ipcm_Protective Coatings n. 41 - April 2022

ISSN 2282-1767

Protective Coatings ®

THE MAGAZINE ABOUT CORROSION CONTROL AND PREVENTION TECHNOLOGIES

ipcm_PC digital on www.myipcm.com

2022 - 11th Year | Quarterly - N.41 April

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in this issue 01 EDITOR’S LETTER

© Iberdrola

20

02 BRAND NEW 12 SUCCESS STORIES Black Paints Save Birds

12

14 FOCUS ON TECHNOLOGY

24

A Winning Choice: Pinturas Marcelino González Focused on Powder Coating Quality and Durability for Large Workpieces

20 FOCUS ON TECHNOLOGY

The Importance of “Zero Shot” Blasting Operations to Allow Sheets to be Handled Correctly through an Overhead Crane with a Magnetic Lifter

© SAMES KREMLIN

34

© Belzona

© Cortec

38

24 SUCCESS STORIES

The Application of Hydrophobic Epoxy Coatings to Pumping Systems Allows to Save in Energy Consumption

36

© Adobe Stock

28 SUCCESS STORIES

Achieving CFB Boiler Maintenance Goals

30 BRAND NEW 34 HIGHLIGHT OF THE MONTH

Innovative Solutions for the On-site Application of Anti-corrosion Paints

36 SUCCESS STORIES

Unstoppable Multi-Metal Corrosion Protection Even in Aggressive Outdoor Conditions

38 INSPECTION LOGBOOK

Coating Inspections - Inspection of Steel Surface Preparation, Part 6

42 THE MARKETING CORNER Digital Marketing Trends 2022: Everything There is to Know

48 ZOOM ON EVENTS

© ITF

Get you r ticket now!

World´s Leading Trade Fair for Industrial Coating Technology 26 – 29 April 2022 Exhibition Centre Karlsruhe, Germany

www.paintexpo.com In cooperation with:

AN EVENT BY LEIPZIGER MESSE

EDITOR’S LETTER

A

s the war in Ukraine escalates and energy costs skyrocket, it is imperative to diversify energy sources with the aim of increasing the share of energy produced from renewable sources.

The International Energy Agency has drawn up a ten-point plan to reduce the EU’s dependence on Russia within a year. This identifies three options for energy production, not all of which are equally environmentally sustainable: speeding up solar and wind power production, returning to coal and oil production, and boosting (or going back to, as is the case of Italy and twelve other EU countries that had given it up) nuclear power.

Certainly, energy transition to renewable sources is the most far-sighted and environmentally conscientious choice. The Mediterranean’s first offshore wind farm will be inaugurated in Taranto (Italy) on Thursday, 21 April. However, it is a long road, which is not going to produce effects in the short to medium term.

In the immediate future, the most feasible measure to cope with the emergency is negotiating an increase in gas supplies from African countries such as Algeria, Mozambique, Congo, and Angola. However, these countries’ political instability as well as growing domestic demand for energy (they are all developing economies) could lead to supply paralysis. Not to mention a third critical factor: the infrastructure deficit in these areas.

The construction of transport and refining infrastructure for energy resources is of strategic importance for states with resource-intensive economies that, at the same time, propose themselves as new European energy partners. A recent and particularly significant example is exactly Mozambique, where the discovery of offshore oil and gas fields is accompanied by major public and private infrastructure investment1.

Both routes to diversification of energy sources and energy supply partners, therefore, require investment in new infrastructure, as well as maintenance and upgrading of existing infrastructure, namely not only gas and oil pipelines, but also regasifiers, floating storage and regasification units, wind farms, and photovoltaic plants.

Endless opportunities for development and growth open up for the corrosion protection sector. Protecting such infrastructure against weather conditions will be the task of our industry in the years to come and coating manufacturers will also be able to champion these investments, as is already the case in other fields (PPG, which provides thermal, fire, and corrosion protection systems for electric vehicle batteries, is helping accelerate the shift to electric vehicles2).

In order to keep up to date with all the latest technologies and innovations in corrosion protection, prevention, and mitigation, the coming months will offer a high number of international trade fairs. It starts at the end of April with PaintExpo 2022, where you will also find this magazine issue, and it continues in May with OTC in Houston (USA), Pipeline Coating in Vienna (Austria), StocExpo in Rotterdam (The Netherlands), IVS in Bergamo (Italy), and Pipeline & gas Expo in Piacenza (Italy). The topics of energy transport and refining will be central for all these events, with a special focus on the coatings available for their corrosion protection. ipcm®_Protective Coatings will be your guide and travelling companion at all these trade fairs!

Alessia Venturi

1

https://www.ispionline.it/it/pubblicazione/africa-la-grande-partita-delle-infrastrutture-24560

Editor-in-chief

2

https://www.startmag.it/energia/cop26-ecco-sfide-e-opportunita/

ipcm® Protective Coatings - 2022 APRIL - N. 41

01

BRAND-NEW © AGM

AGM Expands its Range of Graphene-Enhanced Anti-Corrosion Paints AGM has launched its own range of graphene-enhanced anti-corrosion paints alongside another high-performance non-metal additive.

A

pplied Graphene Materials (AGM) has introduced two new product

hybrid range, which is free of metals and VOC, maximizes synergies

developments in quick succession, continuing to demonstrate its

between complementary systems to offer the paint and coatings industry

commitment to innovation.

excellent corrosion protection. The new graphene additives are based

Following exceptional results achieved through extensive internal

on the company’s established Genable technology, which improves

research and testing, AGM has launched a range of industrial anti-

performance such as chemical resistance, barrier properties and anti-

corrosion paints incorporating its own Genable graphene additives. The

corrosion properties.

two epoxy-based prototype primer systems represent an easy way for

Genable 3100 and Genable 3105 are optimized formulation-ready

those considering the adoption of graphene to quickly test and evaluate

dispersions that are easy to formulate, safe to incorporate and stabilized

its potential benefits.

in a standard epoxy resin; Genable 3120 offers a more sustainable option

The Genable Epoxy primer is a C3-classified hybrid product that contains

in an environmentally friendly bio-based epoxy resin to increase anti-

graphene and a zinc phosphate additive to allow the end user to benefit

corrosion performance while contributing to environmental goals.

from the synergies offered by both systems in standard applications,

Adrian Potts, Chief Executive Officer for AGM, said: “We are pleased to be

such as urban and industrial environments. The Genable CX primer is

able to launch these new Genable products, which we anticipate will help

a high-performance hybrid system based on graphene and aluminium

further accelerate the adoption of graphene nanoplatelet technology in

chemistries which allows to protect surfaces against corrosion even in

the industry. Our technology development programmes have focused

harsh environments, such as offshore and marine applications.

on extensive testing and evaluation for a range of applications, and this

Additionally, AGM has also introduced a range of non-metal, active anti-

experience is valuable to guide customers in the use of our products.”

corrosion graphene to extend its Genable 3000 dispersion series. Using a combination of graphene with traditional sacrificial additives, the new

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For further information: www.appliedgraphenematerials.com

BRAND-NEW

A New Cooperation Event on Corrosion Protection with Zinc Flake Systems The second cooperation event with practical presentations on corrosion protection with zinc flake systems will take place on May 17-18 in Markdorf (Germany).

O

n May 17th and 18th, 2022, the cooperation event “Corrosion

• Manual coating: the easiest way of application - Stefan Baum (Wagner)

protection with zinc flake systems in the spraying process” will take

Full and partial automation of coating systems – Lars Hayen (Sidasa)

place in the Wagner’s headquarters in Markdorf on Lake Constance

• Surface preparation by shot blasting - Christian Hoffmann (Vulkan Inox)

(Germany). After a successful first cooperation event in 2021, the

• Edge sharp application of rotationally symmetrical parts - Alexander

companies coatmaster, Dörken, Fanuc, Sidasa, Vulkan Inox and Wagner

Vonbach, Michael Hense, Matthias Mandal (Wagner)

have joined forces again and organized a joint event. As in the previous

• Zinc flake systems as solution for various applications - Markus Nowak

year, the latest developments as well as current knowledge and trends

(Dörken Coatings)

in the field of spray application will be presented and discussed during

• Efficient rack coating with robots - Christian Eising (Wagner)

this meeting. What is special about this is that thanks to the cooperation

• Industrial robots of today: intuitive and easy to program - Marc

between the companies, participants will gain insights into different points

Wischnewski (Fanuc).

in the process and value chain - practically and individually. Here they can

Another highlight is the joint evening event on the first day, which will

benefit from the combined know-how of the experts.

offer plenty of opportunities to network and exchange ideas. The event is

The topics of the practical presentations are:

limited to 32 participants and the registration is available until May 2nd.

• Corrosion protection with in-process coating thickness measurement Andor Bariska (coatmaster)

For further information: https://bit.ly/3Jp9izb

BRAND-NEW

© AGTOS

AGTOS Has Confirmed Its Participation at EUROGUSS At the trade fair EUROGUSS, AGTOS will present the latest developments in shot blasting technology.

A

GTOS has recently announced that it will take part in the next

The company will present its latest innovations and provide visitors with

edition of EUROGUSS, the trade fair dedicated to die casting that

useful insights on how to increase the power of existing shot blasting

will take place from 08 to 10 June 2022 in Nuremberg (Germany), to

machines, so that turbines specially designed for this purpose work

present its latest innovations in the shot blasting technology field.

more gently and the abrasive consumption is reduced. In addition, it will

The requests for the surface treatment of complex cast workpieces

also showcase the new AGTOS Service APP, via which service technicians

made from aluminium or magnesium are becoming more and more

can provide instruction in the case of maintenance and repair work and

sophisticated, so the reproducibility of the shot blasting process for

share supplementary documents such as drawings, illustrations and

mass-produced parts is extremely important.

photos.

AGTOS has then designed and developed special shot blasting systems

AGTOS will exhibit in hall 9, stand 9-300.

th

th

for coherently treating lightweight parts and aluminium and magnesium castings.

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For further information: www.agtos.de

BRAND-NEW

Cortec Launches EcoClean Scale and Rust Remover HP Cortec has launched EcoClean Scale and Rust Remover HP with the aim of achieving fast-acting scale removal on a safer level.

C

ortec has introduced EcoClean® Scale and Rust Remover HP, which

EcoClean Scale and Rust Remover HP is a much better route to scale

can clear away scale buildup on all water-contacting equipment

removal in terms of worker safety.

surfaces in a variety of industrial systems, such as, heat exchangers,

Since EcoClean Scale Remover HP is classified as non-corrosive to mild-

chillers, condensers, cooling towers and pipes.

steel, it is non-regulated for ground shipments per US DOT, a great

Scale removal is an important maintenance activity, as over time,

advantage for those distributing the product. EcoClean Scale and Rust

calcium carbonate from hard water builds up on the surfaces of pipes

Remover HP is phosphate free and also considered a biodegradable

and heat exchangers, reducing water flow and heat-transfer efficiency.

industrial descaler according to product components and is a low

EcoClean Scale and Rust Remover HP also removes corrosion on

contributor to BOD/COD in effluents.

multiple metal types and contains powerful corrosion inhibitors to counteract the aggressiveness of acids on metals.

How to use EcoClean Scale and Rust Remover HP Immersion in the product produces the best results for most

A safer and more sustainable alternative

substrates and often works within five minutes to an hour, depending

EcoClean Scale and Rust Remover HP is a safer alternative to harsh

on the amount of scale and corrosion. Light abrasion helps speed up

minerals and organic acids like muriatic acid.

penetration and removal of corrosion products. Application should be

Classified as only a mild skin irritant according to the OECD Principles

followed with a neutralizing cleaner for further protection. EcoClean

of GLP (Good Laboratory Practice), EcoClean Scale and Rust Remover

Scale and Rust Remover HP can be used multiple times if filtered and

HP is drastically safer than muriatic acid, even if it is still considerably

monitored for pH after use.

fast-acting and effective.

