcoat) that can be applied DTM (direct to metal) for corrosion

in a way that allowed personnel to use the equipment at any time.

protection in outdoor unsheltered applications.

In another case, an Indonesian dealer of heavy equipment applied VpCI®-386 Black and CAT Yellow to maintain the vehicles’ appearance

When it comes to finding a water-based coating for outdoor

while providing corrosion protection in a seaside storage yard after

corrosion protection, VpCI®-386 is a great place to start. VpCI®-386 is

conventional paint failed to provide the desired solution. After three

a fast drying, water-based acrylic one coat system (topcoat) that can

months, VpCI®-386 had outperformed the conventional paint on

be applied DTM (direct to metal) for corrosion protection in outdoor

tested areas, so the customer decided to do a full paint job on the

unsheltered applications. It offers a variety of environmental and user

equipment bodies using the custom tinted VpCI®-386 coatings.

benefits.

As a permanent coating that can be welded over, VpCI®-386 does

VpCI -386 is a good alternative to solvent-based corrosion

not need to be removed before final installment or use of the

inhibitor coatings. VpCI®-386 has a relatively low VOC of 0.6 lbs/gal

protected metal components. Although it is ideal to apply VpCI®-386

(72 g/L), well below the typical cutoff of 3.5 lbs/gal (419 g/L) for VOC

at the manufacturing site from the outset, it can also be applied

compliance in many regions. As a water-based product, VpCI®-386

farther down the line to protect expensive metal assets that will sit

is able to compete with many paints and zinc-rich coatings thanks

for extended periods at storage sites. This was the case at a power

to the power of Cortec’s “NANO” VpCI inhibitors. These inhibitors

plant being built in the southern U.S. in a corrosive environment

of temperature and humidity

a molecular protective layer that

swings. Custom-built smokestack

follows the intricacies of the

sections from Asia had been

substrate’s micro-cavities. This

delivered to the site almost two

offers fuller inhibitor coverage

years ahead of time. VpCI®-386

than traditional sacrificial metal

was used to coat the ID (inner

inhibitors, which leave gaps due to

diameter) of the smokestack

their relatively large particle sizes.

sections for interim protection

Implementing VpCI®-386 allows

in order to avoid construction

users to lower environmental

delays. The coating met their

impact by reducing VOCs while

needs for a product that was

also minimizing worker exposure

easy to apply and did not need to

to solvents and making coating

be removed upon installation.

cleanup easier.

VpCI®-386 is an excellent

VpCI®-386 is adaptable to a variety

option for industries needing a

of applications. As mentioned, it

water-based corrosion inhibitor

can be applied DTM. It can also be

coating. In addition to its

applied as a clear coat on top of

corrosion protection benefits,

another coating, creating minimal

VpCI®-386 minimises changes

change to surface appearance. This

to surface appearance, reduces

was beneficial for a Pacific military

VOCs, and minimises worker

fight micro-corrosion by forming

base that wanted to protect Airfield Damage Repair vehicles that were sitting in very corrosive conditions

exposure to solvents to present an overall friendlier profile for users and the environment.

near the ocean. A low-gloss version of VpCI®-386 was applied as a clearcoat over the vehicle paint

N.33 - 2020 APRIL - ipcm® Protective Coatings

Panels coated at 1.0-1.2 mils DFT and subjected to ASTM B117 salt spray testing.

For further information:

www.cortecvci.com

BRAND-NEW

Preservation Holding AS, Owned By Norvestor From Oslo Supports Growth of MONTI-Werkzeuge Gmbh Presserv, a distributor of Monti in Norway and also majority owned by

Norvestor will be a majority owner in both Presserv and MONTI through

Norvestor will continue their operations under their well-known names.

the newly established Preservation Holding AS. MONTI employs 40 people through its production facility and main corporate offices

MONTI, headquartered in Hennef, Germany, including its subsidiary,

in Hennef, Germany, and the U.S branch offices in Manassas, Virginia and

MontiPower Americas Inc., is a globally renowned manufacturer of rotary

Houston, Texas.

bristle blasting technology and special surface preparation equipment

Presserv employs 70 people through its headquarters in Stavanger,

used for surface cleaning, coating & millscale removal and anchor profiling.

Norway, and offices in St. Paul Minnesota US, Aberdeen UK, Rio de Janeiro,

MONTI’s patented technologies and innovative solutions ensure

Brazil and Singapore.

the best possible bond for protective coatings and sealants without abrasive materials and waste media. MONTI products supplement

For further information: www.montipower.com

coating performance to maximize the long-term protection of assets in the transport, Oil & Gas, windmill, pipeline, public infrastructure and heavy equipment sectors, amongst others. Outside the USA/Canada,

MONTI operates globally through a network of trained distributors and resellers, including Presserv. “MONTI has a successful track record of over 30 years and is known worldwide for its MBX and Bristle Blaster technologies. MONTI’s founders built an amazing company and since joining MONTI in 2018, it has been my pleasure to continue to build on the wonderful heritage of innovation and great products. Today, a team is bringing decades of global coatings industry experience to MONTI’s surface preparation technology. This experience and know-how support a new vision for MONTI with an expanded offering of products and services to the global coatings industry and beyond. Our partnership with Presserv will enable us to access new markets, expand our offering and support our clients through different platforms. We are very excited to begin this new chapter”, says Drs. J.F. (Frits) Doddema, CEO of MONTI. “MONTI is a unique company with a diversified product portfolio, well

From left: Tor Erling Gunneroed from Norvestor’s Preservation Holding AS, JF. Doddema, CEO of MONTI and Werner Montabaur, the founder of Monti-Werkzeuge Gmbh.

known by Presserv through their cooperation for many years. It is a European manufacturer with strong German roots and a history of developing innovative products with applications for many different industries. The combination of great products, a strong brand, and an expanding market opportunity is very attractive. We see a great value proposition in markets from both Presserv and MONTI, where asset owners are looking for safe, cost-efficient and environmentally sound solutions. In addition, by adding MONTI, we are partnering with a strong management team with a proven track record in the protective coatings industry and a history of building great businesses. The combined strength of our two companies, Presserv and MONTI, in this segment will create a unique platform to both, develop products and services to our segments in the everlasting fight against corrosion”, says Tor Erling Gunnerød, Partner in Norvestor Equity AS and Chair designate in Presservation Holding AS.

A team is bringing decades of global coatings industry experience to MONTI’s surface preparation technology.

ipcm® Protective Coatings - 2020 APRIL - N.33

HIGHLIGHT OF THE MONTH

Women in STEM: Shining the Light on Danijela Milosevic-Popovich Edited by SIFCO ASC Independence, Ohio - USA

www.sifcoasc.com

Taking place on the 1st to 31st of March every year, Women’s History

strive for independence. Growing up in the Balkans, it wasn’t common

Month sets to recognize and celebrate the achievements of females all

for girls to go to college and while his support of her continued studying

over the world. While it’s important to acknowledge the accolades of all

was considered a taboo, he never let the criticism distract her.

women, we’re focusing on those working in STEM (Science, Technology,

Danijela realises just how much her childhood and education shaped

Engineering and Math).

her career. Science and math help Danijela to think more critically. She approaches every problem knowing that there is a logical process to follow. She also questions any critical factors associated with resolution.

t’s no secret that the world of STEM has been a men’s club for decades,

She said: “I believe a strong STEM background helps train the brain to

with only 28% of women making up the workforce as opposed to 72%

think more critically. Intuition and critical thinking together create the

of men. To show that this gap is slowly (but surely) closing in, we’ve

perfect storm of problem solving and I believe math and science are key

shone the spotlight on Danijela Milosevic-Popovich, a Research and

building blocks to perfect this process.”

Development Manager at SIFCO Applied Surface Concepts (ASC). Danijela graduated from the University at Buffalo with a Bachelor

Education - the passport for the future

of Science and Master of Engineering in Chemical Engineering. She

With a bachelor’s degree and two masters degrees under her belt,

then continued to earn her Master of

Danijela knows just how important

Engineering Management from Ohio

education and qualifications are for

University. Before becoming part of the

anybody, whether male or female, wanting

team at SIFCO ASC in 2005, she worked in

to work in STEM. While there’s still a

the semiconductor and rubber industries.

long way to go before we close the gap

From talking about how to remove the

of women working in these fields, the

glass ceiling for women in engineering, to

number of women awarded STEM degrees

changing the future of electroplating, we

every year has increased by over 50,000 in

found out what inspires Danijela, and how

the past decade.

she strives to create a better future for

Danijela embarked on her last masters

herself and other females in STEM.

degree when she was pregnant with her first daughter, and continued to study and

Science and math: the foundations of STEM

work full time. Driven by her passion to expand her horizons and learn as much as

Danijela knew she wanted to work in a

she could, she persevered.

STEM field since she was young - her

This story echoes a similar message

passion for science and math started in

that Audrey Gelman, CEO of The Wing

grade school. She loved the challenge of

told when she became the first visibly

figuring out equations, learning theories,

pregnant woman to grace the cover of Inc.

and knew from very early on that having a

Magazine. Gelman wanted to show that women can, “take greater professional

background in science would provide her with a strong foundation no matter what career path she followed. Her father - her biggest cheerleader and inspiration - always motivated her to advance her education and

N.33 - 2020 APRIL - ipcm® Protective Coatings

Danijela Milosevic-Popovich, a Research and Development Manager at SIFCO Applied Surface Concepts (ASC).

risks whilst also not shelving their dreams of becoming a mother and starting a family.” Afterall, if men can have it all, why can’t women?

HIGHLIGHT OF THE MONTH

Changing the electroplating landscape

plating solutions that aim to replace

cadmium and chrome in the future.

When asked about her day-to-day role at

“Right now, there is no ‘one size fits all’

SIFCO ASC, Danijela lights up as she talks

solution for drop-in replacement of

about all of the areas she’s involved in.

cadmium or chrome, so we’re focusing

“Everyday brings something new to the

on making solutions such as ZnNi

table. My role encompasses so much more

(Zinc-Nickel) as cadmium alternatives, and

than the traditional R&D activities - it’s

MMC (Metal Matrix Composite) solutions

multifaceted, and keeps me on my toes.

for chrome alternatives.”

My department and I are the repository for

This will unquestionably make a change

technical know-how, which ultimately leads

in the world and will undoubtedly impact

to growing the knowledge base capabilities

future generations.

of our existing product lines and the solutions, and technology.”

The challenge of being a woman in STEM

Through this research and knowledge base,

When asked the question “what are

Danijela and her team are slowly changing

the challenges of being a woman in

the perception that brush plating is a

STEM?”, Danijela says they are the same

dirty, uncontrollable and manual process.

stereotypical barriers that have been

Advancements such as programmable

internalised over several decades. She

power packs and process automation

talks about the unconscious bias where

development of new applications, plating

both men and women are conditioned to

have not only revolutionised the way electroplating is done, but has given repair engineers even more control.

think that men are more inquisitive, motivated and in charge. As a result,

“As we’ve developed various plating applications, we’ve been able to

women have to work harder.

introduce more controls to the processing phases. As a result, we’ve

However, she muses that if we change the narrative, we may be able to

refined the plating process parameters to provide repeatable and

remove the glass ceiling for both women and minorities in STEM, if we

controllable deposit characteristics for a process that is traditionally

start to celebrate their accomplishments, rather than the challenges

manually performed by an operator. This level of control has propelled

they face. She says: “Every woman in a STEM field has a unique set of

us to further develop semi and fully automated plating applications

challenges ahead of her that no man will ever have to experience.

and equipment along with going away from traditional brush plating by

I’d like to shine a spotlight on the accomplishments of women in STEM

developing encapsulated plating technologies.”

historically so that we can lay a framework for continued recognition of

Creating a safer and more sustainable future

our girls as they turn into women and change the world alongside their male colleagues.”

It’s not just the electroplating process that’s feeling the impact - this

For any female looking to advance a career in STEM, whether younger or

research and development is paving the way towards a much safer and

older, Danijela says that believing in yourself and finding a mentor who

sustainable future for repair mechanics and the environment. Working

will advise you and push you out of your comfort zone is the best thing

with a team of engineers, Danijela develops REACH (Registration,

you can do. There’s one experience with her first boss and mentor that

Evaluation, Authorisation and Restriction of Chemicals) compliant brush

left a life-long impression on her, and helped shape her future. She said:

plating alternatives to the toxic chemicals that are currently in use

“Before any big meeting, we would run through my presentation and

across the globe.

attend the meeting together. There was one high-level meeting where

For example, cadmium and hard chrome are commonly used by

there were four levels of managers in attendance, quite overwhelming

maintenance repair engineers who are undertaking component repairs

for a young woman especially when most of the crowd was male. I ran

for a wide range of industries due to their increased wear resistance,

through my presentation with my boss beforehand, and he told me he’d

surface hardness and durability. However, exposure to both metals

meet me there. Only, he didn’t show up. I survived the meeting, walked

in their compound state can be incredibly harmful for both plating

over to his office and asked why he didn’t show up. He told me he “didn’t

technicians and the general public, as they are carcinogenic.

want to take the spotlight away from me, he didn’t want the rest of the

Danijela and her team’s seemingly small actions are beginning to have

room to see a MAN standing behind me.” He taught me that I was quite

profound consequences on the plating industry and the planet. Through

capable of standing on my own two feet and that I shouldn’t ever feel

exploration, analysis and development, SIFCO ASC has developed brush

inferior regardless of who is in my company.” ‹

ipcm® Protective Coatings - 2020 APRIL - N.33

BRAND-NEW

Exemplary Teamwork: New Electroplating Drum Unit at Reisser Combines the Know-How of All Participants © Dörken MKS

A highly-modern electroplating drum unit recently entered operation at Reisser Schraubentechnik in Ingelfingen (Germany). The concept and realisation were undertaken in an exemplary joint project of all parties involved, showing that this can result in significant added value for customers as well as all partners.

Excellent example of co-operative project management The goal of Reisser management was to expand the existing coating

capacity and thereby increase productivity. A particular aim was also to offer the long-standing customer Eaton – a worldwide leading provider of pipe connector systems for hydraulics – an even broader spectrum for the In the state-of-the-art electroplating drum unit objects such as fluid parts for various applications can be coated with the DELTA-PROZINC® system.

coating of diverse parts. Against this background the company, part of the Würth Group, joined with the corrosion experts at Dörken MKS and the plant manufacturers A.S.T. and Forplan Surface Technology to construct

an electroplating drum unit tailored to future coating requirements, one of the most modern worldwide in the field of alloy-free zinc technology, opening up further attractive coating options for Reisser as a long-standing Dörken MKS licensee. Matthias Basler (Dörken Application Engineer) was particularly impressed with the trust-based co-operation of all participants: “In a very early stage of the planning all of the parties with their specialist know-how and experience were brought together. Throughout the project the interaction was very open and highly collaborative.”

Specifically tailored to the requirements of plant technology Fluid parts for Eaton will also be coated on the new unit. These are used One-stop coating process employed state-of-the-art centrifuge technology.

in various forms in vehicle engines and in plant engineering, ensuring the optimal fluid flow at connecting points of pipes and pressurised hoses. Due to the numerous challenges, these parts need to satisfy the highest

corrosion protection requirements. The high corrosion resistance and outstanding functional characteristics make the galvanic zinc system from Dörken MKS DELTA-PROZINC® ideal for this. To enable a particularly efficient, one-stop coating process, in co-ordination with the other project planners Forplan employed state-of-the-art centrifuge technology as well as a special furnace drying procedure. This ensures especially gentle treatment of the parts during and after topcoat application and enables the even distribution of heat in the drying process, thus achieving a consistently high standard of coating quality. Interesting information on project planning, the co-operation of the participants and much more can be found at the following link: https://www.youtube.com/watch?v=HZP8QypUoVc.

The electroplating drum unit created by Forplan Surface Technology ensures gentle treatment of the parts during and after topcoat application.

N.33 - 2020 APRIL - ipcm® Protective Coatings

For further information: www.doerken-mks.de/en/

BRAND-NEW

Dynamic Infrastructure Partners with InVision To Improve Maintenance of Bridges and Tunnels In Greece The New York and Tel Aviv-based company Dynamic Infrastructure, is

tollway in Greece. The cooperation will enable InVision to expand its

expanding in Greece following a broad cooperation agreement with

offerings to Greek customers for the implementation of

Greece’s InVision Consulting, a leading consulting and software providing

Dynamic Infrastructure’s predictive maintenance solution, allowing bridge

firm specialising in the transportation industry.

and tunnel operators updated visual diagnosis of the assets they manage. Athens-based InVision currently supplies software solutions to Greece’s

InVision will offer Dynamic Infrastructure’s AI-based predictive

leading tollway operators: Aegean, Attiki, Egnatia, Moreas Nea, Olympia

maintenance solution to tollway operators in Greece to help them

and Kentriki. They operate thousands of miles of highways, along with

maintain their assets and improve Opex.

hundreds of bridges and tunnels that cross the country.

Dynamic Infrastructure’s deep learning system quickly creates

“InVision and Dynamic Infrastructure are cooperating in bringing

“medical files” for every bridge, tunnel and elevated highway, based on

the most advanced solutions to our customers. The combination

existing photos taken through annual planned

of InVision’s expertise and products with such

inspections and photos of day-to-day operations.

innovative solutions is key for us as market leaders.

The proprietary cloud-based software compares

We will provide our customers, for the first time,

existing images to new ones to detect maintenance

an option for maintenance services that can

and operation issues and identify defects before

substantially reduce their current and future costs,”

they evolve into large-scale failures. Like an

said Christos Koulouris, CEO of InVision Consulting.

MRI, these “medical files” serve as benchmarks

“We are proud and honored that InVision chose

for changes in maintenance conditions. The

us as a technological partner. The cooperation of

diagnostics can be easily accessed through a

both companies will provide our Greek customers

simple browser and can be instantly shared with

an incomparable advantage in maintaining key elements of the transportation grid,” said

peers and suppliers to facilitate maintenance workflows and increase return on investment. The cooperation with InVision follows a successful pilot completed by the two companies on a major

Saar Dickman, CEO of Dynamic Infrastructure.

Saar Dickman, CEO of Dynamic Infrastructure. For further information: http://diglobal.tech/

ipcm® Protective Coatings - 2020 APRIL - N.33

ÂŠ Adobe Stock

INNOVATIONS: PRESENT&FUTURE

Intumescent Coatings Can Meet Demanding Aesthetic and Safety Standards Ronnie Peskens PPG Protective and Marine Coatings - Amsterdam, The Netherlands ronnie.peskens@ppg.com

A new generation of waterborne fire protective coatings for structural steel can address green building needs and speed up on-site and in-shop applications, writes Ronnie Peskens, Global Product Manager Fire Protection, PPG Protective and Marine Coatings

he use of exposed steelwork, both internally and externally, has grown rapidly over the last 20 years as architects have implemented

modern design principles with a strong focus on aesthetics. Structural steel is no longer hidden behind walls and ceilings but has become a part of everyday life. Open office plans feature circular columns and air-conditioning systems which run though cellular beams. Sports arenas make extensive use of curved trusses in roof assemblies, which are considered an architectural feature. In summary, exposed steelwork can be used to create an identity to a building and to a business. These changes in building design have had a knock-on effect to the process of passive fire protection (PFP). Traditional PFP systems, including cementitious spray and fire resistant boards, have seen increasing levels of competition from intumescent coatings. Cementitious sprays, although considered a cost-effective solution, are usually applied in very high thicknesses. This adds substantial weight to the structure and may even require the use of thicker steel. The risk of corrosion underneath the cement and the difficulty of repairing subsequent damage, have been a source of major concern in recent years. Moreover, these kinds of sprays deliver very rough finish standards, which are often not acceptable to designers. The installation of boards on the other hand is a high cost process, which requires specialist skilled labour. Even though boards provide a highly efficient thermal barrier, the lack of pre-fabricated shapes for complex structures limits their use to standard beams and columns. Intumescent coatings are designed to expand at high temperatures, from a very thin, lightweight film into a thick foam-like layer that forms an insulation char to protect the steel. They offer an aesthetically pleasing,

N.33 - 2020 APRIL - ipcmÂŽ Protective Coatings

INNOVATIONS: PRESENT&FUTURE

single solution for both corrosion and fire protection. The steelwork

Leadership in Energy and Environmental Design and Building Research

is typically treated with an anti-corrosive primer before application of

Establishment Environmental Assessment Method.

the fire-retardant paint. This can take place either in-shop or on-site.

One of the key elements in these schemes is indoor air quality (IAQ) of

Intumescents can be applied to nearly every shape and size of steel and

building materials. This not only includes volatile organic compounds

can be customized with a variety of colour topcoats.

in the can, prior to application, but also the release of residual solvents

Traditional intumescent coatings, first introduced in the 1990s, use

and other emissions after installation is completed. In several Countries,

solvent-based, acrylic technology. These coatings are easy to apply

such as Denmark, the on-site use of solvents has now been restricted

with standard airless spray equipment, allow high film builds and offer

and it is clear that alternative technologies are required.

relatively fast drying and recoat times. Typical fire ratings range from 15

The use of waterborne intumescent coatings has been steadily growing

to 120 minutes. As buildings often consist of modules with a number of

over the last few years and these systems are especially suitable for

different fire ratings, this usually requires a multi-product solution.

on-site application, as well as maintenance and repair. They contain

Intense competition and technological limitations have resulted in

little to no VOCs, have low odour, and are very easy to apply with spray,

specialized products to address fire ratings above 60 minutes and from

as well as brush and roller in locations where spraying is not allowed.

60 to 120 minutes but such multi product offers can be challenging in

This is especially important in industries where fast return-to-service

both shop and site applications since there is a risk they are mistaken

and high levels of safety are required, such as airport terminals. In-shop

for one another.

application companies are now investing in ventilation and

In recent years, there is clear trend towards the use of ‘green

air-conditioning equipment to accommodate application of waterborne

building schemes’ in the construction industry, examples of which are

materials as well. This is may open new opportunities for the industry. © PPG Industries

As well as providing a long-lasting smooth finish, PPG STEELGUARD waterborne coatings are compatible with a wide range of fast drying PPG primers and topcoat colours. These include waterborne solutions specially formulated to protect steel against corrosion under a variety of atmospheric conditions.

ipcm® Protective Coatings - 2020 APRIL - N.33

INNOVATIONS: PRESENT&FUTURE

The latest generation of waterborne intumescent coatings is developing

or boron containing compounds. This is not only beneficial during the

rapidly as the technology improves. Advancements in resin synthesis

application process, as it also improves indoor air quality and provides

and formulation has led to a new generation of products.

lower smoke toxicity than traditional systems.