While proper precautions should be taken, including the use of PPE,

For further information: www.cortecvci.com

© Cortec

ipcm® Protective Coatings - 2022 APRIL - N. 41

05

BRAND-NEW

Belzona Launched the Solvent-Free Containment Grade Coating Belzona 5815 The new coating with enhanced flexibility developed by Belzona allows to protect secondary containment areas.

T

he manufacturer of polymer repair composites and industrial protective coatings Belzona has

recently launched Belzona 5815, a new solvent-free containment grade coating with enhanced flexibility specifically developed for the protection of secondary containment areas.

Concrete is commonly used to build secondary chemical containment areas and bunds that need to retain spilled chemicals and facilitate product recovery.

However, it is susceptible to physical and chemical damage due to its porosity and other damages caused by cracking and reinforcing bar corrosion.

© Belzona

Belzona 5815 allows to solve these issues, as it has high tensile and flexural strength and can resist pressure up to 2,430 psi, allowing to bridge cracks.

In addition to this, the newly developed coating is able to endure temperatures ranging from -40 °C up to 160 °C and it is particularly easy to mix and apply by brush, roller, squeegee or airless spray system, since it does not require surface conditioner.

“Belzona 5815 is an economical solution to secondary containment areas holding non-aggressive chemicals.

It has undergone testing to prove that the product can resist a range of dilute acids, alkalis, fuels, and oils. Moreover, it can bridge cracks in concrete up to an extent and has great adhesion to non-metallic

© Belzona

and metallic substrates”, stated Osmay Oharriz, the Technical Manager of Belzona.

For further information: www.belzona.com

© Belzona

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N. 41 - 2022 APRIL - ipcm® Protective Coatings

BRAND-NEW

Graco Expands the Reactor® Proportioner Family with the Reactor 3 Spray Foam Proportioner Systems Graco has developed a new fully connected system for spray foam and polyurea applications.

G

raco Inc. has expanded its family of Reactor® proportioner with the

The improved performance and reliability are ensured by the new Core™

Reactor 3™ spray foam proportioner systems to allow contractors

transfer pumps, that communicate directly with the proportioner, and the

to maximise material yield, productivity and profitability. The systems are

independently temperature-controlled and internally heated Xcelerator™

available in the three product tiers Standard, Pro and Elite – that have

hoses that provide quicker heat-up times, increased flexibility and

been designed to meet the current contractor’s needs while allowing

optimised yield.

future upgrades if needed.

In addition, the Reactor 3 system includes a new advanced touchscreen

“The Reactor 3 proportioner project took a fresh look at the entire system.

control, the active ISO lube pump system, larger and easier to maintain

All components were updated from drum to gun to improve performance

inlet filters and advanced software features, including the Smart Control®

and increase reliability. Each system component plays an important role

pressure management system, the Auto Pressure Balancing and the

in the final product being dispensed. So, we wanted a system that could

automatic cellular software updates. Finally, the Reactor 3 system also

self-monitor and automatically adjust to environmental changes. Its

features the exclusive Katalyst™ software that brings a high level of

communication system ensures peak performance and makes it easier

intelligence and allows to optimise spray, eliminate ratio issues and

for contractors to complete their jobs on time and with quality results,”

improve yield.

stated Nick Pagano, Graco Global Product Marketing Manager for Foam and Polyurea Equipment.

For further information: www.graco.com

© Graco

ipcm® Protective Coatings - 2022 APRIL - N. 41

07

BRAND-NEW

Hexigone Has Received a New UK Patent The patent for Improved Corrosion Inhibition Incorporating Phosphates was granted to Hexigone Inhibitors.

H

exigone Inhibitors Limited has announced that in January 2022 it

further enhances the company’s patent portfolio and demonstrates the

has received the UK Patent No: GB2588924 for Improved Corrosion

company’s novel and solid chemistry,” stated Dr. Patrick Dodds, the CEO

Inhibition Incorporating Phosphates for the Intelli-ion® solution.

of Hexigone. “We are working globally to provide the coatings industry

The product developed by Hexigone provides corrosion protection both

with safer and smarter solutions when it comes to corrosion protection.

as a single replacement and as a synergistic inhibitor, as it improves the

This patent demonstrates the high performance of the Intelli-ion® product

performance of phosphate-based inhibitors and lowers the amount of

range as a stand-alone inhibitor, or when used in synergy with other

anti-corrosive additives required in the coating, allowing in this way to

commercially available chromate free inhibitors. We look forward to our

reduce the costs related to raw materials.

products and synergistic materials removing the previous reliance on

Meeting the strict global environmental standards and requirements,

chromium-6 corrosion inhibitors. Hexigone’s technical, manufacturing

Intelli-ion® is used to protect metal assets in several sectors, such as the

and commercial teams are driving the company forward as we undertake

marine and aerospace industry.

further collaborations with our customers.”

“We are extremely pleased to see the hard work and dedication of the Hexigone Team resulting in this new patent being granted. This patent

For further information: www.hexigone.com © Hexigone

Dr. Patrick Dodds, the CEO of Hexigone.

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BRAND-NEW

Researchers Developed a Lava-Like Fire Retardant Coating A team from the University of Southern Queensland (Australia), led by Professor Pingan Song, has developed a lava-like non-toxic, fire extinguishing coating.

T

he researchers from the University of Southern Queensland (Australia) have announced the development of a new non-

toxic fire extinguishing coating that could prevent buildings from being engulfed in flames.

The study, led by the chemical engineer Pingan Song, was inspired by lava, one of the hottest substances that could be found on the surface of Earth. As lava, the new hybrid coating would in fact melt and then gradually form a flowing but non-combustible ceramic layer when exposed to extreme heat.

“Melton lava is like a viscous flowing liquid but non-flammable.

Once cooled, it solidifies to become a ceramic layer that does not support fire. Inspired by this interesting phenomenon, we designed a fire retardant coating that can create a non-combustible ceramic layer which can offer fire protections for the underlying substrates, just like a fire shield,” stated professor Pingan Song.

The flame retardant is composed by a mixture of several metal oxide powders (including oxides of aluminium, silicon, calcium and sodium) that starts to melt at around 350°C (below the temperature of most flames), forming a glasslike sheet. The researchers added then tiny flakes of boron nitride, which flow easily and help fill any spaces between the metal oxides as the glass forms.

Finally, they added a fire-retardant polymer that acts as a binder to glue the rest of the mixture. © USQ

Spraying this new coating on building materials – such as thermal insulation foam, timber and steel structures – during the construction process could prevent disasters like the 2017 Grenfell

The fire-retardant coating still needs to undergo further testing and

Tower blaze in London, where 72 people lost their lives. Besides

refinement before its launch on the market, that is expected to take place

building, the lava-like flame retardant can be applied also in other

within the next three years.

different settings, for example wooden furniture, mining, tunnels

The research, which was financially supported by an Australian Research

and transportations.

Council Future Fellowship, was published in the journal Matter1.

“Polymer foams were identified as the main cause of recent catastrophic disasters, particularly the Grenfell Tower fire. Solid

For further information: shorturl.at/gBR46

wood materials, also widely used in buildings but extremely combustible, can also trigger fires, like the Notre-Dame de Paris blaze in 2019. Our fire retardant coating produces a very robust and thermally stable ceramic layer, compared to existing coatings, which usually produce a protective layer that is fragile and degrades at high temperatures,” continued Song.

1

https://www.sciencedirect.com/science/article/abs/pii/S2590238521006342?via%3Dihub

ipcm® Protective Coatings - 2022 APRIL - N. 41

09

BRAND-NEW

COSCO’s Fleet to Be Coated with Nippon Paint Marine’s FASTAR® Antifouling Nippon Paint Marine will apply its new antifouling system FASTAR® to COSCO’s fleet to provide high performance and improve drydock efficiency.

C

OSCO Shipping has recently announced that it will have its entire

system,” stated Jun Ye, the M & R Sales Director for Nippon Paint Marine

VLCCs fleet coated with FASTAR®, the new antifouling system

in China. “With the current high freight rates, shipowners want to keep

developed by Nippon Paint Marine, once initial applications have been

their vessels trading for as long as possible. FASTAR® antifouling not

evaluated. FASTAR is a self-polishing, antifouling paint that includes a

only provides next level performance but improves drydock efficiency,

nano-domain resin structure designed to minimise the effects of seawater

reducing significantly the time required in drydock for paint work.”

temperatures and vessel speeds on the performance of the coatings.

The shipowner has chosen the newly introduced antifouling to allow

FASTAR will be applied also to the passenger ferry COSCO Star and the

its vessels to meet the Energy Efficiency Existing Ship Index (EEXI)

56,000dwt bulk carrier Xin Liu Lin Hai: COSCO Star will dock at the COSCO

requirements.

Shanghai Dockyard in February for a FASTAR XI application while the

“We were keen to evaluate and assess the feasibility of Nippon Paint’s

bulker is currently scheduled to be coated with FASTAR® I in May at the

next generation antifouling for possible VLCC application. The coating’s

COSCO Guangzhou Dockyard.

potential to reduce fuel consumption and carbon emissions by up to 8%

“COSCO Shipping has a long history of applying Nippon Paint Marine

is attractive and seen as a viable way towards meeting EEXI requirements.

antifouling to the hulls of its vessels as a way of improving propulsion

We also anticipate reduced paint volumes and quick drying time will result

efficiency and reducing emissions. Once the shipowner has verified the

in cost savings,” commented from COSCO Shipping.

®

precise, predictable performance of FASTAR® on these two vessels, more vessels are expected to take advantage of this revolutionary coating

For further information: www.nipponpaint-marine.com

© COSCO Shipping

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N. 41 - 2022 APRIL - ipcm® Protective Coatings

BRAND-NEW

PPG Launched PPG PHENGUARD 985 Phenolic Epoxy Tank Coating The new tank lining developed by PPG offers two or three coat flexibility and increases the resistance against fatty acids.

P

PG has recently announced the launch of PPG

© Oleksandr Kalinichenko-Shutterstock

PHENGUARD® 985, a phenolic epoxy tank lining

specifically developed to provide temperature and chemical resistance against a wide range of aggressive chemicals that contain fatty acids.

“The latest addition to our PPG Phenguard range, PPG Phenguard 985 tank lining features a patentpending formulation that can be applied in two or three coats instead of the traditional three coats without compromising chemical resistance. This gives asset owners and contractors flexibility to apply their preferred coating system build-up while having full confidence in the end result,” stated Bart Martens, PPG global product manager, chemical protection, Protective and Marine Coatings.

Fatty acids are highly aggressive chemicals that could cause several problems for operators within the marine and tank storage industry, as the temperature window required for their storage is narrow and difficult to manage. Since temperature overshoots might jeopardize the efficacy of the tank lining, leading to additional expense, PPG Phenguard 985 has been specifically designed to accommodate an extended temperature window.

“In an increasingly competitive operating environment for asset owners, PPG Phenguard 985 creates the opportunity to reduce tank lining application and servicing costs while also maximizing cargo opportunities. As well as the initial application cost savings from moving from three to two coats, the liner’s higher thickness tolerance reduces the need for costly rework in case of overapplication,” concluded Martens.

For further information: www.ppgpmc.com

ipcm® Protective Coatings - 2022 APRIL - N. 41

11

SUCCESS STORIES

Black Paints Save Birds Based on the findings of a Norwegian research and the experience of French airports, Iberdrola painted wind turbine blades black and applied vinyl shapes resembling eyes to protect birdlife.