The flagship waterborne intumescent of PPG Protective and Marine

As a result of extensive research into the intumescent char mechanism,

Coatings is PPG STEELGUARD™ 651 which is free of phenol ethoxylates

PPG STEELGUARD 651 offers competitive thicknesses across the full

and formaldehyde and does not contain any halogenated fire retardants

spectrum of fire ratings, from 15 up to 120 minutes. This includes three-sided and four-sided I-beam and columns, circular hollow sections

and cellular beams. Dry film thicknesses have been improved dramatically compared to both solvent-based and previous waterborne generations. Fire ratings up to 30 minutes now start from only 193 microns. PPG STEELGUARD 651has been tested and certified in accordance with EN1338-8; BS476, various international standards, and carries the CE mark. In addition to these improvements in product properties and performances, architects are now also taking fire engineering into consideration during the design stage. This usually includes optimization of the steelwork design related to the location and load bearing capacity of the elements, as well the fire rating requirement. This approach can generate significant savings on the total applied cost of the fire protection materials. PPG engineers are available globally to provide expertise in fire protection and advice on the relevant industry standards and fire ratings. PPG has the engineering capability to support clients in the early stages of development, guiding them through the specification process and providing support through to project completion and beyond. ‹

Ronnie Peskens, Global Product Manager Fire Protection.

PPG STEELGUARD™ intumescent coating systems must maintain the steel’s stability in the event of a fire. These highly protective coatings are formulated to expand at increased temperatures, whilst at the same time offering corrosion protection at ambient conditions.

N.33 - 2020 APRIL - ipcm® Protective Coatings

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FOCUS ON TECHNOLOGY

Metal Alloy Upgrade in Corroding Process Vessels Marina Silva IGS Integrated Global Services Inc., Richmond - United States

marina.silva@integratedglobal.com

During a routine inspection in a US refinery a corrosion problem with

of the shell. These coatings needed to be applied repeatedly every 4-5

the second stage desalter and the overhead accumulator vessels had

years. In 2014, the inspection revealed areas where both the historical

been detected. The initial intervention with a nickel-copper thermal

nickel-copper thermal spray (TS) coating and organic patch repairs

spray coating did not appear to be a lasting solution. In 2017, refinery’s

have worn away completely, leading to deep pitting and metal wastage

engineers decided they needed a more permanent solution: High Velocity

beyond existing corrosion allowance.

Thermal Spray (HVTS) coating by IGS.

Moreover, when weld repairs were attempted adjacent to the failing

Introduction A US refinery identified a problem with its second stage desalter and

TS, a crack had formed on its heat affected zone (Fig. 2). In 2017, refinery’s engineers decided they needed a more permanent solution.

their overhead accumulator vessels during a routine inspection.

Evaluation

A nickel-copper thermal spray coating had been applied in both

IGS inspected the vessels and proposed a High Velocity Thermal

of these vessels approximately 20 years ago. Initially, the coating

Spray (HVTS) cladding solution to stop corrosion for the expected life

performed as expected, however after some time, localized damage

of the asset without any further maintenance anticipated for at least

was evident on the bottom third of both vessels (Figs. 1A - 1B). Initially,

the next 15+ years. HVTS technology utilizes next generation alloy

various organic coatings were chosen for patch repairs to the bottom

materials, which offer erosion-corrosion protection, even in HT/HP

N.32 - 2019 DECEMBER - ipcm® Protective Coatings

FOCUS ON TECHNOLOGY

service up to 1371°C/2500°F. Both organics and weld overlay were

and address any issues with the vessels’ substrate. The Overhead

evaluated as potential options by the refinery and given the upgraded

Accumulator required no mechanical work whereas the First Stage

metallurgy and the time savings of HVTS compared with overlay, the

Desalter needed to be welded due to the deep pitting that occurred

refinery project manager welcomed this proposal and HVTS work was

due to the poor quality of the previously applied coating (Fig. 3).

scheduled for the Spring of 2019.

TS Coating Failure

Application

Typical Thermal Spray (TS) coatings are not suitable for internal

IGS started by clean blasting each unit, allowing refinery’s QC to inspect

protection of mission critical process equipment due to their

Figures 1A and 1B - Corrosion damage on the desalter shell.

ipcm® Protective Coatings - 2020 APRIL - N.33

FOCUS ON TECHNOLOGY

Figure 2 - Crack on the TS HAZ.

Figure 3 - HVTS application, no HAZ, no PWHT.

permeability, weaker bond strength and propensity to cracking. TS

inherently highly stressed, and such highly stressed coatings have a

systems cannot produce flat and tightly-packed particle sizes or nano-

high propensity to crack and subsequently fail in service.

scale grain structures, leading to the coating’s failure due to corrosion and/ or permeation (Fig. 4).

Completed Application

In addition, TS materials’ cladding particles form surface oxides in

HVTS application was completed on time and within schedule, even

flight. These oxides then form part of the applied TS structure and

accounting for unexpected delays. Bottom third of the overhead

are permeable, creating a pathway for corrosive media to penetrate

accumulator, including the stem pipe with a vortex breaker and a

through the coating leading to subsequent substrate corrosion, and

flange were protected with HVTS. With regards to the crude desalter,

premature TS failure.

HVTS was applied to the 5 O’clock to the 7 O’clock position of the

Moreover, being applied at high thicknesses, TS structures are

vessel and the manway (Fig. 5).

Figure 4 - TS particles vs HVTS tightly-packed particles.

N.33 - 2020 APRIL - ipcm® Protective Coatings

FOCUS ON TECHNOLOGY

Figure 5 - Completed application.

Figure 6 - Overhead accumulator HVTS thickness measurement.

Inspection

magnetic liftoff gauge (Fig. 6).

Final inspection of the work scope involved the generation of a cladding

IGS has invested heavily in the development and optimization of its High

thickness record with mapped electromagnetic stand-off gauge (MLO)

Velocity Thermal Spray (HVTS) process technology, materials technology,

readings on a defined reference grid across the area protected. This

application procedures and field personnel capability. Decades of

record will be used for future inspection and verification of cladding’s

successful cladding applications coupled with fast mobilization and

integrity. HVTS cladding systems can be readily inspected visually for

turnkey applications are helping position IGS as a go-to service provider

any signs of deterioration and thickness measurements taken with a

Q U A EXCELLENCE I T Y

C O R P O R AT I O N Environmentally Safe VpCI ®/MCI ® Technologies

for the Oil, Gas and Petrochemical sites worldwide. ‹

The 33,000 tonne 225 m long cargo ship “Algarrobo” leaves dry dock after re-painting including 700 m2 section of Talphene®-enhanced primer coating along the starboard side. © Talga Resources Ltd

INNOVATIONS: PRESENT&FUTURE

Global First as Talga Graphene Coating Begins Commercial-Scale Trial on Ocean-Going Cargo Vessel Nikki Löf Talga Resources Ltd - Perth, Australia

info@talgagroup.com

Advanced battery anode materials and graphene additives provider Talga Resources Ltd is pleased to announce the commencement of a commercial scale trial of a Talga graphene-enhanced coating applied to a 33,000t container ship. The result is expected to be a range of environmental and economic benefits, which for marine applications includes improved corrosion resistance, decreased metallic paint loss into oceanic ecosystems and increased efficiency through lowering dry-docking cycles.

N.33 - 2020 APRIL - ipcm® Protective Coatings

INNOVATIONS: PRESENT&FUTURE

elieved to be the world’s largest single application of graphene,

the laboratory to commercial scale application on a 33,000 tonne ship,

the 700 m2 coating of the cargo vessel’s hull is part of advanced

being tested across global marine environments, we are showcasing

testing of Talga’s functionalised graphene (Talphene®) additive as a performance booster for existing commercial marine coatings (part of

our graphene’s real-world potential as a bulk industrial product.”

the global 54 million tonne per annum paint and coating market1).

Marine coatings market

The commercial-scale application follows completion of in-house

Within the global ~54 million tonne per annum paint and coatings

development and patent pending technology that successfully

market2, the marine coatings segment is projected to grow to

translates graphene’s exceptional mechanical properties into paint

USD$12 Billion by 2024. Drivers for new coating technologies include

and coatings. The result is expected to be a range of environmental

environmental and regulatory demands, fuel efficiency, construction

and economic benefits, which for marine applications such as shipping

costs (pre-fabrication) and maintenance costs. Growth in emerging

and offshore infrastructure includes improved corrosion resistance,

economies such as China, India and Brazil are large volume drivers

decreased metallic paint loss into oceanic ecosystems and increased

while in terms of value, the Asia Pacific marine coatings market is

efficiency through lowering dry-docking cycles.

projected to grow at the highest CAGR during the forecast period3.

The freshly coated ship is now at sea and over the coming 12-18

Key players operating in the marine coatings market include Hempel

months the Talphene-coated area will be evaluated in the harsh real-life

(Denmark), Jotun (Norway), AkzoNobel (Netherlands), PPG Industries

conditions of global cargo shipping.

(US), Sherwin-Williams (US), Chugoku Marine Paints (Japan), Nippon

Talga Managing Director, Mr Mark Thompson: “The maritime coating

Paint (Japan), Kansai Paint (Japan), Axalta (US), and BASF Coatings

sector is a very large market and well suited to use of our Talphene®

(Germany).

graphene additives for improved environmental and economic outcomes. Additionally, by successfully taking this new product from “Marine Coatings Market, Industry Analysis Report & Forecast” Global Market Insights, Aug 2019

“World Paint & Coatings-Demand & Sales Forecasts, Market Share, Market Size, Market Leaders” Freedonia Group, Jun 2016

Vessel in dry dock during removal of existing paints.

“Graphene based anticorrosive coatings for Cr (VI) replacement” K. S. Aneja et al, Nanoscale, 2015

Talphene®-enhanced primer (left) being spray coated onto starboard hull of vessel, alongside the test reference coating (right).

ipcm® Protective Coatings - 2020 APRIL - N.33

INNOVATIONS: PRESENT&FUTURE

Talga technician performing in-house ASTM salt spray testing on coating samples.

Coating adhesion tests by Talga scientist.

Mixing of epoxy coating system.

Talphene® coating product development

this highly optimised industry, indicating that graphene’s exceptional

Coatings are one of Talga’s key target products due to the large

mechanical properties translated into the coating system and warranted

volume market and graphene’s potential to provide substantial new

commercial-scale trials.

levels of performance and environmental sustainability. For maritime applications, Talga’s additive development has included multi-stage

Commercial ship application & trial details

testing to optimise graphene loadings (i.e. quantities) and Talga’s unique

Based on the successful lab results, plans were drawn up for a major

patent-pending dispersion technology for epoxy based commercial

commercial scale application and sea trial. A 2-part epoxy based

primer coating systems. Testing by Talga included industry accepted

commercial coating system was purchased and mixed with the Talphene

ASTM prescribed Salt Fog Test (ASTM B117) where steel panels coated

additive before dispatch to the ship management company for

with epoxy primer containing Talphene additive showed improved

application during vessel dry docking (carried out every ~5 years for

corrosion protection performance compared to ‘state of the art’

ships this size). The test areas along the ship’s starboard side, both

commercial systems currently used world-wide in large volumes.

below the water line and above in contact-wear sites, were blast

Further evaluation included mechanical performance tests, carried out

cleaned to remove prior paint systems before the Talphene-enhanced

to ASTM standard by the highly recognised research organisation The

primer coating was applied (next to a test reference coating without

Welding Institute (TWI), as the coated surfaces of ships and maritime

Talphene) in two coats, using manual spray systems. A major challenge

infrastructure are exposed to considerable abrasion and mechanical

of the product development was to translate the positive lab-scale

damage during service. The results showed a significant improvement

tests into practical, large-volume use by on-site commercial applicators.

in primer performance, including greater adhesion to the substrate (by

The successful application of the Talphene-enhanced coating

~7%), greater interlayer adhesion to the subsequent (antifouling) coating

without any adverse effect in terms of stability in resin, application,

systems (by ~14%) and consistent improvement in abrasion resistance.

curing and surface features is a highly positive step forward in the

These improvements in performance were a notable outcome for

commercialisation process. The test areas have been over-coated with

N.33 - 2020 APRIL - ipcm® Protective Coatings

INNOVATIONS: PRESENT&FUTURE

the standard topcoats used on the rest of the vessel and marked to ensure identification during service. Periodic inspection will be carried out over the next 12-18 months to determine real world performance.