I

berdrola, one of the world’s principal energy companies, a leader in

The solution creates more contrast between the blades and makes

renewables, is spearheading the energy transition towards a

them easier for birds to see. This work to adapt the wind turbines takes

low-emission economy. It supplies energy to around 100 million

place 100 metres above the ground on fully assembled wind turbines

people in dozens of countries and has renewable, grid and commercial

and requires sanding, cleaning and painting the blades. The tasks are

activities in Europe (Spain, the UK, Portugal, France, Germany, Italy and

undertaken when there is little wind and no rain to ensure the safety

Greece), the US, Brazil, Mexico and Australia, while counting markets

of the specialised wind turbine maintenance and operation workers.

including Japan, Ireland, Sweden and Poland as growth platforms. It

Each blade on the Cavar wind turbines is 65 metres long and up to 14

is continuing to roll out solutions to promote the coexistence of its

metres wide, so it can take a week to paint them.

renewable facilities, one of the foundations of the energy transition, and the ecosystems in which they are located. The company has

Vinyl shapes to discourage birds of prey

launched two initiatives on several wind farms to improve the visibility

The second of these initiatives consists of marking wind turbine towers

of their wind turbines and to deter certain species of birds from the

with two vinyl transfers that look like staring eyes. These one-metre-

areas of influence around the projects. The solutions are based on

diameter concentric circles are fixed at between 3.5 and four metres

studies conducted by the Norwegian Institute for Nature Research and

from the base of the wind turbines. It has been shown that sticking

experiences at French airports.

these black shapes to the white base of the wind turbine tower is a deterrent to birds of prey.

Painting wind turbines black

The solution has been implemented in seven wind farms in Burgos and

One such initiative involves painting one of the three blades black on

has involved applying these vinyl shapes to more than 60 wind turbines

several wind turbines on wind farms in Cavar (111 MW) in Navarre;

on the Ballestas-Casetona, Cotera, Páramo Vega, Urbel del Castillo,

and Zorreras (20 MW) in Zahara de los Atunes (Cádiz) in Andalusia. The

Valdeporres, Viñas and Fuente Blanca wind farms. The project does

project, which will be rolled out in some of the company’s other wind

not affect the structure of the wind turbine and has no impact on the

farms, is based on a study published by the Norwegian Institute for

operational systems or electricity produced by these production plants.

Nature Research , which estimates a 70% reduction in the number of

There are plans to install these vinyl shapes at another six wind farms in

birds spotted after applying this measure.

Burgos province, while the possibility of further extending the scheme

1

is being analysed.

1

https://onlinelibrary.wiley.com/doi/10.1002/ece3.6592

© Iberdrola

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N. 41 - 2022 APRIL - ipcm® Protective Coatings

© Iberdrola

SUCCESS STORIES

This method has been tried and tested at Lourdes-Tarbes-Pyrénnés airport in south-eastern France and has proven efficient for keeping birds away. A 65% reduction in the number of birds of prey spotted in the airport area was observed when the vinyl shapes were used.

Competitive energy and environmental balance Iberdrola has fully integrated the conservation of the biological diversity of ecosystems into its strategy, demonstrating that competitive, clean and sustainable energy supply can effectively coexist in balance with the environment. The company plans to achieve “no net loss” of biodiversity by 2030, by committing to the net positive impact of new infrastructure developments. In this regard, it has carried out more than 1,450 measures to protect biodiversity in the last three years alone, combining renewable project development with the conservation of the biological diversity of ecosystems and caring for flora, fauna and natural heritage.

Among other initiatives to achieve its sustainability goals is reforestation, with the launch of the Trees Programme, whereby Iberdrola will plant 20 million trees by the end of the decade, with which it will capture approximately six million tonnes of CO2.

© Iberdrola

For further information: www.iberdrola.com

We will be attending

Hall 3, Stand 3133

FOCUS ON TECHNOLOGY

A Winning Choice: Pinturas Marcelino González Focused on Powder Coating Quality and Durability for Large Workpieces Alessia Venturi ipcm® When staking everything on an industrial challenge, in addition to a dose of luck, the key to winning it is to rely on high profile, reliable, solid, and technically skilled partners. This is what has happened to Pinturas Marcelino González, which is now the most important powder and liquid coating contractor for large manufactured parts in central Spain also thanks to its close relationship and technical exchange with AkzoNobel Coatings S.L.U., supplying it with a wide range of Interpon-branded primers, intermediate finishes, and top coats.

I

n the contract coating sector, there tend to be two approaches to customer service: some companies lack an industrial culture of

specialisation and quality and prefer to compete on costs, whereas others offer very high quality coating processes and clearly understand the importance of guaranteeing the durability of the coatings applied.

The latter often work for international groups, extending their market beyond national borders –a rare accomplishment for contractors, 90% of which tend to work for local businesses. However, these companies’ coating know-how is such that their reputation goes beyond their country’s borders, attracting customers from neighbouring nations.

Pinturas Marcelino González (Valladolid, Spain) belongs to this second group of businesses. It is one of the largest and most flexible industrial coating contractors in its country, and above all one of the few in the nation and the only one in central Spain to offer liquid, powder, or mixed coating processes capable of meeting both very high aesthetic requirements and corrosion resistance standards up to C5M High, the highest in the classification of the ISO 12944 regulation, on large, highmass parts.

Marcelino González can carry out painting projects both on site and in its workshop, ranging from the decorative and industrial sectors,

© ipcm

Poles powder coated by Pinturas Marcelino González (Valladolid, Spain).

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N. 41 - 2022 APRIL - ipcm® Protective Coatings

with a focus on anti-corrosive applications, to maintenance and industrial flooring. That is an incredible amount of skills and experience

FOCUS ON TECHNOLOGY

accumulated since 1973, the year it was founded by Marcelino González, the father of its current managers. Over the years, this has been greatly enhanced through the implementation of the powder coating technology in 2007 and through the beginning of a continuous, profitable, and constructive collaboration with AkzoNobel Coatings S.L.U. (Vallirana, Barcelona), which is now Pinturas Marcelino González’ main supplier of powder coatings. The range of AkzoNobel products used by the company is very wide, ranging from the complete Redox primer portfolio to industrial and architectural finishes, such as those from the Futura and Textura collections.

The history of a long-standing enterprise Pinturas Marcelino González SL started to operate in 1973 with the aim of filling a major gap in this sector and becoming able to serve © ipcm

all types of customers, from private individuals wanting to paint their own house to companies with complex industrial projects requiring both liquid and powder coatings. After about ten years of carrying out small orders from private customers for the renovation and conservation of façades, the firm installed its first industrial wood treatment plant in 1986. The next evolution step was beginning to serve the industrial sector with a metal surface treatment plant.

Today, Pinturas Marcelino González covers an area of more than 6000 m2 in the San Cristobal Industrial Park in Valladolid and it is equipped with one of the largest and most modern powder coating lines in Spain, complemented by a large shot blasting plant, liquid coating booths for large parts, and highly qualified personnel to carry out work both on site and in its workshop. “80% of the overhead contact lines and electrification towers for the Spanish high-speed AVE railway line came out of our factory, which we have recently doubled,” says Carlos González Valdivieso, the plant director of Pinturas Marcelino González. “We specialise in the application of anti-corrosion systems

© ipcm

The inside of the corundum shot blasting machine and the lowerator in the loading/unloading area.

ipcm® Protective Coatings - 2022 APRIL - N. 41

15

FOCUS ON TECHNOLOGY

© ipcm

© ipcm

Manual application of powder paint in the coating booth.

The powder centre.

on large-sized, high-volume parts, with the possibility of achieving the

“We soon realised that our coating plants were inadequate to meet the

C5M High resistance class, i.e. 1440 hours of salt spray resistance with a

needs of a group like Indal. Therefore, in 2007, we invested in a new line

three-coat powder system (galvanising primer, epoxy intermediate layer,

that could treat parts up to 12.5 metres in length, including a metal shot

and polyester top coat) applied after shot blasting and chemical pre-

blasting booth, two liquid coating booths (a large one and a smaller one

treatment.”

for high quality finishes), and an automatic powder coating booth. Now,

“We started out as a coating contractor for the Indal group, which

we are able to reliably carry out any type of coating project and anti-

specialised in outdoor lighting (later transformed into Philips and then

corrosion treatment up to C5M class, even on large-sized, high-volume

Signify) and which decided to rely on our company, thus introducing us

parts. Finally, in 2020, we doubled our paint shop by installing a line with

to the painting of iron, particularly for light poles. This first experience

a corundum shot blasting plant and two large liquid coating booths in a

in the coating world paved the way for the implementation of further

new building.”

different metal surface treatment processes, always performed both in our workshop and on site. On that occasion, we were introduced to

Full use of AkzoNobel’s Interpon product portfolio

powder coating and we also initiated our collaboration with AkzoNobel,

“With our powder coating system, we are able to carry out a

which was Indal’s specified powder supplier: it was already using powder

traditional cycle including phosphodegreasing and zirconium-based

products for its street lighting equipment and all its contractors had

nanotechnology passivation + 1 coat of powder, achieving a salt spray

to adapt. Thanks to the consultancy and continuous coaching of our

resistance of 400 hours, or an anti-corrosion cycle including shot

operators by AkzoNobel’s technicians and through the research activity

blasting and chemical pre-treatment as above + 2 or 3 layers of powder,

carried out by both parties, we soon realised that powder coating

achieving the C5M High class in compliance with ISO 12944,” explains

offers a higher industrial quality level and far greater durability than

Carlos González Valdivieso.

liquid coating. In 2007, Pinturas Marcelino González decided to invest

“As a result, we are highly specialised in the use of powder primers,

on powder coatings for its future.” This was certainly a winning choice,

which we change depending on the material to be coated. AkzoNobel’s

given the reputation gained by this contractor all over Spain and with

Interpon Redox line is a fantastic tool for us, as it is the most

all the foreign groups it supplies through partnerships with Spanish

comprehensive range of multi-layer powder primers on the market.”

companies.

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“AkzoNobel has always supported the professionalisation of applicators and provided companies with technical assistance, helping them choose (and test) the right products for their quality and durability requirements and developing the most appropriate systems with them. In fact, this is the most exciting part of our job as agents,” says Juan José Sánchez Maqueda, AkzoNobel’s sales representative. “Together with Pinturas Marcelino González, we normally choose the most suitable primers for the type of materials to be painted from the Interpon Redox range. For instance, when

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treating carbon steel, we select a zinc-rich primer such as Redox PZ, which offers long-lasting cathodic protection enhanced by a barrier effect, or a primer from the Redox Active epoxy range, which contains pigments that activate a passivation process to protect the substrate. When dealing with porous materials such as galvanised steel or die cast aluminium, we prefer a primer with a degassing

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additive; indeed, these materials have gases trapped beneath their surfaces: the Interpon Redox Plus FL151F degassing primer prevents them from surfacing during application and curing of the polyester top coat, thus avoiding pinhole defects.”

“We paint such a wide range of different substrates, from steel and galvanised steel to aluminium, that having a complete portfolio of products applicable in multi-layer systems is the only way to meet any aesthetic and/or functional specification,” states Carlos González Valdivieso. “AkzoNobel also supplies us with Qualicoat class 1 and 2 polyester finishes. We also choose some finishes from the Futura D2525 (super durable) collection and textured finishes from the D1036 Textura or D2525 Structura series, depending on customer requirements and the intended use of products. We use the full range of colours offered by the Interpon finishes, including metallic and brilliant shades.

“We also paint aluminium: therefore, our chemical pre-treatment process is a multi-metal, step-by-step operation, a must for treating parts up to 12.5 metres in length. Only this system enables us to avoid dragging water and chemical solutions from one pre-treatment

Our technical staff can help you decide which product you need for long lasting and complete protection of your corrosion sensitive products.

stage to another. Its cycle includes fluoride-based degreasing, one rinse with mains water, one rinse with demineralised water, and a zirconium-based no-rinse nanotechnology passivation phase. The chemicals used are provided by Proquimia; for the nanotechnology passivation phase, we use the ProSpray atomisation system developed by Proquimia itself, which mixes and applies ever-fresh product without any waste or bath contamination.”

Relying on market leaders to win this industrial challenge “Since we were totally unfamiliar with powder coating, we chose to rely on the leaders in the field, not only for the powders themselves, with AkzoNobel, but also for the system: the conveyor was designed

by Futura Convogliatori Aerei for heavy and special loads, including

®

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FOCUS ON TECHNOLOGY

a lowerator. Geinsa designed the pre-treatment tunnel

© ipcm

and the ovens. Gema designed the powder coating booth.

After the building crisis of 2008-2009, most outdoor lighting manufacturers have disappeared. If we had not had such a high-performance plant that was also so flexible in terms of type of workpieces to be powder coated, we would not have been able to overcome that crisis quickly and unscathed. In fact, the versatility of the system and of the powder products we have learned to use allows us to paint everything from light poles, train tracks, railway station arbours, and electrification towers to furniture and design components that require an automotive-degree aesthetic quality. Powder coating has opened up a market we did not even think existed.”

“We were actually lucky to “inherit” AkzoNobel as a supplier from Indal, because their technical assistance has helped us learn and master a technology that was unknown to us, providing us with hours of support to

© ipcm

ensure that everything worked at its best. Our relationship has been going on for fifteen years and it has been very positive at all times,” indicates Carlos González Valdivieso.

“For AkzoNobel Coatings, Pinturas Marcelino González is an important customer not only (or not so much) because of the volumes of powder it consumes, but because of its extreme specialisation, which enables us to use it as an industrial laboratory to test our powder products before putting them on the market. It has accumulated such a great deal of expertise in both liquid and powder coating.

It also works for German customers, passing very strict audits and even suggesting improvements to the specified systems, if any,” explains Juanjo Sanchez Maqueda from AkzoNobel.

“We are currently launching some super durable powders from the Interpon D3020 series (an alternative to PVDF) and here at Pinturas Marcelino González we can test the products before releasing them in the market. Thanks to its application culture, it help us to understand if we are doing well, not only at the laboratory but also at the industrial level.”

This is what a true partnership between a supplier and a customer looks like. ‹

A large workpiece transported by the Futura Power & Free conveyor.

A powder coated part.

Carlos González (left) with Juanjo Sánchez from AkzoNobel.

© ipcm

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27 30 September 2022

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© I.T.F.

The shot blasting machine installed at the customer’s premises.

FOCUS ON TECHNOLOGY

The Importance of “Zero Shot” Blasting Operations to Allow Sheets to be Handled Correctly through an Overhead Crane with a Magnetic Lifter Gabriele Lazzari ipcm® I.T.F. has built a fully automated shot blasting plant for large-sized components in order to meet the complex requirements of a manufacturer of sheets that are over 3 metres wide and weighing up to 15,000 kg. As well as allowing the recovery and replacement of abrasives even during processing, the machine is equipped with three blowers that guarantee “zero shot” operation and the safe handling of sheets through an overhead crane with a magnetic lifter.

T

he optimisation of processing times is often achieved with

This is why, for a major manufacturer of sheet metal and steel

automated production and handling equipment. However, when

products, I.T.F. has designed and installed an automatic shot blasting

pre-treating and finishing metal sheets and other large structures,

machine with a roller conveyor and a blower system that achieves the

special attention should also be paid to the quality of surfaces after

“zero shot” result, i.e. it eliminates any residual shot from the parts’

treatment, in order to avoid compromising their handling operations

surfaces to ensure the correct and safe handling of sheets by means of

and creating a dangerous situation.

an overhead crane with a magnetic lifter.

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N. 41 - 2022 APRIL - ipcm® Protective Coatings

FOCUS ON TECHNOLOGY

Speed and automation as basic requirements This nationally recognised company located in north Italy, specialises in the processing and marketing of hot-rolled coils or individually rolled sheets and other large steel products for various markets such as automotive, industrial vehicles, agricultural and earth moving machinery, shipbuilding, and railway.

Previously, it used a machine with manual positioning adjustment. However, wanting to increase its production rates, it needed a fully automated shot blasting plant guaranteeing “zero shot” operation, so that the sheets could be handled by an overhead crane with a magnetic lifter to speed up production.

Therefore, it turned to I.T.F. - Impianti

© I.T.F.

The rendering of the I.T.F. shot blasting machine.

Trattamenti Finiture (Mesero, Milan, Italy), specialising in the design, manufacture, and installation of finishing equipment, for a shot blasting machine with a roller conveyor.

In January 2021, I.T.F. supplied it with the GLPX 3205-8 pass-through plant that met all requirements, also allowing to optimise resources and reduce the process’ environmental impact.

The GLPX pass-through shot blasting system that adapts to any sheet dimensions I.T.F. has developed a GLPX pass-through plant suitable for sheets, profiles, and structures with dimensions of up to 3,200 millimetres in width and 500 millimetres in height. For ease of transport and installation, this shot blasting machine equipped with a roller conveyor was built in modules with very thick materials and strengthened with metal profiles in order to support structures weighing up to 15,000 kilograms (each roller supports a weight of 3,000 kilograms).

Thanks to its size, the machine can even handle several sheets at the same time: it © I.T.F.

features a 26-metre long inlet and outlet roller conveyors divided into two equally long sections that are independent of each other,

The magnetic overhead crane that releases the sheet metal on the inlet roller conveyor of the shot blasting machine.

as they are equipped with their own self-

ipcm® Protective Coatings - 2022 APRIL - N. 41

21

FOCUS ON TECHNOLOGY

© I.T.F.

© I.T.F.

A sheet entering the plant.

A sheet exiting the plant.

ventilated drive controlled by an inverter, allowing to place two 12-metre

and maintenance areas of the “upper” part of the plant, the pneumatic

long sheets. This has enabled the creation of a buffer for the storage

separator, the upper auger with a screen basket, and the elevator head

and continuous automatic handling of sheets, which further speeds up

for tensioning the conveyor belt.

production.

When the metal sheets are loaded onto the conveyor rollers of one

The importance of blowers for “zero shot” operation

of the two sections (all rollers are equipped with a safety rope), the

Then, the sheets reach the station devoted to removing the shots

operator selects the start option, and initiates the sheet’s sideshift. At

projected by the turbines and deposited on the plant’s floor. Here, there

the entrance to the pre-vestibule of the shot blasting chamber, there

is a mobile system called a “brush carriage” that, depending on the

are photocells for the recognition of the product geometries, in order to

workpiece thickness detected by the photocells at the machine inlet,

adapt the shot blasting process accordingly.

positions itself at a pre-set height.

An automatic timer set by the photocells allows the opening of the

A ploughshare evens out the thickness, then the rotating brush removes

abrasive dosing valves (a combination of spherical and angular steel) at

the shot from the part’s surface, sending it to an auger that conveys it

the exact moment in which the sheet is positioned near the first of the

laterally back into the abrasive cycle. Finally, a blow-off nozzle system

eight turbines with motors of 22 kilowatts each, thus avoiding that shot

removes the residual shot, guaranteeing the “zero shot” result required

blasting takes place without the piece in front, optimising resources.

by the customer.

The turbines, made entirely in I.T.F.’s own workshop with heat-treated

“The additional blow-off phase proved essential to meet the customers’

steel and with manganese wear plates, are arranged equally above and

requirements. Any shot residue on the surfaces of the treated sheets

below the roller conveyor and tilted, so as to guarantee even treatment.

could compromise the magnetic lifter’s handling operations, delaying

The plant has a series of doors that allow easy access and inspection

production and creating a dangerous situation of all operators,” explains

of the shot blasting chamber and the vestibules, as well as a raised

the technical personnel of I.T.F. “Most blowers in this field do not allow

metal platform complete with a ladder for accessing the adjustment

the “zero shot” result to be achieved. So, I.T.F. has installed two ultra-

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N. 41 - 2022 APRIL - ipcm® Protective Coatings

FOCUS ON TECHNOLOGY

high-pressure blade blowers, and a nozzle blower

© I.T.F.

with a dedicated compressor to completely eliminate any dust and shot residues.”

Further application details In addition to process automation and cleaning quality, the plant also stands out for its special shot-control devices that optimise the use of resources. Instead of conventional abrasive valves, shot dosage is managed by a special magnetic valve with automatic adjustment of the shot’s flow rate, managed by the PLC according to the current absorbed by the turbine motors: the valve acts on the pass-through section by means of a magnetic field, regulating the opening and closing the shot’s jet and preventing it from flowing out when not needed. Finally, the plant is also equipped with an automatic shot refilling system for the highcapacity main storage tank (loaded with 1500-kg big bags). ‹

I.T.F.’s shot blast machine is over 60 metres in length.

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SUCCESS STORIES

The Application of Hydrophobic Epoxy Coatings to Pumping Systems Allows to Save in Energy Consumption Belzona developed a hydrophobic epoxy coatings solution for pumping systems that allows to save up to 20% on energy costs.

M

anufacturing operations are faced with many challenges in today’s

Fluid handling equipment can suffer from several physical and

marketplace. With global energy prices soaring, many industries

mechanical problems, including general and/or localised corrosion,

are being impacted in the form of rising production costs, supply chain

cavitation or reliability linked with poor efficiency or performance. All

issues and lower output. With this in mind, now is the time to think

these parameters may affect the power consumption of the equipment,

about reducing your business’ energy costs.

increasing considerably its lifetime running cost.

The British Pump Manufacturers Association (BPMA) estimate that

One effective way to reduce the loss of equipment performance is to

pumping systems account for almost 20% of the world’s electrical

protect pumping systems using erosion/corrosion resistant coatings.

demand and the cost of energy represents 95% of the cost to run

In this area, Belzona Polymerics Ltd has provided coating technology

pumping equipment. It is clear that solutions developed to increase

solutions for over 70 years within all industry sectors.

pump performance would be of great benefit to industry.

Belzona 1341 offers a unique hydrophobic surface coupled with high

© Belzona

© Belzona

Damaged pump asset during strip and inspection.

24

N. 41 - 2022 APRIL - ipcm® Protective Coatings

Pump casing with corrosion and erosion damage.

SUCCESS STORIES

© Belzona

© Belzona

The pump after coating with 1st coat of Belzona 1341.

The pump completed with 2nd coat of Belzona 1341.

erosion/corrosion resistance, which reduces friction losses and thus the

efficiency was down at 38.3%. Work began on a strip and inspection with

energy input required. Belzona 1341 (Supermetalglide) can also be used

reports of both processes submitted to the customer.

on new equipment to enhance pump efficiency and reduce electrical consumption. Its unique system provides gains in hydraulic efficiency

The solution

from 3% - 8% on new pumps as well as up to 20% on those already in

The customer was keen to proceed, and the team set to work. This

service.

started with the heavily eroded volute casing being repaired with Belzona 1111 (Super Metal), a metal repair composite.

Pump efficiency coating

The volute casing was then re-profiled to suit the impeller vane tips

A car manufacturer had four long-coupled end suction pumps that had

and Belzona 1341 (Supermetalglide) was applied to improve the units’

been deemed beyond economical repair by another third-party repairer.

hydraulic efficiency, flow rate and head characteristics.

Each new replacement pump would cost £18,000 (about €21.600) and

Flow rate was an important factor in the customer’s operation, and

had an expected lead time of up to five months from the USA, meaning

this was identified as a key metric for improvement prior to the

an expensive and drawn-out process for the customer.

refurbishment. The pumps’ seals were also upgraded to the latest

Hayley 24/7 Industrial Pumps team were given the opportunity to offer a

EagleBurgmann SN Single cartridge seals, with bearing isolators installed

second opinion.

to help eliminate bearing contamination.