Next steps Talga intends to continue development of this Talphene additive for marine coatings under its range of paint and coating additives now trademarked as Talcoat™. The next steps include a trial of the additive as an after-market product, to be mixed into the coatings on-site by the commercial applicators, as opposed to being dispersed by Talga prior to despatch. Talga has also identified a range of potential commercial partners and commenced discussions, under NDA, regarding the incorporation of Talcoat products into their existing and new coating product lines4. The company notes that these negotiations are preliminary, and further updates will be released as and when any definitive commercial agreements are reached. ‹

SEM image of coating development on steel.

See the article “Talga’s New Graphene Coating Starts Large Scale Trial in the Maritime Industry” at page 37.

HIGHLIGHT OF THE MONTH

The Global Value Chain and the Importance of Measuring and Control Tools to Guarantee Product Quality Adriano Antonelli IBIX S.r.l. - TECNO SUPPLY DIVISION, Lugo di Romagna, (Ravenna), ITALY

adriano.antonelli@tecnosupply.com

Measurement and control instruments are fundamental to check that

the loss of know-how and production management capacity. In general,

the required coating layers have actually been applied and they can

we assumed that any component could be obtained quickly. However,

therefore guarantee adequate protection to the treated products.

we found out how weak and fragile the value chain actually is. Any

Automation Dr. Nix develops and manufactures its range of coating

health, financial, or economic crisis in a given area is enough to stop the

thickness gauges exclusively in Germany, in order to ensure maximum

construction of a complex machine.

quality throughout the entire production chain. Tecno Supply, a division

In these cases, how can a company reorganise its production chain to

of IBIX Srl, distributes its thickness gauges in Italy.

avoid production stoppages without affecting costs? How can it regain lost skills? Is it possible to have two separate supply channels to get all the necessary components? Currently, we can only answer these questions

ately, we have come to realise that the world production chain is very

with hypotheses. In this article, we would like focus on a company that

fragile. In fact, we have gone from a framework in which the industrial

decided to carry out its entire production process in-house: Automation

districts supporting global companies were geographically close enough

Dr. Nix develops and manufactures its range of coating thickness gauges

to be controlled, managed, and financed to a system composed of

exclusively in Germany, in order to ensure maximum quality throughout

vertically integrated districts where components come from multiple

the entire production chain. Tecno Supply, a division of IBIX Srl, distributes

areas of the world. The districts’ peculiarity and specialisation level has

its thickness gauges in Italy.

led to the reduction of costs on the one hand and, on the other hand, to

Measurement and control tools are crucial pieces of equipment for any

A QNix coating thickness gauge produced by German manufacturer Automation Dr. Nix and distributed in Italy by Tecno Supply, a division of IBIX Srl.

N.33 - 2020 APRIL - ipcm® Protective Coatings

HIGHLIGHT OF THE MONTH

Figure 1 – The QNix coating thickness gauge series.

firm dealing with surface treatments. Without proper instruments, it

accurately. Rigorous quality tests guarantee their universal use all over

could not assess its products’ coating quality and, above all, understand

the world. In addition, rubies makes the probes and the whole instrument

the professionalism inherent in these processes. The measurement of

durable and robust.

coating thicknesses is therefore a decisive operation to check that the

• Three-year guarantee.

required coating layers have actually been applied and that they can guarantee adequate protection to the treated products.

The company’s already wide range has been recently integrated with

Automation Dr. Nix’s QNix coating thickness gauges are characterised as

two new tools: QNix 9500 and QNix 5500. After a three-year design

follows (fig. 1):

process, the two of them were launched on the market with the aim of

• No calibration: calibration is not necessary (although it is possible to carry

offering cutting-edge measurement tools that can simultaneously meet

it out, if needed). All gauges are supplied with a calibration certificate.

different needs in multiple segments. They stand out thanks to their

• Reliability and sturdiness: their proven technology enables these gauges

unprecedented sturdiness and ease of use combined with the quality,

with a built-in ruby to perform millions of measurements precisely and

versatility, and precision that have always characterised the QNix gauges.

Figure 2 – QNix 9500.

ipcm® Protective Coatings - 2020 APRIL - N.33

HIGHLIGHT OF THE MONTH

Figure 3 – QNix 5500.

QNix 9500, for instance, is characterised as follows (fig. 2):

Flexible and extensible • Future-proof thanks to interchangeable probes;

Safety through precise and correct measurements

• Portable instrument for Fe, NFe, and Dual probes;

• High accuracy over the entire measurement range;

• Quick switch to cable probes.

• High repeatability of measurement results; • Thermal compensation directly in the sensor;

User-friendly and easy to use

• Precise measurements also on curved surfaces and small parts;

• Easy calibration;

• Simple adjustment on rough, smooth, and curved substrates.

• Portable instrument and software user-friendly interface: only three clicks are required to get a report;

Sturdy and durable

• One quick-access button to be customised with a chosen function;

• Fibreglass-reinforced five-part body with IP65 dust and water resistance

• Pre-set regulations and standards.

properties; • Three-layer protection to absorb shock;

QNix 5500 (fig. 3), a gauge with an integrated or interchangeable probe

• H6 chemical and scratch-resistant LCD screen;

but without any internal memory, has the following features:

• Operating temperature from -20 °C to +70 °C; • Stainless steel probes with an anti-dust membrane (IP65).

Safety through precise and correct measurements • High accuracy over the entire measurement range;

Speed through ergonomics

• High repeatability of measurement results;

• Direct feedback through the display showing the limit values and the

• Thermal compensation directly in the sensor.

probe’s RGB LED; • 2.4”, 600 lm, high light intensity IPS LCD colour screen with a reading

Sturdy and durable

angle of 70°;

• Fibreglass-reinforced five-part body with IP65 dust and water resistance

• Excellent readability even under direct solar radiation. Automatic or

properties;

manual brightness adjustment;

• Three-layer protection to absorb shock;

• Automatic or manual screen rotation by 0°, 90°, 180°, and 270°;

• H6 chemical and scratch-resistant LCD screen;

• Large, soft touch keys and low centre of gravity.

• Stainless steel probes with an anti-dust membrane (IP65).

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HIGHLIGHT OF THE MONTH

Figure 4 – One of the main characteristics of the QNix 5500 coating thickness gauge is its excellent ergonomics.

Speed through ergonomics

• 2”, 350 cd/m2, high light intensity IPS LCD colour screen with a viewing angle of 70°; • Automatic screen rotation by 0°, 90°, 180°, and 270° (fig. 4); • Low centre of gravity and a large contact surface for precise measurements. Flexible and extensible • Portable instrument for Fe, NFe, and Dual probes; • Integrated, interchangeable, and cable probes with one instrument; • Greater versatility thanks to the quick probe change operation. Automation Dr. Nix’s range includes other very sound tools. QNix 8500 (fig. 5), for example, can be used in several different industries thanks to its technical characteristics, which are as follows: • This measuring system uses interchangeable probes and it has a measuring range up to 5000 µm; • The wireless probe allows measuring even in difficult-to-reach areas, it is easy to use and it weighs only 30 g. It is available in Fe and NFe versions and even a combination of both for measurements up to 5000 µm. The probe is recharged through the gauge and it guarantees at least 2000 readings without the need for recharging; • The pen probe (fig. 6) can be used for small parts. Its robustness is guaranteed by its stainless steel finish and it offers a measuring range up

Figure 5 – QNix 8500.

to 500 microns.

ipcm® Protective Coatings - 2020 APRIL - N.33

HIGHLIGHT OF THE MONTH

Figure 6 – The pen probe used for small parts.

Figure 7 – The special cover complete with Velcro strips guarantees the protection of the instrument.

• It is possible to perform accurate measurements on small parts,

• It comes complete with software for analysis and statistics. The PC

non-ferromagnetic metal coatings (e.g. chrome, copper, and zinc), paint,

software package is easy to use and it seamlessly integrates the

enamel, or copper-based coatings on ferromagnetic substrates. This

QNix® 8500 system. It offers options such as practical documentation and

tool’s application fields are the most varied, including the measurement

data analysis and configuration;

of angles, washers, screws, bolts, nuts, and connections. For instance, it

• A special cover complete with Velcro strips protects the tool (fig. 7).

ensures reliable measurements on steel bolts and nuts used for wind power plants or bridges and on window hinges. It also measures the

Automation Dr. Nix’ QNix 1500 gauge (fig. 8) is the only tool for the

thickness of PVD coatings such as TiN, TiCrN, CRN and TiAlN.

non-destructive measurement of coating thicknesses approved by

• Measurement speed: up to 120 measurements per minute;

Daimler-Chrysler and Volkswagen. This leading instrument in the

• A large memory allows storing up to 30,000 measurements and up to

automotive sector, however, is also appreciated in the coating field

200 measurement groups;

in general. Its particular shape and the two independent Fe and NFe

Figure 8 – QNix 1500.

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HIGHLIGHT OF THE MONTH

Figure 9 – Coating thickness gauges from the QNix 4200 and 4500 series.

probes also enable to measure in difficult-to-reach areas. It is used for

which make it one of the best-selling tools in its category:

large surfaces and it can measure up to 5000 microns. This instrument

• Compact instrument;

is handy, easy to use, and above all reliable. It switches off and on

• Versions: integrated and cable probe;

automatically. It works with a 9-Volt battery. Calibration is not required;

• Measurement speed: up to 120 measurements per minute;

it is supplied with a self-calibration certificate. Its weight (only 150 g,

• Measuring range: up to 5000 µm (Fe) or up to 3000 µm (NFe).

including the battery) enables the operator to appropriately carry out hundreds of measurements. The three-year guarantee granted is proof

With no internal memory, this gauge is very easy to use because it

of the quality of this gauge. It can also be supplied with a QNix 1500

turns on and off by itself and it automatically distinguishes Fe and NFe

M memory; in this case, a USB socket will be sufficient to interface the

substrates. It also has a cable version (fig. 10) that can work with a probe

instrument to the computer and download the QNix software package

connected via a 1-metre cable.

in order to record and store all the measurements performed. If only ferrous substrates are treated, it is possible to opt for the cheaper QNix

Finally, QNix Handy is the only gauge in this portfolio with a measuring

1200 version.

range from 10 μm to 10 m. With basic functions, it is proven and reliable

QNix 4500 (fig. 9) deserves to be mentioned due to some of its features,

despite its very low cost. ‹

Figure 10 – The QNix 4500 cable version.

ipcm® Protective Coatings - 2020 APRIL - N.33

INSPECTION LOGBOOK

Coating Inspections – Review and Preparation Of Inspection Documents (Part 1) Massimo Cornago NACE International Certified Coating Inspector, NACE CIP PEER Reviewer cornago@ipcm.it

ollowing the previous indications about the figure of a Coating

methods and acceptance criteria to be used. In this plan, the main

Inspector, we have to understand which documentation a Coating

inspection points should be identified, for example:

Inspector has to use during a “Coating Work Project”, taking into

• Examination, measurements and test to be conducted

consideration two main types of documents:

• Verification and acceptance criteria for any individual test • Mandatory inspections surveillance points, witness points and hold

• Documents associated with the specification detailing the work to be

points

done by the applicator, including the specific inspection requirements:

• Methods for documenting inspection findings

“Work Plan”, “Quality Control Plan”, “Safety Plan”, Other Submittals” and

• Methods to identify conformance or rejection of work in process

“Pre-Job Meeting Report”.