One of the pumps was sent to the Hayley 24/7 facility, installed on the

Reassembly of the unit was completed, and the pump was re-tested

state-of-the-art test rig and its performance was analysed. Its hydraulic

before being shipped back to the customer’s facility.

ipcm® Protective Coatings - 2022 APRIL - N. 41

25

SUCCESS STORIES

The result The refurbishment and upgrade cost the customer significantly less than what they had been quoted for a new replacement pump, from the American OEM. By providing this service, Hayley 24/7 enabled the customer to secure a capital expenditure saving of £11,500 (about €13.800) and cut the delivery lead-time down to just 2.5 weeks.

It was calculated that the refurbished pump would deliver an annual energy cost-saving of £14,500 (about €17.400), based on the following performance test results: • Hydraulic efficiency: increased to 48.3% • Flow rate: increased from 77.3% to 85.1% • Motor absorbed power: reduced from 42.6kW to 40.8kW • Pump differential head: increased from 20.6m to 23.5m.

The customer is now looking to roll-out a comprehensive programme of pump refurbishments at their site, including all 12 active pump assets. By doing this, the customer will benefit from an annual energy cost-saving of around £173,000 (about €207.300). The reduction in energy consumption will also have a positive impact on the company’s current environmental initiatives.

For further information: www.belzona.com

© Belzona

Refurbished pump asset, ready for despatch.

About Belzona Established in 1952, Belzona has pioneered innovative polymer technology that has revolutionised industrial repair and maintenance procedures. Belzona is a leading company in the design and manufacture of polymer repair composites and industrial protective coatings for the repair, protection and improvement of machinery, equipment, buildings, and structures. At Harrogate, the full company’s product range is manufactured to stringent quality and environmental control guidelines complying with the requirements of ISO 9001:2015 and ISO 14001:2015.

Belzona has over 140 distributors in more than 120 countries ensuring not only the availability of its materials, but also specification support, project management, application, and supervision services. Distributorships and their teams are supported by Belzona Corporate offices in Europe, North America, and Asia.

26

N. 41 - 2022 APRIL - ipcm® Protective Coatings

HEAR FROM INDUSTRY EXPERTS The forum for the steel pipeline community, exploring pipeline coatings, hydrogen transportation, new technology and markets

Kim Schacht Technical Director Oil & Gas LOGSTOR A/S Dr. Denis Melot Coating, Polymer and Composite Specialist TOTAL Fabio Braga Azevedo Consultant PETROBRAS Martin H. van Agteren Principal Advisor Asset Management GASUNIE

Sponsored by:

Arie Dam Owner DAMCOATING Nicolas Singling Polymer, Painting & Coating Specialist SAIPEM

Book your place here Media supporters:

www.ami.ltd/event-pipeline-PC

SUCCESS STORIES

Achieving CFB Boiler Maintenance Goals Integrated Global Services, Inc. (IGS), the international provider of surface protection solutions headquartered in Virginia (USA) improved a pulp mill’s operation thanks to repair and maintenance of the eroded surface areas.

T

his pulp mill in South Eastern United States operates a CFB boiler

that they had some issues on the roof of their CFB boiler. They had

unit built in 1989. The boiler was recently upgraded from the

an emergency outage and called a thermal spray vendor to apply a

viewpoint of operating mass flow rate to the 450,000 lbs/hr. The fuel

product with a low velocity arc spray.”

type for this particular unit is a combination of biomass sludge, some

“I was somewhat surprised by the choice of product specified by the

tire derivatives as well as some plastics. This type of fuel has led to

thermal spray vendor, because the roof area in a CFB boiler usually

the issues at hand – erosion causing tube leaks and numerous forced

receives high erosion. The specified product, a high nickel chrome

outages. As a result, the mill had a number of goals that they would like

material, is usually applied in the waterwalls of a PC-fired boiler for

to achieve, including:

corrosion protection” continued Paul.

• Increase reliability of their CFB boiler by reducing the number of tube

Integrated Global Services (IGS) offered to do an erosion test using

leaks so that it would better facilitate them to meet the requirements

their bed ash to compare the IGS 5xxx series material and the

of a 20-year PPE agreement.

previously applied material against uncoated carbon steel. The results

• Increase outage cycles from a current 12-month to an 18-month

showed the IGS 5xxx material to be five times more erosion resistant

turnaround.

than the product that the previous thermal spray vendor chose to

• Reduce the number of mechanical repairs that used to be needed

apply on the roof.

every outage.

IGS HVTS application in 2018

Path to reliability

Paul said: “I think they saw that an improved process and improved

Paul Strauss, IGS Boiler Maintenance expert said: “Back in 2017, I had

material could help the mill meet their goals and IGS was subsequently

the opportunity to meet with the pulp mill’s engineering manager,

awarded the 2018 project and we mobilized to site in May of 2018.”

operations manager, and maintenance manager. And I found out

IGS completed the HVTS (High Velocity Thermal Spray) application on

© IGS

© IGS

Previous vendor’s coating.

28

N. 41 - 2022 APRIL - ipcm® Protective Coatings

© IGS

A tube leak.

IGS HVTS cladding applied with a top coat as a wear indicator.

SUCCESS STORIES

the roof, upper cyclone area and the sidewalls covering the total area

“A very lengthy subsequent conversation ensued revolving around

of approximately 425 square feet. The scope of work was completed on

IGS advantages over the “lower velocity thermal spray” suppliers.

time and the mill’s in-house QC coordinator was very satisfied with the

Upon conclusion of the meeting, the current maintenance team and

quality.

its leadership were very much in favor of establishing a long-term

Paul said: “The 2018 application looked excellent upon inspection.

service agreement between IGS and the pulp mill’s facility with a view of

Subsequently, in 2019, IGS completed an additional scope of 450 square

expanding this agreement to their other sites.”

feet on the other three walls at the refractory line. Additional 75 square foot of repairs to the previous vendor’s coating on the roof tubes was

Long-term service agreements ensure lasting reliability

also completed. Again, the entire scope of work was delivered on time

The pulp and paper company’s corporate inspector visited the IGS

with good quality.”

laboratory in Richmond, VA, in July 2021. He was impressed with the facilities and the engineers that work in the lab. Long-term service

Change of strategy in 2021

agreements will ensure that not only this mill, but all company sites

Due to the changes in the maintenance team and the involvement of

will be able to achieve their key three maintenance goals: increasing

the procurement department, the mill appointed a new vendor for their

reliability of their CFB boiler, increasing outage cycles, and reducing

thermal spray needs in 2021. Unfortunately, they actually ran over the

mechanical repairs.

allocated critical path by well in excess of 30 hours.

Kevin Phillips, IGS Pulp and Paper Maintenance Solutions Expert, said:

SHOTBLASTING

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SHOT-PEENING

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BRAND-NEW

The New Coating Technology Carbonamine Uses CO2 Waste to Ensure Improved Sustainability and Performance The cost-effective and solvent-free Carbonamine contains up to 18% CO2 waste and can be fast cured at low temperatures.

C

arbonamine is a new coating with patented technology that combines the durability of

polyurea/polyaspartic with an ingredient made from waste carbon dioxide, allowing the inclusion of up to 18% of CO2 waste, and can be cured at low temperatures down to minus 5 °C.

It does not contain expensive low-viscosity isocyanates and it is odourless, solvent free and non-flammable, so manufactures are able to produce environmentally-friendly coatings at a reduced cost for a wide range of applications, such as concrete and anti-corrosion primers, UV-resistant top coats and clear floor varnish for protecting decorative systems.

Carbonamine’s durability, flexibility, adhesion and abrasion resistance ensure ease of application also on damp substrates including aluminium, concrete, wood and steel, without foaming.

“It’s well known that alkylene carbonates will react with primary (reactive) amines, and they are used in fast-curing polyurea spray systems and several other similar applications. However, only small amounts of alkylene carbonates were previously used in polyaspartic coatings, as it was thought that they wouldn’t react into the resin matrix,” stated Richard Foster, the developer of Carbonamine.

“Additionally, my work on Carbonamine revealed that when a catalyst is used to cause the alkylene carbonate to react into the resin system far larger quantities can be used. While large percentages of alkylene carbonates are not usually used in resin systems, Carbonamine employs up to 30 per cent propylene carbonate because it is a readily available, inexpensive commodity product. Alkylene carbonates have a very low viscosity similar to water, meaning that solvents are usually unnecessary.”

For further information:

www.carbonamine.com

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© Xymertec

BRAND-NEW

Carboline Celebrates 75 Years from Its Foundation To Celebrate its 75th Anniversary, Carboline has announced several events and opportunities. related stories for a chance to win a signature red bucket filled with Carboline products and items. “Two thousand twenty-two marks our 75th Anniversary, an accomplishment we are tremendously proud of.

For 75 years, Carboline has been solving some of the industry’s most challenging problems. We remain committed to the idea that there

C

is always a solution. On behalf of our employees worldwide, vendor

arboline, a global manufacturer of coatings, linings and fireproofing

partners, and customers, we look forward to the next 75 years,” stated

technologies, celebrates its 75th anniversary with the announcement

Chris Tiernay, the president of Carboline.

of numerous events. Through the entirety of 2022, Carboline will

Carboline was founded in 1947 by Stanley Lopata in St. Louis (Missouri,

presents its roots and several achievements, as well as the plans for the

U.S.A.) and has now become a global company that serves several

future of the company.

industries and projects such as NASA’s Cape Canaveral Launch Station,

The events to celebrate 75 years from the foundation will include “75

Olympic Stadiums and countless other museums, refineries, power

Ways to Give Back”, in which the worldwide employees who volunteer

plants, water tanks and marine vessels.

in their community can share their experience, and “75 Red Buckets of Surprises”, where Carboline customers can provide their brand-

For further information: www.carboline.com

Sherwin-Williams Has Received Four JPCL Prestige Awards Sherwin-Williams has been awarded for the excellence in talent, product innovation and coating projects.

T

he Protective & Marine division of Sherwin-Williams has received

and the mentorship inside and outside the industry.

four 2021 JPCL Prestige Awards, ranking first in the “People”,

• The long-lasting polyurethane flooring solutions from the FasTop™

“Innovation” and “Project” categories. The annual JPCL Prestige Awards

Multi Systems were awarded in the “Top Innovation” section thanks to

programme honour influential individuals, impactful products and

the performance, durability and ease of application. Holding up against

the most noteworthy projects in the protective and marine coatings

repeated wear, they can be easily cleaned and disinfected and are

industry. “The Sherwin-Williams team had an impressive showing in

resistant to chemicals, abrasions, slips, heat, steam and moisture.

this year’s JPCL Prestige Awards program with key wins in categories

• The application of a durable protective coating on The Providence – a

that help to shape the continued success and growth of the protective

new 500-ton lift capacity floating dry dock for Biblia Marine Towing and

coatings industry. From expert industry leaders to innovative products

Transportation – received the “Top Project” award. The edge-retentive,

that solve persistent market challenges to projects that rely on our

ultra-high solids epoxy amine coating system is expected to triple Biblia’s

skilled professionals and advanced coatings solutions, Sherwin-Williams

maintenance intervals.

already holds high prestige in the market. But it’s very nice to be

• The premium, two-component fluoropolymer urethane coating

recognized for it, as well,” stated Bryan Draga, the vice-president

Fluorokem® HS 100 earned a distinction in the “Top Product in the

of marketing for Sherwin-Williams Protective & Marine. Overall,

Coating for Steel”, as it extends maintenance and repainting life

Sherwin-Williams Protective & Marine division received four awards:

cycles while providing exceptional colour and gloss retention severe

• Carl Burrell (Global Product Director – Fire, Sherwin-Williams Protective

environmental exposures and extreme weather conditions.

& Marine) received the “Top People” award for the leadership in the fire protection market, the commitment to educating the industry about

For further information:

best fireproofing practices, the contribution to critical industry standards

http://protective.sherwin-williams.com ipcm® Protective Coatings - 2022 APRIL - N. 41

31

BRAND-NEW

Multi-Metal Corrosion Protection with Strong Static Dissipative Properties The revolutionary EcoSonic® VpCI®-125 ESD Shrink Film (HP-UV) is the new product designed by Cortec® to prevent corrosion and ESD damage. © Cortec

© Cortec

N

© Cortec

ew EcoSonic® VpCI®-125 ESD Shrink Film (HP-UV) combines the latest

part; protecting its exterior, as well as void spaces and recessed areas.

film technology with the most effective corrosion protection for all of

Equipment is completely protected from corrosion during storage, lay-up,

your metal products. This revolutionary ESD shrink film is a mixture of high

and staging as well as during domestic and overseas shipments.

(UV) and Vapor phase Corrosion Inhibitor Technology. This film is unique in its ability to prevent corrosion and ESD damage. It combines multi-metal

Advantages

corrosion protection with strong static dissipative properties, and has

• Contains Vapor phase Corrosion Inhibitors (VpCI®) to protect void spaces

many practical characteristics. Users of the film can shrink wrap their small

and recessed areas

or large components as normal to conform to the shape of the object.

• Will shrink using a wide variety of shrink tools including electric and

EcoSonic VpCI -125 ESD Shrink Film (HP-UV) replaces conventional

propane heat guns

rust preventatives such as oils and desiccants, allowing your product to

• Provides UV protection for outdoor storage

be used immediately without cleaning or degreasing. Sealing a product

• Provides multi-metal VpCI® protection to ferrous and non-ferrous metals.

®

®

in this VpCI ESD Shrink Film will protect a wide variety of metals from ®

rust, tarnish, stains and oxidation. It enables cost savings because it will

Designed with the circular economy in mind

eliminate all the degreasing or coating removal required in the past. The

This recyclable and non-toxic film prevents ESD damage while not affecting

products can be used immediately. Additionally, it does not contain free

optical properties. It will not affect plastics used in electronic industry.

amines, phosphates, or halogen-based materials and is non-toxic and

The film meets NACE TM0208-2008 “Vapor Corrosion Inhibiting Ability”

recyclable.

and NACE RP0487-2000 “Selection of Rust Preventives Standards”. Today,

This new revolutionary product effectively protects components from

“greener” ways to approach packaging have become imperative. This

electrostatic discharge. It conforms to the surface resistivity and static

includes looking at the entire range of the product’s life cycle—from raw

decay requirements of MILPRF-81705 D (Static Dissipative Packaging

material sourcing to disposal. With this in mind, Cortec® Corporation

Materials). The film is safe to use and does not contain any harmful Prop

has been working tirelessly to introduce viable packaging options that

65 ingredients. EcoSonic VpCI -125 ESD Shrink Film (HP-UV) has been

can make the “circular economy” a reality. For more than two decades,

tested effective for up to 2 years of corrosion protection and 1 year of

Cortec® has been a leader in environmentally safe films and bags.

®

®

ESD protection. The corrosion inhibitors vaporize and condense on all metal surfaces within the enclosed space and diffuse to every area of your

32

N. 41 - 2022 APRIL - ipcm® Protective Coatings

For further information: www.cortecvci.com

smm-hamburg.com /trailer

the leading international maritime trade fair

driving the maritime transition 6 – 9 sept 2022 hamburg

smm-hamburg.com/news

linkedin.com/company/smmfair

twitter.com/SMMfair #SMMfair

facebook.com/SMMfair

youtube.com/SMMfair

HIGHLIGHT OF THE MONTH

Innovative Solutions for the On-site Application of Anti-corrosion Paints Edited by SAMES KREMLIN Meylan – France

marie-anne.guilldou@sames-kremlin.com

SAMES KREMLIN offers airless solutions for the application of anti-corrosion paints integrating new innovative and patented technologies.

T

he application of anti-corrosion paint has many challenges. Having to

They must not stall, they must not freeze, they must not leak,” explains

paint outdoors, applying complex or highly abrasive paints, painting

Christophe Denis Bosio, Business Development Manager at SAMES

very large parts or at very great distances makes this job extremely

KREMLIN.

demanding. It depends on many parameters: the preparation, the

“We know that frost is the most complicated parameter to control and

conditions of intervention, the equipment for transferring or applying

is the number one enemy of anti-corrosion applicators. The expansion

the paint, the ability of the painters to control the production tool. These

of the air in the exhaust of the pump’s motor creates cold which causes

parameters influence the quality of the finish and the life span of the

the moisture in the motor’s air circuit to condense and frost. This

protection. Making the right investments will optimise the application of

icing accumulates in the air distributor and eventually blocks it. Our

paint and reduce the maintenance costs of the works.

technological answer is VDE (Venturi Dual Exhaust) which prevents this

“Our customers tell us that when they have an outdoor job site, they have

icing phenomenon”.

a weather window to paint everything. They need to be sure that they can

So what is this famous VDE technology? The design of 2 foam blocks (Dual

do all the painting in that window. Meanwhile, their airless pumps must

Exhaust) at the exhaust of the pump’s air motor distributor has several

remain operational and efficient without affecting the paint application.

functions:

© SAMES KREMLIN

34

N. 41 - 2022 APRIL - ipcm® Protective Coatings

HIGHLIGHT OF THE MONTH

© SAMES KREMLIN

• The first one, the evacuation of humidity out of the air circuit is done

cleaned during rinsing operations and thus degrading its sealing function”.

through integrated channels. The design of the housing allows the

There is perhaps no application more demanding than anti-corrosion.

continuous evacuation of moisture to the outside. The air circuit remains

That’s why our pumps are designed to transfer the most difficult paints

dry and therefore does not freeze.

with very high productivity. But the job of anti- corrosion painter is

• The second, the heating of the air by compression at the exhaust in the

extremely difficult. That is why SAMES KREMLIN has focused on the

foam outwards and its acceleration through the Venturi outlets keeps it

parameters that allow it to work better and be more productive.

warm and prevents icing.

This technology integrated in the air motor of SAMES KREMLIN pumps

“SAMES KREMLIN worked on the silencer system installed on the engine.

allows applicators to start the job and concentrate only on their work

This technology makes its pumps the quietest on the market. The

as applicators. The pump will not stall and will maintain its performance

material chosen and the density of the foams muffle the sound allowing

throughout the application.

to respect a decibel rate at the exhaust below 80 db, which nobody has succeeded to date. In fact, when the operator works near the pump(s),

On the other hand, a pump must not leak at the upper lubricant cup, as

he no longer needs earplugs, which increases safety on the site and limits

this causes the product jet to pulse at the gun, thus overconsuming paint

the risk of hearing loss. We also worked a lot on his main tool, the gun.

and also polluting the environment of the workstation.

Notably its ergonomics to allow the painter to be more comfortable in his

The painter must in this case tighten the sealing cartridge and is

application. Furthermore, being far from the pump, when the nozzle clogs,

constantly asking himself the question: how often should the cartridge be

our reversible system is designed to allow the painter to turn his nozzle

tightened to prevent it from leaking, did I tighten it too much, not enough,

and unclog it without lowering the pressure or using a tool to loosen the

etc.? This destroys cartridges and pistons, stops the painter in his work

nozzle base. Our filters are also extremely efficient in preventing nozzle

and is extremely expensive in the long run.

clogging and thus increase the painter’s productivity”.

Christophe Denis Bosio confirms: “The very principle of the chevron joints

In addition to these technical advantages, special attention is paid

is that they must be constantly tightened (under pressure) to guarantee

to simplify maintenance solutions: optimisation of the number of

their basic function: to ensure watertightness. Their undeniable advantage

components, minimisation of the number of operations to be carried out

is their lifespan, because even when worn they can still seal by tightening

and easier access to the areas where work is to be carried out.

them. However, this must be considered, and the painter often notices

SAMES KREMLIN offers robust and powerful airless solutions,

this when the pump leaks. He must therefore tighten the cartridge until

integrating innovative technologies, with very high productivity, capable

it is destroyed or even damage the piston. This is very expensive in spare

of transferring and applying all types of anti-corrosion paints. They

parts. Not to mention that during this time he does not paint.

provide effective answers to the problems encountered on building sites

Our technological answer is the adoption of cartridges with self-tightening

and allow a reduction in the cost of ownership (*) of paint application

seal technology. Thanks to this self-tightening seal system in the upper

equipment. ‹

part of the pump hydraulics, customers no longer need to worry about tightening their seals, they are constantly self-adjusting. Moreover, this

(*) All costs related to the use of equipment: consumption of products, energy,

system is not immersed in the paint, so there is no risk of being badly

maintenance costs, etc.

ipcm® Protective Coatings - 2022 APRIL - N. 41

35

SUCCESS STORIES

Unstoppable Multi-Metal Corrosion Protection Even in Aggressive Outdoor Conditions Cortec® launched Powerfull VpCI®-126 HP UV Shrink Film that provides multi-metal protection for parts and equipment for up to three years even in most aggressive outdoor conditions.

S

hrink film market is expected to rise at a compound annual growth

Corrosion Inhibitor (VpCI®) technology. This shrink film provides multi-

rate of more than 6% for the forecast period of 2021-2029. This

metal protection for parts and equipment for up to three years even

rise is mostly attributable to increasing packaged goods consumption

in most aggressive outdoor conditions. Unlike some preservation

as a result of lifestyle changes. Best seller from EcoCortec plant,

films that rely on white pigments to reflect UV light, VpCI®-126 HP UV

Cortec’s patented, VpCI®-126 HP UV Shrink film, combines high

is transparent; containing unique inhibitors that protects the polymer

strength resins with ultraviolet light stabilizers (UV) and Vapor phase

from UV exposure and prevents degradation. © Cortec

Shrink film market is expected to rise at a compound annual growth rate of more than 6% for the forecast period of 2021-2029.

SUCCESS STORIES

© Cortec

VpCI®-126 HP UV is ideally suited for transit staging, and lay-up of critical equipment, including equipment with large void spaces, multiple metals, and complex geometries.

© Cortec

VpCI®-126 HP UV is an excellent replacement for conventional rust preventatives such as oils and desiccants, making equipment ready to use with no additional cleaning and or degreasing necessary.

VpCI®-126 HP UV can be applied in numerous applications. It is ideally

The components were first given a thorough cleaning with VpCI®-415

suited for transit staging, and lay-up of critical equipment; including

(dilution in water) as needed to remove any dirt or grime. After drying, the

equipment with large void spaces, multiple metals, and complex

most sensitive metal surfaces were coated with VpCI®-368 D removable

geometries. It is an excellent replacement for conventional rust

coating at 50-75 µm (2-3 mils) wet film thickness using a roller. Finally,

preventatives such as oils and desiccants, making equipment ready to

each element was wrapped and heat shrunk in either VpCI®-126 HP

use with no additional cleaning and or degreasing necessary. This will

UV Shrink Film or MilCorr® VpCI® Shrink Film, depending on length

save our customers a lot of their valuable time and money.

of protection needed. The components were shipped out along with

VpCI -126 HP UV Shrink Film, in conjunction with other Cortec ’s

VpCI®-414 as part of a complete kit to clean off VpCI®-368 D at the

products, provides a total turnkey preservation for long-term storage.

destinations when required. After testing Cortec® VpCI® materials, the

Metal parts packaged in VpCI®-126 HP UV Shrink Film receive

customer ultimately decided to incorporate them into their new wind

continuous protection against salt air and humid environments,

turbine projects to avoid corrosion problems from the past as they were

moisture, aggressive industrial atmospheres, and dissimilar metal

extremely satisfied with their performance.