(Standards)

• Documents prepared by the Inspector to document the work accomplished by the applicator: “Purpose of Inspector’s Documentation”, “Items for Inspection Documentation”, “Inspector Plan”, “Completing Inspector’s Daily Reports”, “Documenting Deviations from Specification” and “Documents after the Job is Completed”. In this article, named Part 1, we focus the attention on the first part of the documentation, which is “documents associated with the specification”. In the next one, named “Part2”, we will discuss all the documents that a Coating Inspector has to prepare.

A. Work plan In order to provide “details” on “how the required work will be accomplished”, the job specification (or work specification) writer may require the applicator to submit a “Work Plan” that mainly includes: “Materials to be used”, “Manpower and Equipment to be used” and “Job Schedule”. Most job specification defines what is to be achieved, avoiding descriptions of the working methods to be used. When working methods are described in the job specification, there could be the risk that the method specified will not produce the required result, leading to an inevitable dispute between the parts involved in the process and potential litigation.

B. Quality control plan The owner requires the preparation of a “quality control plan” giving indication to the Coating Inspector of how the inspection is to be performed, including a very detailed description of equipment, test

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INSPECTION LOGBOOK

• Methods to ensure that corrective actions are inspected again

clear and do not generate any conflict with the other parts of the

• Criteria for final acceptance.

specification. Any difference or discrepancy, etc., must be resolved.

C. Safety plan

E. Pre Job Meeting Report

The owner requires a formal quality system as such ISO 9000-9001-9004

A working team formed by the coating inspector and the

but the quality control plan should be more detailed and should comply

representatives of the owner, applicator and paint supplier should

with the requirements and restrictions provided by the quality system.

attend a pre-job meeting with the final purpose to resolve any

The owner may also require the applicator to submit a “safety plan” for

uncertainties and differences of interpretation in the specification. In

approval, to be sure that all the safety requirements provided by the

order to prevent any future discussion, at the end of the meeting they

job specification adequately protect the workers, in compliance with the

have to share the same understanding of the work requirements.

legal requirements.

The coating inspector should identify any missing, incomplete, not

In order to meet some safety requirements, the applicator must have

clear or ambiguous statements and communicate this to the owner’s

more than one option, in fact, the coating inspector does not have

representative. In addition, the degree of authority of the coating

any responsibility to enforce the safety plan but he must advice the

Inspector should be established by the owner and communicated to

person who has this responsibility when violations are noted or simply

the applicator. In fact, the coating Inspector must never overstep this

observed, as request by law.

authority. All the subsequent correspondence, between the coating inspector

D. Other submittals

and the parties present at the pre-job meeting, should be kept in the

All the documents from manufacturers and suppliers should be

contract files, for future reference. A “pre-job meeting report“ should be

accurately examined in order to be sure that they are completely

prepared, and it becomes an amendment to the contract.

F. Procedure to review job specification and associated documents In order to review the job specification and the associated documents, the coating inspector should: • Obtain from the project manager a copy of the job specification and supporting documents and accurately review them. • Verify that the major elements are included in the job specification, that are: - Work Plan - Quality Control Plan - Safety Plan - List of the specific material and related quantities to be used - Manufacturer’s technical data sheets and application instructions - Material Safety Data Sheets (MSDS) - Samples, test reports and certificate of compliance. • Examine the quality control plan to verify that it contains forms to be completed and the following inspection hold points: - Inspection of materials - Inspection of equipment - Completion of surface preparation - Initiation of paint application - Completion of paint application - Partial or final acceptance. • Verify that all the uncertainties and differences of interpretation brought up during the pre-job meeting have been solved, and that there are no inspection problems that require resolution. Also, check that the contract has been amended to include all agreements made during the pre-job meeting and keep these agreements in the contract files. ‹

ipcm® Protective Coatings - 2020 APRIL - N.33

FOCUS ON TECHNOLOGY

The Perfect Synergy between Coatings Supplier and Applicator Allows to Negate Vessels’ Erosion and Corrosion Issues Barbara Pennati, ipcm® The choice for the right coatings system allows assets owners to obtain highest performances and to guarantee long lifetime to their equipment in all industries, but in particular in the marine sector. If we add to this a perfect synergy between coatings supplier and applicator, we can obtain the best solution to erosion and corrosion problems.

n the marine industry, the right coatings are essential in order to avoid premature failure of expensive equipment which will entail high maintenance

costs. This is the reason why vessel owners are under pressure to ensure repairs are done right the first time and to keep operating costs down. These are the issues that Resimac, a UK-based manufacturer of epoxy and polyurethane coatings, repair materials, and composites, analyses and resolves every day in more than 50 countries in the world. In the following article, we will analyse the case study of a repair intervention that Mark Specialist Applications Ltd, a Resimac’s partner and supplier of specialist solutions and applications for the refurbishment and protection of ships, plants, machinery, equipment, buildings and structures, did for one of the world’s leading ferry operators in Northern Europe.

The two companies “Resimac was formed in 2009 by myself”, says Matthew Mcdonnell, Resimac’s Managing Director. “I have many years of experience in the coatings sector. Resimac exports its industry-leading products to more than 50 countries worldwide and its turnover has increased by 15% in the last year. The research and development-led company is a market leader specialising in solvent free coatings and repair materials across multiple sectors”. The purpose of these types of products developed by Resimac is to bring damaged and worn equipment and surfaces back to the original equipment manufacturers specifications. Very often, these repairs are undertaken as a safe alternative for welding or hot works.

N.32 - 2019 DECEMBER - ipcm® Protective Coatings

Among the most common problems for vessels we can find erosion of the leading edge of the rudder, bimetallic corrosion in the bow thruster tunnel and erosion on the surface of the A-frames.

FOCUS ON TECHNOLOGY

“These types of repairs are common within the marine industry and there is a requirement to repair and refurbish expensive equipment”, Mcdonnell continues. “A successful application reduces the life cycle cost of rudders and beckers, bow thruster tunnels, pumps, valves, seawater filters and other devices and stops the need for expensive CAPEX purchases for new equipment. We have found that all vessels above a certain size have the same issues - age of the vessel plays a significant role in the use of our materials as well (it is accepted that once a vessel gets beyond 10 years of age, major refurbishment of the equipment is needed)”. The relationship between Resimac and Mark Specialist Applications has its roots far back in time, even when the two companies had not yet been founded. “We actually go back a long way”, Mark Lewis, Managing Director at Mark Specialist Applications Ltd., says. “It was Bermuda 1976 on a sales conference. We were only children, but both our fathers were involved with Belzona’s products: Matt’s dad, Chris McDonnell, was the Head Research Chemist and later became Managing Director. My dad, Roy Lewis, was an independent distributor and by far sold more ‘sticky stuff’ than any other distributor in the UK history. So, you could say we have been involved with this industry all our lives, both indirectly and directly. I founded my first company, named Technosol in 1995, which was sold to Belzona Polymerics in 2003 and it became Belzona Technosol. Following my departure a few years later, I formed Mark Specialist Applications to meet market demands, so I have been involved in the application of specialist products for over 25 years now”.

Resolving the corrosion issues in the marine industry Meeting the customers’ needs by offering the right coatings solution is Resimac’s mission. “It is the solvent free epoxy repair materials, coatings and composites that are most commonly used within the marine industry”, Mcdonnell notes. “Epoxy based materials are known to be hard wearing and offer excellent resistance to the seawater environment and to chemicals used in the marine industry. Solvent free is a major consideration as on-board many areas of vessels are classified as confined space and therefore solvent based products cause major issues to vessel owners and applicators. Typically, for major equipment such as rudders, bow thrusters, a- frames, pumps, pipes and valves, abrasive blast cleaning would be the recommended level of surface preparation. These works are generally undertaken during dry dockings. However, another major area of repair is the on-board repair while at sea. These types of repairs are normally carried out with minimal surface preparation and performed by the ship’s own engineers. Resimac not only offers highly engineered repair solutions but also products that can be used for temporary fixes while the vessels are still in operation”. “Generally, ship owners or shipyards would contact Mark Specialist Applications directly at tender stage of a “refit” although we do carry out emergency call outs whilst ships are in service”, Lewis states. “We are very proud to work directly for Cammell Lairds, DFDS, Damen, P & O Ferries, © Adobe Stock

Maersk, Stena, Irish Ferries, Isle of Man Seam Packet, Seatruck to mention a

ipcm® Protective Coatings - 2020 APRIL - N.33

FOCUS ON TECHNOLOGY

few, and we have great working relationships with these companies”.

Case study: repair intervention on corroded ferries parts

The demand of coatings with increasingly higher performance has led the

In 2011 one of the world’s leading ferry operators in Northern Europe

two companies to develop their collaboration further in order to obtain

approached Mark Specialist Applications Ltd to analyse a recurring issue

coating systems of a higher level.

on the A-frames, rudders and bow thrusters on its ferries.

“Resimac has a wide range of methods for applying its products”, explains

“Among the most common problems for these types of vessels”, Lewis

Mcdonnell. “They are all multi-layer systems, which rely on each other

says, “we can find erosion of the leading edge of the rudder, bimetallic

to create a hard-wearing barrier. Typically, they are applied by hand, but

corrosion in the bow thruster tunnel and erosion on the surface of the

spray is becoming more and more effective, especially for the lining of

A-frames.

in-situ pipework. We are working with Mark Specialist Applications to

Due to seawater erosion and corrosion, the leading edge of the rudder

develop and improve application techniques”.

was found to have lost up to 12 mm of its structural surface leaving deep pitting on the metal surface. Common practice for repairing the leading © Resimac

edge of the rudder would be to weld steel plate to replace any lost surface thickness”. Instead of using hot works (welding), Resimac and Mark S. A. recommended abrasive blast cleaning of the surface of the rudder and then the use of a blend of epoxy composite repair material to repair and resurface the rudder surface. Resimac repaired all 3 vessels during January and February of 2011. All rudders and A-frames were repaired using the recommended Resimac repair system. Various repair interventions were made in the following period, such as the fire water pump in 2011 and on seawater filters in 2012. “Although various touch-up works had been carried out in the intervening years”, Mcdonnell says, “At the beginning of 2020 the ferry operator’s technical department asked Mark Specialist Applications and Resimac to complete a full refurbishment of the rudders on all 3 ferries”. This work was carried out at the Damen Yard in Dunkirk, France and was © Resimac

The thruster is one of vessel parts that are subject to heavy wear.

Deep pitting on the thruster’s metal surface.

N.33 - 2020 APRIL - ipcm® Protective Coatings

The thruster’s repair intervention.

FOCUS ON TECHNOLOGY

Intervention work on the rudder.