®

®

corrosion. The VpCI’s vaporize and condense on all metal surfaces within exterior, as well as void spaces and recessed areas.

Green solutions - latest developments in corrosion protection environmentally safe packaging

Features:

European EcoCortec® plant is located in Croatia and specializes in

• Multi-metal corrosion inhibition providing contact, barrier, and vapor

production of sustainable corrosion protection packaging under

phase protection.

the license of its mother company, Cortec Corporation. It has been

• Will shrink using a wide variety of shrink tools including electric and

promoting safe, environmentally sustainable packaging solutions for

propane heat guns

more than 15 years. The plant offers films, papers, and bags, mostly

• Recyclable and non-toxic.

from renewable, biobased and recyclable materials. VpCI® film has

the enclosed space; and diffuse to every area of your part, protecting its

already had a large impact on making corrosion protection more

Protection of wind turbine shafts, rings and hubs

environmentally friendly by reducing the need for traditional hazardous

Major Spanish wind energy component manufacturer makes shafts,

rust preventatives. From highly effective film and foam technology to

rings, and hubs for wind turbines and continuously ships them all over

premium custom converted papers, EcoCortec® plant exports its wide

the world from various locations in Spain. They experienced problems

range of products all over the world.

with corrosion and needed a system that would protect the components from corrosion for two to five years in indoor and outdoor conditions.

For further information: https://bit.ly/37gyiLZ

ipcm® Protective Coatings - 2022 APRIL - N. 41

37

© Adobe Stock

INSPECTION LOGBOOK

Coating Inspections - Inspection of Steel Surface Preparation, Part 6 Massimo Cornago NACE International Certified Coating Inspector, NACE CIP PEER Reviewer

cornago@ipcm.it

A

s mentioned in the previous article, we will now discuss the

to enhance the adhesion of the coating system to the substrate. Profile

surface profile testing methods used to check that a specified

measurement is key to comply with specifications, but also to ensure

surface profile has been attained. In fact, when protective coatings

that the blast cleaning process is controlled and it does not produce

need to be applied on structures, it is important that their surfaces

inadequate or excessive profile heights.

are clean and dry in order to prevent premature failure of the coating

Two ASTM standards dealing with surface profile assessment, namely

itself and guarantee a long service life. In many situations (for both

“D 4417-Standard Test Methods for Field Measurement of Surface

new build and repair of structures), blast cleaning of surfaces is

Profile of Blast Cleaned Steel” and “D 7127-Standard Test Method for

required to remove any contamination and create an anchor pattern

Measurement of Surface Roughness of Abrasive Blast Cleaned Metal

38

N. 41 - 2022 APRIL - ipcm® Protective Coatings

INSPECTION LOGBOOK

Surfaces Using a Portable Stylus Instrument”, are normally used. In this

both the blasted steel and the disc. Matching may also be done visually

article, we will discuss the standard ASTM D 4417, describing three

without magnification. It is not advisable to do the matching by touch,

methods for assessing profiled surfaces, while taking the appropriate

in order to avoid any surface contamination. If the profile falls between

international standards, i.e. NACE, SSPC, and ISO, into consideration.

two standard profiles, indicate a profile range between these two profiles (i.e. 50-76 micrometres or 2.0-3.0 mils).

Testing for surface preparation (ASTM D 4417)

3. Determine the profile at sufficient locations, as indicated in the

The inspector should verify that the specified surface profile has been

project specification or as agreed upon by the interested parties, in

attained, based on the definition of surface profile as the distance

order to characterise the surface, making three assessments at each

(height) from the peaks to the valleys (or the roughness) created

location.

by abrasive blast cleaning. Increasing the surface profile effectively increases the surface area of steel, promoting good coating adhesion.

Five grades may be recorded:

Too shallow a surface profile may result in premature coating failure

1. Finer-than-Fine Grade – any profile assessed as being lower than the

due to lack of adhesion, which can result in peeling, blistering, or

limit for Fine

delamination. Too high a profile may have peaks that are inadequately

2. Fine Grade – profiles equal to segment 1 and up to, but excluding,

covered, resulting in rust rashing or rust spots.

segment 2

Surface profile tests should be done daily and every time there is a

3. Medium Grade – profiles equal to segment 2 and up to, but

change in the abrasives, the blasting pressure, or other operating

excluding, segment 3

parameters.

4. Coarse Grade – profiles equal to segment 3 and up to, but

The three methods normally used in the industry for assessing surface

excluding, segment 4

profiles, described in ASTM D 4417 in order of preference, are as

5. Coarser-than-Coarse Grade – any profile assessed as being greater

follows:

than the upper limit for Coarse.

• Comparators (Method A) • Profile depth gage (Method B).

The calibration of a comparator shall be carried out every six months

• Replica tape (Method C).

(see ISO 8503/1). Comparators require careful handling and if any surface wear is observed, re-calibration shall be carried out before

Profile comparator (Method A)

further use. As a guide, comparators in daily use may require re-

Method A is commonly referred to as the Surface Comparator and the

calibrated every three months. In all cases of dispute, re-calibration

most commonly used version is the “ISO Surface Comparator”, which

should be carried out prior to re-assessment of the test surface.

meets the requirements of ISO 8503 – 1. There are two versions of

The accuracy, precision, and repeatability of the test depend greatly on

this comparator, one for grit blasted surfaces and one for shot blasted

the individual administering the test.

surfaces. The difference can be seen in the shape of the profile, the grit profile is angular and the shot profile is more rounded. Each ISO

Profile depth gage (Method B)

comparator has four segments representing grades of profile depth.

Method B describes the dial gauge depth micrometre, also known as

The comparator is used by either visual or tactile comparison with the

the Surface Profile Gauge. A profile depth gage (or depth micrometre)

surface to be inspected and the two segments that bracket the test

consists of a dial gage and a stylus (pointer) that protrudes from the

surface are determined.

base of the gage. The base of the gage rests on profile peaks, while

Other similar comparators include the Keene-Tator Surface

the stylus protrudes into the valleys of the blasted steel surface. The

Comparator, the Rubert Surface Comparator, and the Rugotest Surface

profile is therefore determined based on the relative position of the tip

Comparator. These are less commonly used since the ISO test method

of the stylus and the base of the gage. Several readings must be taken

was published, but as paint specifications have a relatively long life they

to ensure that the stylus rests on the tops or sides of the peaks rather

are still used.

than fully penetrating the valleys.

The correct procedure is as follows:

The correct procedure is as follows:

1. Select the comparator disc prepared for the type of abrasive used

1. Hold the gage by the base and press it down onto the blasted steel

(i.e. grit/slag, shot, or sand) and place it directly on the blast cleaned

surface until a reading appears on the dial.

steel surface.

2. Make several measurements at several locations and average those

2. Compare the test area visually using a 5X magnifier to best match

taken at each location. Do not slide the gage along the surface, as this

one of the standard profiles. The magnifier should be in focus with

will damage the tip of the stylus.

ipcm® Protective Coatings - 2022 APRIL - N. 41

39

INSPECTION LOGBOOK

3. Calibration is done placing the gage on a smooth glass plate and

can be undertaken for the replica tape is on the dial gauge used to

adjusting the outer ring of the dial, if necessary, to read zero, in

measure the tape after the replica has been formed. The dial gauge

compliance with the National Physical Laboratory procedure in the UK

readings can be checked using the same measured thickness foils or

or the NIST one in the US; the certificate also has this traceability.

shims that are provided for coating thickness gages using values in the range 50 to 250 μm. Foils of this type can be supplied with a calibration

Replica tape (Method C)

certificate and the measurements are traceable to NIST or other

The replica tape is the most commonly used method for measuring the

National Standards such as the National Physical Laboratory in the UK.

surface profile of prepared steel. It consists of a layer of deformable

As part of the verification process, it is essential to ensure that the

plastic bonded to a polyester backing.

correct grade of replica tape is used to measure the profile in question.

The deformable side of the tape is rubbed onto the blast-cleaned

Each tape has an upper and lower limit for the range of profile height.

surface with a rigid swizzle stick to produce a reverse replica of the

The Replica Tape requires the replica to be taken and then measured,

profile (mirror image of the real profile). The tape profile is inserted

and the burnishing can take several seconds. However, an experienced

between the anvils of a spring micrometre and a measurement of the

inspector can get values within half a minute, and the replica tape can

surface profile or roughness is obtained.

be stored in an inspector’s notebook as a permanent record of the test.

The tape consists of a 51-micrometre (2.0-mil) thick film of noncontaining microscopic bubbles. The tapes can be stored as permanent

Testing for surface contamination after surface preparation

records of profile heights.

After surface preparation, the inspector may again be required to verify

compressible Mylar, which serves as a backing for an emulsion

that the surface is free of any contamination, particularly of soluble The correct procedure is as follows:

salts, grease/oil, and dust.

1. Select a piece of tape representing the desired profile range,

• Soluble salts: this test is normally performed after the steel has been

between COARSE (20-50 micrometres or 0.8-2 mils) and X-COARSE

prepared by blast cleaning; however, if a long time interval occurs

(38-110 micrometres or 1.5-4.5 mils). It may be possible to measure

between the application of one coating layer and another (i.e. full

up to 150 micrometres (6 mils) using X-COARSE tape. Remove its

top coating shop-applied primer), it may be advisable to check for

paper backing and place it on the blast cleaning steel surface, with the

contamination on the existing coating to be overcoated.

adhesive side downwards.

• Grease/oil: after surface preparation, the inspector may again

2. Holding the tape firmly in place, rub the circular portion with a

be required to verify that the surface is free of grease and oil

burnishing tool until the non-deformable Mylar

contamination, to reduce © Adobe Stock

any coating adhesion. The

backing on the tape turns

prepared surfaces must be

uniformly grey.

completely free of grease

3. Remove the tape and

and oil.

measure its thickness

• Dust: abrasive blasting

within the circle using a

and other media at the

spring micrometre. Then,

jobsite can leave dust on

subtract the thickness (50

cleaned surfaces. Dust

micrometres or 2 mils) of

collected on cleaned

the Mylar backing to obtain

surfaces can interfere with

the actual profile measure.

coating adhesion, so the

4. Measure the profile

prepared surfaces must be

at sufficient locations,

completely free of dust.

as indicated in the specifications or as agreed

In the next article, we will

upon by the interested

further discuss the testing

parties, to characterise the

methods for surface

surface profile.

contamination after

The only verification that

40

N. 41 - 2022 APRIL - ipcm® Protective Coatings

surface preparation. ‹

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THE MARKETING CORNER

Digital Marketing Trends 2022: Everything There is to Know Barbara Pennati eos Mktg&Communication Srl

info@eosmarketing.it

The latest reports speak of an increasingly digitalized world, which is moving at great speed towards more immersive experiences, new formats and new technologies. From recommerce and NFTs to cryptocurrencies, here are 7 digital marketing trends to keep an eye on in 2022.

A

More and more people are using the Internet, translation tools and voice assistants

marketing strategy that can be defined as such that does not take into

The latest figures tell us that 62.5% of the world population uses the

consideration the needs, expectations and behaviours of its audience.

Internet. This means that the gap between those who have access

Therefore, it goes without saying that knowing how people use the

to the internet and those who do not have it is getting smaller and

internet and social media, what content they enjoy, what they prefer

smaller.

when it comes to the digital world and what are the latest trends in the

The user base is therefore expanding and is destined to increase

sector is essential for planning a truly effective communication strategy.

to include a large part of the world population: to date, only about

Just a few days ago, We Are Social and Hootsuite published the Digital

3 billion people remain without internet, a sign that digitization is

2022 Global Overview Report, which every year brings us over 200

almost everywhere.

pages of data and statistics on the digital world and which is invaluable

But how do people use the Internet? 61% of users use the internet to

for us to understand in which direction the digital is heading.

find information; 55.3% to stay in touch with friends and family and

In this article we will summarize the main digital marketing trends and

53.1% to stay updated on news and events.

how brands can exploit them in their 2022 marketing strategy.