The Mark’s team at work on the seawater filter.

completed January to March of this year. All rudders were to be abrasive

blast cleaned and a new coat of 203 Super Ceramic coating had to be applied to all of the leading edges of the rudders. “Any minor surface damage was then repaired using Resimac 101 metal repair paste. This is an innovative high build solvent free metal repair composite, ideal for rebuilding and resurfacing damaged metallic surfaces with the capability of filling surface defects up to 25 mm in a single coat. The product can be machined within 2 hours of application allowing contractors to bring damaged surfaces back to the original manufacturer’s specifications. Any filled surface was then mechanically abraded to ensure the repair surface was as smooth as possible. Once all surfaces were cleaned, they were then coated with 2x coats of 203 SUPER FLOW at 300 microns wet film thickness. Super Flow is a liquid applied solvent free epoxy coating containing hardened ceramic particles. The coating is then left for 6 hours to cure. Once cured the coating creates a super smooth surface which improves flow efficiency and gives high performance abrasion and wear resistance”. The rudders were inspected by Mark Specialist Applications alongside the ferry operator’s technical team and Lloyds Register Surveyor. A scope of works was then planned for each vessel dry-dock.

The technical support by Resimac’s team during the operations on site.

Conclusion

fit in seamlessly, reducing pressure and stress on Chief Engineers and

One of the most appreciated characteristics by the customers in the

Superintendents. Very often, there will be hull painters, seals people,

Resimac and Mark S.A. partnership is the presence on-site of the coatings

welders etc., all wanting to get a job done in one area. We find it is better

manufacturer during the repair intervention.

to talk to each other and work together. We take “Safety First” stance and

“This gives our customers continual peace of mind”, Lewis concludes. “We

are Safecontractor approved.

talk with Matt on a regular basis and this strengthens our partnership,

Mark Specialist Application is ISO 9001 certified and work to QA Plans. All

thanks to which our team travels throughout the UK and overseas,

aspects of the project are monitored and recorded by a NACE certified

prevailing over local applicators. We fully understand the time constraints

coatings inspector. This leads to successful applications time after time, as

and demands of dry dockings and others working in the vicinity. We

in this case”. ‹

ipcm® Protective Coatings - 2020 APRIL - N.33

BRAND-NEW

New USDA Certified Biobased and Biodegradable Temporary Rust Preventive for Outdoor Protection Cortec® Corporation, a leading corrosion inhibitor manufacturer

Today, U.S. federal agencies and their contractors have to meet special

committed to using sustainable materials where possible, launches

biobased requirements when purchasing products from 139 categories

EcoLine 3690, a USDA Certified Biobased Product that can be used to

identified by the U.S. Department of Agriculture (USDA). One of these

replace solvent- and mineral-oil based (RPs).

is corrosion preventatives, which must have 53% minimum biobased

content to be a qualified product under the mandatory federal purchasing initiative of the USDA BioPreferred® Program1. Cortec® Corporation, a © Cortec Corporation

leading corrosion inhibitor manufacturer committed to using sustainable materials where possible, meets this need in the form of EcoLine® 3690, a USDA Certified Biobased Product that can be used to replace solvent- and mineral-oil based (RPs). EcoLine® 3690 is a ready to use canola-oil-based temporary coating designed for corrosion protection in severe marine and high humidity conditions. It contains 72% USDA certified biobased content and leaves behind an oily protective film that does not dry. It is an excellent solution for contractors who manufacture parts or equipment for the federal government and need to prevent rust in interim periods of storage or shipment. It is also good for any manufacturer around the world who wants to go to the next level of sustainability while reducing VOCs and minimizing worker exposure to mineral-oil or solvent-based RPs. EcoLine® 3690 can be easily removed with an alkaline cleaner and can help users avoid hazardous waste disposal costs associated with traditional rust preventatives. One particular tubing manufacturer who adopted EcoLine® 3690 for protection of newly manufactured tube ends was pleased with the corrosion protection results and safety benefits of EcoLine® 3690 for its employees. The temporary coating replaced a solvent-based rust preventative and impressed the manufacturer with its performance after a multi-month trial on tube bundles in outdoor storage. For best results, EcoLine® 3690 should be applied to clean metal surfaces by spray, roll, brush, or dip at a recommended WFT (wet film thickness) of 1.0-3.0 mils (25-75 μm). It can also be applied over painted surfaces. EcoLine® 3690 has no VOCs and is temperature stable up to 180 °F (82 °C). It protects multiple metal types: • Carbon Steel • Silver • Cast Iron • Stainless Steel • Copper • Magnesium • Aluminium. For further information: www.cortecvci.com

A tubing manufacturer adopted EcoLine® 3690 for protection of newly manufactured tube ends.

N.33 - 2020 APRIL - ipcm® Protective Coatings

For more information about the BioPreferred® Program: https://www.biopreferred.gov

BRAND-NEW

Talga’s New Graphene Coating Starts Large Scale Trial in the Maritime Industry Advanced battery anode materials and graphene additives provider

products as they commonly require factory conditions or liquid

Talga Resources Ltd announced the commencement of a new

dispersions to work. The application of the coating was successful in

large-scale commercial trial of its Talcoat™ graphene additive for

meeting all conditions and standards required for ships of this size,

maritime coatings. At the core of the Talcoat product is Talga’s new

confirming the potential of the Talcoat product as a ready-mix component

patent pending graphene functionalisation technology in the form of

for on-site incorporation by coating companies or paint applicators alike.

an on-site dispersible powder that can successfully add graphene’s

To further test the versatility and compatibility of the Talcoat additive,

exceptional strength into paint and coatings.

the trial used a commercial coating system from a world-leading coating supplier different to that used in the first trial.

Back in November 2019, Talga applied the graphene-enhanced coating

The ocean-going cargo vessel, of similar size to the initial container ship

to a 33,000t container ship . Supported by the same ship owner, Talga

being approximately 225m long and weighing 33,000 tonnes, has

has provided its next generation graphene additive to enhance a primer

re-entered service at sea where over the next 12-18 months the test

coating successfully applied over a sizeable area of a second large

area will be evaluated on the performance boost delivered to the

container ship.

coating system.

Unlike the first trial, the Talcoat product and the 2-part epoxy based

“We continue taking graphene out of the lab and into the real world with

commercial coating system were supplied separately and mixed on-site

these large-scale coating trials underway on cargo ships. This application

by the paint applicators before spray application to the vessel during dry

joins the other large-scale clean technology product verticals we have

docking.

been developing for several years such as graphene enhanced concrete,

This is a significant commercial development for graphene-based

plastics and packaging products”, said Talga Managing Director,

Mr. Mark Thompson. See the article “Global First as Talga Graphene Coating Begins Commercial-Scale Trial on Ocean-Going Cargo Vessel” at pages 24-27.

For further information: www.talgagroup.com

Commencement of Talcoat™ - enhanced primer being applied to M/V Arica.

ipcm® Protective Coatings - 2020 APRIL - N.33

INNOVATIONS: PRESENT&FUTURE

Results: Anti-Corrosion Additives for Ferrous Metals Ella Newington Hexigone Inhibitors Ltd - Baglan, United Kingdom

marketing@hexigone.com

Hexigone embarked on the challenge of finding a chrome-free solution.

and 5% sodium chloride (ASTM B117 1000 hours), the results show

The team moved their research away from mainstream thinking and

Intell-ion containing primers protect on shot blasted steel significantly

explored smart-release vehicles that can hold onto chemicals that were

better than the inhibitor which has been used for the last 25 years.

previously incompatible with coatings. The result? A safer, smarter way

Patrick Dodds, CEO and Founder at Hexigone said: “It’s amazing to see

to protect against corrosion.

these sorts of results in a downstream incorporation method. Our

inhibitor has been proven to work in a variety of different coatings arlier in the year, trials with a $700m T/O industrial coating

systems, and we look forward to exploring the results further with our

manufacturer demonstrated Hexigone’s product was up to ten

global partners in the coil coated steel industry.”

times more effective than the market-leading corrosion inhibitor on

Intell-ion replaces toxic chromate for ‘chemically intelligent’ additives,

non-ferrous metals. The product has been tested on ferrous metals

offering a completely unique approach to tackling corrosion via three

by adding Hexigone’s anti-corrosion additive (AX1) into a selection of

modes of electrochemical protection. The technology protects by

control samples – with fantastic results.

using ‘smart’ micro reservoirs that make the coatings responsive to the

The corrosion inhibitor was added to ‘off the shelf’ organic primers from

environment, triggering the release of the inhibitor ‘on demand.’

three leading industrial primer manufacturers, with no reformulation.

Over 50 coatings companies are already formulating with Hexigone’s

Following 42 days of accelerated weathering, with constant 100% spray

N.33 - 2020 APRIL - ipcm® Protective Coatings

technology to protect end-products for longer. ‹

INNOVATIONS: PRESENT&FUTURE

Results from the addition of Hexigone’s corrosion inhibitor (5% AX1) to three leading primer manufacturers’ ‘off the shelf’ products

ipcm® Protective Coatings - 2020 APRIL - N.33

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SAL O M O NI

SUSTAINABILITY

Five on Five Interview: Sustainability According to the Industry Players Series 2 - Part I

MAR

ack in January 2019, to officially kick-start the Sustainability section in

our magazines, we asked five key players of the industry if they were

willing to answer 15 questions on the role of sustainability, its challenges

and the different approaches to the practice. The result was an inspiring, in-depth interview on some of the Best Practices of Sustainability in the surface treatment sector.

TA N

BLA

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Back then we also promised we would do a series of interviews, involving

other companies as well. Today we deliver on our commitment. After a brief hiatus, here we present the second instalment of the 5 on 5 Interview on Sustainability, which questions have been answered once again by five different companies that play a key role within our industry and that are at the forefront of the journey towards a greener and healthier environment for everyone. We are under no illusion: this journey is long and full of challenges, and we are running out of time. According to a 700-pages report1 by the

C E CIL

Intergovernmental Panel on Climate Change (IPCC) – the United Nations

body for assessing the science related to climate change – the impacts of

global warming of 1.5 degrees Celsius will lead to unprecedented changes:

from rising sea levels to more devastating droughts to more damaging storms. Pooling together more than 6,000 scientific publications, drawing contributions from 133 authors, and having more than 1,000 scientists review the findings, the IPCC report concluded that we have less than 12

REZ

years to make massive and unprecedented changes to the global energy

infrastructure to limit global warming to moderate levels. We are glad to see that companies in our sector are not only acknowledging the issue but they are also putting words into action, by proving that being sustainable not only is possible but it can also provide for a great business value. We would like to thank AkzoNobel, BASF’s Coatings Division, Evonik, Perstorp and PPG for their commitment to participate to this interview and we hope it will make for an interesting, thought-provoking reading once again.

SUSTAINABILITY

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N.33 - 2020 APRIL - ipcm® Protective Coatings

”Global Warming of 1.5 ºC” – https://www.ipcc.ch/sr15/

SUSTAINABILITY

For this third instalment we once again had the sincere pleasure of working with the following industry leaders: Claudia Salomoni – AkzoNobel Coatings SpA Specification Sales & Marketing Coordinator Marco Benen – BASF’s Coatings Division Sustainability Officer Gaetano Blanda – Evonik Senior Vice President and General Manager Coating Additives and Stefan Silber – Evonik Senior Vice President Innovation Management Coating Additives Cecilia Svensson – Perstorp Holding AB EVP Communications & Sustainability Pedro Perez Vintaned – PPG EHS Director EMEA

1. How does your company define sustainability today?

Another level is how we work with our products and how they are produced; LCAs, compliance and to build in sustainability as a default when we innovate. The ultimate level is our ambition to become Finite

Claudia Salomoni, AkzoNobel – AkzoNobel firm believes that

Material Neutral, a bold ambition that means switching to alternative

sustainability is business, and business is sustainability. When people ask

resources that are abundant and/or renewable, or to close the loops in

us, what sustainability means to AkzoNobel, we tell them that our success

order to recycle those that are finite.

depends on it, as Powder Coatings inner force is to be eco-friendlier than any other coating in the world. We know only too well

Pedro Perez Vintaned, PPG - The way we define sustainability at

that our future hinges on our ability to do radically more while using less:

PPG is through our commitment to transparent reporting on our

• More innovative to less traditional solutions

environmental, economic and social performance as a company. This

• More renewable energy and materials

is designed to cover all our areas of business, our employees, our

• Less fossil-based

customers, and the communities in which we operate. Not only does

• More value chain focus and less introverted thinking.

this allow us to be transparent, but it informs our guiding approach to sustainability today. PPG’s efforts in sustainability over the last year

Marco Benen, BASF - Our understanding of sustainability at BASF’s

alone drove more than USD $6.5 million in total cost savings and

Coatings division is based on the three pillars of environment, economy

offered additional growth opportunities. We consider sustainability a key

and society. Acting responsibly in all of these areas ensures our

foundation of our success.

success. We also take the whole value chain into consideration. From sourcing responsibly and a safe and efficient production to products and processes that help our customers to save resources. A holistic approach is key.

2. What have been the biggest issues encountered in bringing theory into practice?

Gaetano Blanda, Evonik - Sustainability is part of our corporate

Claudia Salomoni, AkzoNobel - In coatings in general, most of

thinking and action, and it is firmly embedded in Evonik’s DNA.

the raw materials implied in the formulation come from petroleum

We provide innovative solutions that help to make our lives more

synthesis products. Thanks to a continued rationalization of products

sustainable, healthier, and more comfortable.

and suppliers on a regular control of the derivation (extraction and processing) of the raw materials, is possible to limit the carbon footprint.

Cecilia Svensson, Perstorp – Sustainability is about pretty much

Furthermore, we constantly check our production plants and processes

everything we do, in our production, our products and our way of

to reduce the energy consumption per kilo.

working. We also consider sustainability on several different levels. A lot of work is about the basics; developing the way we work with

Marco Benen, BASF - Products which looks at first glance “green” are

health & safety, leadership, supplier management, compliance etc.

not per se more sustainable. You need to consider all factors and the

ipcm® Protective Coatings - 2020 APRIL - N.33

SUSTAINABILITY

whole life cycle. Therefore, making the benefits measurable and tangible

are developing fast, and some solutions might be groundbreaking,

is crucial. Our actions should have a provable impact. Customers,

others not.

for example, often ask what is in it for them, when they can choose between a traditional and a more sustainable product, which might be

Pedro Perez Vintaned, PPG - I would call them challenges more than

more expensive. Having reliable and comprehensible data can be an

anything else. We are trying to be at the front of the market where

important selling point.

sustainable solutions are increasingly important. The main challenge in this is to continuously encourage our employees and the company to

Gaetano Blanda, Evonik - For Evonik as a specialty chemicals company,

look into environmentally friendly developments. This also presents a

safety has always been top priority. We learned that in this respect –

challenge in how we can become better about bringing innovation into

apart from technical aspects – human behaviour is crucial. We therefore

the company and the ways we demonstrate that to our customers. We

launched a comprehensive “safety@Evonik” culture initiative several

are always striving to put strategic programmes in place that allow us to

years ago. Today, Evonik has a good safety track record.

become more environmentally friendly.

Cecilia Svensson, Perstorp - We have had a fantastic response, both internally and with customers, after launching our Finite Material Neutral ambition which, of course, carries a lot of promise and responsibility.

3. What do you see as the key drivers of sustainability in industry today?

I would say the biggest issue today is to navigate the landscape of alternative routes to raw materials. Some solutions require big

Claudia Salomoni, AkzoNobel - Working with customers and suppliers

investments and what if you invest heavily in something that, all of a

to develop leading solutions that do more with fewer resources. It

sudden, proves to be yesterday’s solution? The technical opportunities

also means continuously improving ourselves. Thanks to this ongoing commitment, we are widely acknowledged as a leader in our industry,

N.33 - 2020 APRIL - ipcm® Protective Coatings

SUSTAINABILITY Moreover, sustainability aspects are gaining significance on the capital markets. Financial analysts and investors base investment decisions more and more on the sustainability performance of companies. To them, extra-financial performance indicators are valuable pieces of information assessing the risk of exposure or future market opportunities of a company. Last but not least, global initiatives such as the UN Sustainable Development Goals as well as stricter regulatory requirements triggered, for example, by the European Union are drivers for sustainability. Cecilia Svensson, Perstorp – The indisputable no. 1 driver is to find ways to lower the carbon footprint. Other important drivers are ways to get resource efficiency across global value chains and the implementation of circularity principles. Pedro Perez Vintaned, PPG - Without a doubt, environmental aspects are the key drivers of sustainability within our industry today. This is an area in which we are striving to innovate. In all our company forums it has become quite clear that we need to make better use of energy sources. We are also trying to minimise waste throughout our operations. We are focusing on these things because we are trying to more responsibly use our most important and precious natural resources. One recent example of this is the waste mapping exercise that our Environmental Department at PPG Architectural CoatingsUK conducted last year, as part of our reduce, reuse and recycle campaign at two of our UK sites. The team held a workshop on reducing changeover waste left in the manufacturing tanks at the end of a batch. The brainstorm brought about an idea for a new method of tank scraping that has resulted in more than 100 tonnes of paint being saved from entering the waste system in a year. Whilst in our Birstall facility a

reflected by our performance in many of the world’s most prestigious

new reclamation plant and recycling process has allowed PPG to reduce

sustainability rankings, in addition to the DJSI. For example, we are also

our waste intensity by 10 percent since 2016.

listed on leading sustainability indexes such as the Carbon Disclosure

These initiatives also have a positive financial element to them – the

Project, Sustainalytics, FTSE4Good, EcoVadis and Corporate Knights.

more effective we become in our processes the more likely we are to

While it is an honour to be recognized, we will not stop improving. We

use less energy and generate less waste. Ultimately that financial benefit

will continue to take our industry forward and ensure Powder Coatings

is where we prove how well we’re doing on our sustainability initiatives.

provide many sustainability benefits compared to other coatings. Marco Benen, BASF - Three things come to mind: Firstly, we aim to minimize the usage of critical substances in our products. Secondly, we

4. What business value have you seen?

make sure to source responsibly, which means we pay close attention to good working conditions for the whole value chain. Thirdly, eco-efficient solutions combine ecological and economic benefits.

Claudia Salomoni, AkzoNobel - Working with customers and

Shortened processes like our Integrated Process II for example save up

suppliers opens infinite possibilities in a finite world and means finding

to 20 % CO2 as well as energy costs for the customer.

opportunities where there does not appear to be any!

Stefan Silber, Evonik - First of all, we see a rising demand from our

Marco Benen, BASF – Our refinish products that are certified with

customers and their customers for products that demonstrate a good

BASF’s biomass balance approach are a successful example for a

balance of economic, ecological, and social factors. Sustainability is

sustainable product, that convinces our customers. The paint shops can

becoming an increasingly important factor in purchasing decisions.

promote these more sustainable solutions directly to their customers,

ipcm® Protective Coatings - 2020 APRIL - N.33

SUSTAINABILITY

who then decide whether they want to use a product that helps to

the value chain. Long term is about the survival of our industry = 100%

reduce fossil resources in the production process. Our customers

business value.

appreciate an opportunity to position themselves as environmentally conscious.

Pedro Perez Vintaned, PPG - Some of the opportunities in which we have been successful have been because we developed products

Gaetano Blanda, Evonik - Evonik has defined four growth engines

that are more environmentally friendly. For example, we developed a

in its portfolio with a clear focus on sustainability: Specialty Additives,

clear coat called the UHS Fast ClearCoat, which is a coating that dries

Animal Nutrition, Smart Materials and Health & Care. Businesses aligned

quicker and emits lower volatile organic compounds. This allows for

to these growth engines (such as silica and silanes for the “green” tire,

faster applications which provide benefits to the safety of our customers

additives for eco-friendly coatings, or probiotics for animal nutrition)

and the environment and has provided for greater efficiencies for our

show above-average growth rates and play an important role in

customers’ processes. This has brought value to our business from

achieving our sales and earnings targets.

the customers we’ve gained because of the sustainable benefits our products provide to them.

Cecilia Svensson, Perstorp - I think you have to see business value both in the short and long term. One example of short-term business value is the evolution of several of our customer relationships based

5. How do you compare to the competition?

on our portfolio of Pro-Environment (renewable) products. We now interact directly with more functions, such as sustainability and business

Claudia Salomoni, AkzoNobel - We use independent ratings such

development, which builds an increasing degree of partnership along

as the DJSI as a benchmark. It gives us objective insights into our

N.33 - 2020 APRIL - ipcm® Protective Coatings

SUSTAINABILITY

performance and enables us to assess ourselves against the best of the competition. Thousands of companies are assessed each year and we are proud to be among the leaders for the 13th consecutive year. It is a recognition of the long-term value we create for all our stakeholders, while our consistently strong performance is a clear signal that we are always looking to improve. There is no room for complacency, however, so we are looking beyond rankings, because we are on a journey which requires us to look further and climb higher. In particular, we have adopted a sharper and more deliberate focus on the resource productivity of our operations, and on innovation to drive value selling. With resource productivity, we are creating a culture of care for all materials used, while eliminating waste. With value selling, we drive sales and growth through product portfolios designed to bring tangible benefits and deliver a positive social and environmental impact. Marco Benen, BASF – We do have a strong position in eco-efficient products and shortened processes. With the biomass balance approach, we even are a first mover. BASF’s Verbund concept allows us to replace fossil resources with renewables such as bio-naphtha right at the beginning of the chemical production process. That way, we can produce products with the same performance and quality but without using fossil resources. Stefan Silber, Evonik – Regarding sustainability, Evonik is well positioned. The latest milestone is our new sustainability strategy 2020+ endorsed by the executive board at the beginning of this year. Today, Evonik generates already around half of its sales with products for resource-efficient applications. More than 80 percent of the Group’s sales make a positive contribution to achieving the UN SDGs. Our businesses combine sustainability, innovative capability and efficiency to develop innovative products that enable our customers to meet the corresponding high requirements of the end markets. And the pipeline is well-filled thanks to our market-oriented R&D. Cecilia Svensson, Perstorp - I would not like to compare ourselves with other companies in this area. We are all moving forward with the ambition to become more sustainable, but the routes are slightly different. Ultimately, I think we have to collaborate more across value chains in order make an impact. Also, cyclicality will require a lot more collaboration within our industry. Pedro Perez Vintaned, PPG – Our goal is to always be out at the front lines with our competitors. While we always seek to compare our competitor matrix, we recognise that we often vary by definition and it can be like trying to compare apples to oranges. We believe that we’re still just as well placed as the rest to provide our customers with a

competitive advantage.

ipcm® Protective Coatings - 2020 APRIL - N.33

The launch of Solar Orbiter occurred on 10 February 2020 on an Atlas V 411 rocket from Cape Canaveral, Florida.

Solar Orbiter Reaches for The Sun Protected by SolarBlack Skin The Airbus built Sun explorer spacecraft Solar Orbiter was successfully

destructive discharge to the craft.

launched from Cape Canaveral, Florida on 10th February 2020.

SolarBlack is a CoBlast Skin of black calcium phosphate, which has been applied to the outermost titanium sheet of Solar Orbiter’s multi-layered

Solar Orbiter spacecraft will study the Sun at unprecedented close

heatshield. It has been deployed via ENBIO’s CoBlast process, which

proximity – approximately 42 million kilometers, which is a quarter the

replaces, in one process step, a metal’s natural oxide surface layer

distance from the star to Earth. Such an extreme temperature and

with a desired functional Skin – in this case SolarBlack. What makes

radiation environment, required the Agency to seek and qualify suitable

CoBlast unique is the direct bond produced between the desired Skin

next-generation thermal protection systems for the craft’s 3.1m x 2.4m

and the underlying metal, without a troublesome oxide layer, providing

main heatshield.

the durability and adhesion required for skin integrity under such

To provide such a system, ENBIO has been collaborating with ESA and

extreme conditions. CoBlast is also an environmentally friendly process,

Airbus Defence & Space since 2011, to develop a novel protective

requiring no chemical, vacuum or thermal inputs. SolarBlack has been

CoBlast Skin, called SolarBlack. It is critical that the Skin maintains its

qualified to meet the demands of this mission and is being specified on

thermo-optical properties, despite years of exposure to extreme

an increasingly wide variety of additional applications including sensor

infra-red and ultraviolet radiation, whilst not shedding material or

internals and heatshields.

outgassing vapour, which would risk contaminating Solar Orbiter’s highly sensitive instruments. Additionally, the Skin needs to be conductive to avoid the build-up of static charge which might threaten a disruptive or

N.33 - 2020 APRIL - ipcm® Protective Coatings

For further information: http://enbio.eu/coblast/

BRAND-NEW

New Nano-Barrier Could Strengthen Spacecraft Payloads Airbus and the University of Surrey, England, have developed a

considerable costs and problems associated with using CFRPs in space

robust multilayer nano-barrier for ultra-lightweight and stable

missions,” says Professor Silva.

carbon fibre reinforced polymers. It could be used to build

Christian Wilhelmi, Head of Mechanical Subsystems and Research and

instruments for future space missions.

Technology at Airbus in Friedrichshafen, is equally positive: “The new nano-barrier, together with our ultra-high-modulus CFRP manufacturing

Airbus has been using carbon fibre reinforced polymers (CFRPs) on its

capability, will enable us to create the next generation

spacecraft and instrument structures for many years. Good examples

of non-outgassing CFRP materials, with much more dimensional

are the two GRACE FO satellites that are tracking movement of liquid

stability. Reaching this milestone gives us the confidence to look at

water, ice and land masses due to climate change, and BepiColombo

instrument-scale manufacturing to fully prove the technology.”

which will explore Mercury. On those type of missions CFRPs offer many

In future, the coating could offer significant benefits in other areas of

advantages; in particular a high strength to weight ratio.

Airbus’ business too. For example, increase of wear resistance, barrier

But applications are limited because the material absorbs moisture,

properties for many kinds of substances, protection from atomic

often released as gas during a mission. This affects the dimensional

oxygen erosion in Low Earth Orbit, adjustments of thermo-optical

stability and alignment of optical payload structures. Engineers can try

properties and more.

to minimise this problem by performing long, expensive procedures

“Years of cooperation with the University of Surrey, painstaking work

such as drying, recalibrations and bake-out – all of which may not

and collaboration with customers like ESA and DLR have rewarded us

completely resolve the issue.

with a leading-edge technology, with at least one order of magnitude

Now, scientists and engineers from Airbus and the University of Surrey

better performance than any other existing solution,” says

have found a solution: a multi-layered nano-barrier that bonds with

Paolo Bianco, R&T Cooperation Manager. “I’m delighted to see yet

the CFRP and eliminates the need for multiple bake-out stages and the

another R&T cooperation resulting in recognised, concrete technology

controlled storage required in its unprotected state.

that will soon fly.”

Professor Ravi Silva, Director of the Advanced Technology Institute

The new nano barrier could be used for upcoming earth, navigation

at the University of Surrey, is confident that the newly developed

and science programmes such as Copernicus Extension, Earth Explorer

reinforced composite is a “significant improvement over similar

and Science Cosmic Vision.

methods and materials already on the market.” In a paper published by

For further information:

www.airbus.com

scientific journal Nature Materials, the engineers showed that their thin barrier – measuring only sub-micrometres in thickness, compared to the tens of micrometres of current space mission coatings – is less susceptible to stress and contamination at the surface, keeping its integrity even after multiple thermal cycles. “These encouraging results suggest that our barrier could eliminate the

From left: Prof. Ravi Silva, Director of the Advanced Technology Institute at University of Surrey; Michal Delkowski, Development Engineer and Project Technical Lead at Airbus Friedrichshafen; Dr. Jose Anguita, Dr. Christopher Smith and James Hodges from the University of Surrey.

ipcm® Protective Coatings - 2020 APRIL - N.33

TRADE FAIRS & CONFERENCES

MP : MEDIA PARTNERSHIP - ipcm _Protective Coatings is present with own booth or press corner ®

: SPECIALIZED EVENT FOR SURFACE TREATMENTS INDUSTRY

MAY 2020 aistech

May 4-7, 2020

iron and steel technology August 31 September 3, 2020

www.aist.org/conference-expositions/aistech

offshore technology conference

Houston, USA

offshore technology

May 4-7, 2020

http://2020.otcnet.org

western states corrosion seminar

Pomona, USA

corrosion prevention and control

May 5-7, 2020

www.westernstatescorrosion.org

flowexpo

intercorr

canada gas & LNG

europort romania

infrarail

maritime industry

danish maritime fair

Cleveland, USA

N.33 - 2020 APRIL - ipcm® Protective Coatings

Guangzhou, China May 10-12, 2020

valve, pipe and fittings August 8-10, 2020

São Paulo, Brazil May 10-14, 2020

corrosion protection December 15-18, 2020

Vancouver, Canada

www.canadagaslng.com shipping, shipbuilding, port equipment

Constanța, Romania

www.europort.nl/about-europort/ europort-exports

May 12-14, 2020

London, UK

railway infrastructures www.infrarail.com

May 12-14, 2020

Gorinchem, Netherlands

Copenhagen, Denmark May 13-14, 2020

http://icc-congress2020.com.br

gas & liquefied natural gas industry

May 12-14, 2020

www.flowexpo.org

maritime industry October 13-15, 2020

www.maritime-industry.nl

maritime industry www.danishmaritimefair.dk

TRADE FAIRS & CONFERENCES

oil & gas uzbekistan

inland marine expo

Tashkent, Uzbekistan May 13-15, 2020

oil&gas industry August 18-20, 2020

marine transportation industry

St. Louis, USA May 18-20, 2020

http://oilgas.uz

September 29 October 1, 2020

https://inlandmarineexpo.com

JUNE 2020 caspian oil & gas

flowtech china

wampex

global petroleum show

metallurgy russia

seawork petrochemical supply chain & logistics metal & metallurgy china

pumps & valves asia

Baku, Azerbaijan

oil&gas industry

June 2-4, 2020

https://caspianoilgas.az

Shanghai,China

pumps, valves and pipes

June 3-5, 2020

August 25-27, 2020

http://expo.flowtechsh.com

Accra, Ghana

mining & power industry

June 3-5, 2020

www.wampexghana.com

Calgary, Canada

oil&gas industry

June 9-11, 2020

https://globalpetroleumshow.com

Moscow, Russia

metallurgical technology, processes and metal products

June 9-11, 2020

www.metallurgy-russia.com

Southampton, UK June 9-11, 2020

marine industry to a later date

petrochemical industry

Houston, USA

www.petchem-update.com/ petrochemical-supplychain

June 10-11, 2020

Guangzhou, China

foundry, forging, metallurgical equipment www.julang.com.cn

June 11-13, 2020

Bangkok, Thailand June 11-13, 2020

www.seawork.com

pumps and valves September 16-18, 2020

www.pumpsandvalves-asia.com

ipcmÂŽ Protective Coatings - 2020 APRIL - N.33

ZOOM ON EVENTS

Stocexpo Thanks Industry Post-2020 Show The team at StocExpo want to thank the bulk liquid storage industry

the bulk liquid storage sector is. We are extremely grateful to all our

after the show went ahead on 10-12 March.

exhibiting companies, visitors and conference delegates who attended despite the situation, and we are pleased to hear that many good

“We would like to offer our heartfelt thanks to the industry for

conversations took place.

supporting StocExpo 2020 in very difficult circumstances. In the

We’re now working to connect all registered attendees further with our

immediate run up to the show, the coronavirus was still in the

long list of leading exhibitors either through online platforms or other

containment phase in the Netherlands and most other European

media. We will be announcing a supplementary event to connect the

Countries, and during this time, the government authorities continued

industry later in the year.

to tell venues and organisers to run events.

Over the next few months, we will continue to work to support the

We anticipated that the situation would likely disrupt the show but

industry however we can and help ensure we all weather the storm.

since many exhibitors had freight in transit, flights and hotels booked,

And of course, we look forward to working with all stakeholders to

we had to go with government advice at that time. Also, we were still

deliver a successful StocExpo 2021”.

receiving live registrations from terminals and oil majors, despite various travel bans being in place, so we remained vigilant whilst open for business. It’s times like these that we are reminded what a resilient industry

The StocExpo Team For further information: www.stocexpo.com

N.33 - 2020 APRIL - ipcm® Protective Coatings

ZOOM ON EVENTS

Infrarail to be Postponed to May 2021 13th International Railway Infrastructure Exhibition to be co-located

customer value for everyone attending Infrarail by delivering a

with Railtex 2021 at NEC in Birmingham.

high-quality exhibition in 2021. We believe the decision to co-locate Infrarail with next year’s Railtex exhibition with the help and support

Mack Brooks Exhibitions has today announced the postponement of

of our partners will allow us to maximize the potential of both events,

Infrarail, the UK’s leading showcase of railway infrastructure technology

uniting the whole rail industry”, concluded Nicola Hamann.

and expertise. The 13th edition of the event, which was planned to

Mack Brooks Exhibitions as the organiser of Infrarail, trusts that the

take place at London Olympia from 12 to 14 May 2020, is postponed

decision to postpone the show to next year will enable Infrarail to

following the escalation of COVID-19 in Europe. The exhibition will now

continue to serve the rail industry as the leading showcase for every

be co-located and take place alongside Railtex 2021, the UK’s premier

aspect of railway infrastructure technology and expertise in the secure

exhibition of railway equipment, systems and services, taking place at

and safe conditions needed. The Infrarail Team will communicate

the NEC in Birmingham from 11 – 13 May 2021.

closely with customers and partners over the coming weeks and

Speaking about the announcement, Nicola Hamann, Managing

thanks their exhibitors, partners, suppliers and visitors for their

Director of Mack Brooks Exhibitions, said: “The health and safety of

support during this challenging time.

our exhibitors, visitors and staff is our number one priority. After many weeks closely monitoring the evolving situation around COVID-19 and

For further information:

www.infrarail.com

the notices issued by the World Health Organisation as well as Public Health England, the UK Government, the local authorities in London and in close coordination with all partners involved, we have decided to postpone the exhibition.” “This is not a decision we have taken lightly; our customers, partners and the Infrarail Team worked incredibly hard on this event. While it is disappointing to postpone, it is imperative that we prioritise the health and safety of everyone involved. Our goal remains to provide the best

ipcm® Protective Coatings - 2020 APRIL - N.33

Protective Coatings ®

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