Therefore, intercepting our target’s queries and providing an answer

nyone who approaches marketing for the first time is told that the first thing to do is to know your audience. In fact, there is no

© EOS mktg&communication

THE MARKETING CORNER

through interesting content and insights must remain our priority.

Other data that is worth dwelling on concern the use of automatic translation tools and voice assistants.

Every week, 31.9% of users worldwide use tools to automatically translate online content into other languages. A percentage that is destined to rise when we look at the data country by country, i.e., Colombia (57%), Brazil (53.7%) or Poland (46.5%), to name a European country.

This is linked to topic very important for SEO and often underestimated by marketers: not all users are looking for content in English, quite the contrary. Many people not only look for content in their own language but they also translate it with special tools when they land on pages in other languages.

This means that, if our target is international, we must consider translating our content into multiple languages.

Another interesting fact, which we find again this year, concerns the use of voice assistants. Every week, 24.1% of users worldwide use voice assistants like Alexa or Siri to search for information online.

Therefore, our content must also be optimized for voice search, through the use of conversational and proximity keywords.

Social networks are a strategic touchpoint but organic engagement is decreasing Compared to 2021, the social media user

So, although the Meta apps continue to hold

same frequency; however, the fact remains

base registered a +10.1%, reaching 4.62

the podium of the most used platforms in

that an overlap of audience from one

billion users, a truly surprising figure.

the world in terms of active global users,

platform to another is highly probable.

The average time spent on social media is 2

TikTok is rapidly advancing in the ranking,

It is also interesting to note that 43.5% of

hours and 27 minutes, with YouTube leading

attracting the attention of an ever-increasing

users use social networks to search for

the ranking of the platforms on which

number of users and for more and more

information on brands, meaning that they

people spend the highest number of hours

time.

remain an important touchpoint for every

each month on average: 23.7. However, if

Having said that, there’s a trend which we

business. Social media are also important to

the YouTube figure is stable compared to

found last year and that is still valid: the

follow brands from which we have already

that of 2021, TikTok, which has an average

overlap of social accounts. On average, a

bought something, brands from which we

of 19.6 hours per month, recorded a +48%

user uses 7.5 social platforms every month.

are considering buying something and

compared to last year.

Certainly not at the same time nor with the

companies that are relevant to our work.

ipcm® Protective Coatings - 2022 APRIL - N. 41

43

In terms of advertising, global social media advertising spend

vanity metrics are no longer sufficient or absolute proof of success.

exceeded $ 150 billion in 2021, with social media ads accounting for

Having said that, as the data cited at the beginning show, social

around a third (33.1%) of the total digital spend.

networks remain an important touchpoint, so it is good to supervise

This triggered a number of consequences.

them, especially if we have already created brand pages in the past.

First, while advertisers spent 14% more on social media ads in Q4

At the same time, in light of these data and taking into account the

2021 compared to Q4 2020, it also caused a 21.7% increase in CPM

target overlaps between the various platforms, it is good to observe

(an average of $ 9.13 per 1,000 impressions).

which social networks (or formats) give us the best results in terms of

As a result, due to the higher average cost per impression, advertisers

engagement and focus our marketing efforts on these.

generated fewer total impressions in the fourth quarter of 2021

When it comes to advertising, given the higher spend in the face of a

compared to the same period in 2020, despite the higher ad spend.

lower number of impressions, the advice remains to focus our budget

But this has not led to a decline in the effectiveness of social media

on those campaigns that we believe are more valuable for our brand.

advertising. Indeed, the latest GWI data tells us that more than 1 in products and services through social media ads, a figure only slightly

The future of e-commerce is recommerce and live commerce

lower than that of TV ads (31,1%).

When it comes to e-commerce, it should come as no surprise that

In terms of organic engagement, just under 1 in 4 users (23.2%) likes

the growth that began during the Covid-19 pandemic shows no

or actively follows a brand on social media every month, while almost

signs of slowing down and that even tourism-related e-commerce is

1 in 8 (12.2%) says they share the social media posts of brands at least

recovering.

once a month. Locowise data also indicates that Facebook pages can

Data from GWI shows that nearly 6 in 10 internet users (58.4%) buy

expect an average engagement rate of 0.07%, a very low figure: only

something online every week, a figure that experts say is set to rise.

7 fans out of 10,000 react, comment or share any post. Paradoxically,

On the other hand, a trend that is gaining momentum is that of

this percentage is destined to drop further, the greater the number of

“recommerce”, a popular choice for 1 in 7 users (14.4%) who buys a

fans: for 100,000 fans, the average engagement rate is 0.05%.

second-hand item every week.

These data confirm what we probably already knew: engagement

Even Facebook Marketplace and Instagram Shop report growing data,

rates on social networks (some more than others) are decreasing and

a sign perhaps that the barrier between the physical experience and

4 Internet users (corresponding to 27.6%) discovers new brands,

44

N. 41 - 2022 APRIL - ipcm® Protective Coatings

THE MARKETING CORNER

virtual shopping is breaking down, convincing even the most cautious

on a blockchain. These tokens certify the authenticity, uniqueness and

and doubtful buyers to make online purchases.

ownership of a digital object.

A trend that will further help to narrow the differences between the

The success and novelty of NFTs have contributed to creating

in-store experience and online shopping is live commerce, which

speculation, which in some cases is putting this technology in a bad

allows participants to interact immediately with sellers. A format

light, even though it could actually prove to be very interesting and full

already popular in China and registering record sales.

of potential.

With the hope that, after the initial irrational phase, the conversation

Mobile apps have become an established business

will focus more on creating effective and lasting value, in this context,

Data from App Annie tells us that the typical mobile user spends an

brands can start thinking about how to draw on these digital

average of 4 hours and 48 minutes a day using their smartphone.

resources, creating their own NFTs or building partnerships with

Smartphone users around the world spent a total of $ 170 billion on

creators that allow you to build a real community and provide added

apps and in-app purchases in 2021.

value for your customers.

Therefore, the app business (and in-app purchases) presents an format to offer their products and services. And, contrary to what one

Cryptocurrencies will be the future (but only for certain demographic groups)

might think, users are willing to pay for access to an app they find

Another asset that is attracting people’s attention like NFTs are

useful.

cryptocurrencies, on which the debate is often polarized, perhaps

However, as always in marketing, the key to success lies in the

because this time around as well, speculation has put the technology

usefulness of what we offer. Otherwise, the risk is to invest in

in a bad light, even if more and more people use it: the number of

something that will give no added value to our audience and no return

people owning cryptocurrencies increased by over a third (+ 37.8%)

to our brand.

compared to last year.

important opportunity for brands, which can take advantage of this

GWI reports that more than 1 in 10 users now owns some form of

NFTs towards the creation of a lasting value

cryptocurrency, a figure that rises to more than 2 in 10 in Thailand.

NFT stands for non-fungible tokens, i.e., unique digital assets such as

Indeed, it is precisely in countries with developing economies – where

an animation, graphic design, GIF, audio/video file, or meme, that exist

conventional currencies are more subjected to exchange rates

ipcm® Protective Coatings - 2022 APRIL - N. 41

45

fluctuations – that cryptocurrencies are

about data privacy and on the other, about

collection methods that put consumer privacy

becoming more widespread.

the end of third-party cookies.

first. How? By investing in campaigns aimed

Therefore, digital currencies offer a potential

In reality, the privacy discourse highlighted a

at collecting proprietary data through e-mails,

that has not yet been explored: if in a country

problem that we already knew but to which

newsletters, social media and CRM.

like the United States they are used by a

we have probably never paid too much

It may seem to some that we are regressing

niche of users, in other countries they are

attention: what we call “our audience” has

compared to where we are today. But it is not

more widespread. If our audience is in those

actually always been owned by Facebook,

only the success of our marketing strategy

countries, accepting cryptocurrencies could

Instagram, Twitter or any other platform. We,

that asks this from us but – obviously – our

help attract new customers.

as a brand, have no direct control over that

own audience as well.

audience.

The transition to first-entry data is getting closer and closer

This is why experts identify 2022 as the year

Summing up

we should actually start owning our audience.

Thanks to the spread of digitalization, the

For two years now, we have been talking on

Translated into practice, this means that

increase in connection speed, as well as the

the one hand about the growing concern

brands need to start integrating data

greater accessibility to increasingly powerful digital tools, the digital world is moving rapidly towards increasingly immersive experiences and new, more engaging formats, able to draw the best from social media and entertainment.

Brands that want to stand out in this scenario will have to be able to keep up with the times, quickly abandoning the initial distrust of new technologies and instead thinking about how to present the brand. ‹

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46

N. 41 - 2022 APRIL - ipcm® Protective Coatings

THE BIGGEST EUROPEAN EXHIBITION & CONFERENCE SPECIFICALLY DEDICATED TO THE CONCRETE AND MASONRY INDUSTRIES

28-30 April 2022 Piacenza Italy

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AMONG THE CONFIRMED EXHIBITORS AT GIC 2022

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Under the Patronage of

For info and stand bookings: www.gic-expo.it ph. +39 010 5704948 - info@gic-expo.it

ZOOM ON EVENTS

PaintExpo 2022 – More Than 420 Exhibitors Are Presenting Their Innovations in Industrial Coating The next edition of PaintExpo, the world’s leading trade fair for industrial coating technology, will take place in Karlsruhe from 26 to 29 April 2022.

A

fter a break of four years owing to the pandemic, there are only

reflects just how accurate this prediction is. More than 420 exhibitors

a few days to go. The eighth edition of PaintExpo will be opening

will once again fill three exhibition halls for the four days of the world’s

its doors in Karlsruhe from 26 to 29 April 2022. For all those working

leading trade fair in Karlsruhe and update visitors on the current state

for coating companies, in contract coating or any areas of the coating

of affairs in the industrial coating industry.

technology industry, the world’s leading trade fair offers a window aspects of industrial coating. The who’s who of the industry will be

Highly international and large numbers of first-time exhibitors

coming together to present their solutions and premieres. With more

Exhibitors at PaintExpo are from 27 countries. 42 per cent of exhibitors

than 420 exhibitors from 27 countries, PaintExpo represents the entire

will be travelling to Karlsruhe from abroad. Leading companies in

value chain of industrial coating technology and surface coating. Over

the industry from countries such as Italy, Turkey, Switzerland, Spain,

40 per cent of exhibitors come from abroad and around ten per cent

Austria, France as well as Belgium will be exhibiting. One in ten

are taking part in PaintExpo for the first time.

exhibitors will be at PaintExpo for the first time.

“We have been talking to many of our clients and can feel their

Examples of companies celebrating their premiere at PaintExpo across

excitement at the prospect of being able to finally show their latest

all areas of the exhibition include the coating producer Axcentive from

developments in coating technology live and in person once again at

France, the spraying line manufacturers CABO, Coral and Nova Verta

PaintExpo. Exhibitors and visitors alike are looking forward to the 8th

from Italy and also Prelit, a Swiss specialist in chemical pre-treatment.

on a wide range of innovations, future technologies and trends in all

edition of PaintExpo with its opportunities for personal exchanges and a comprehensive overview of the market. Our clients are hoping to

Research and science for tomorrow’s coating technology

agree new projects and shape the future of the industry together”, says

In addition to all the current industry solutions, visitors to the trade

Ivonne Simons, Project Director of PaintExpo. The number of bookings

fair can expect a focused outlook on the future of coating technology.

© FairFair GmbH

48

N. 41 - 2022 APRIL - ipcm® Protective Coatings

ZOOM ON EVENTS A collective stand organised by the German Research Association

are looking for at PaintExpo. Independently of which materials need

for Surface Treatment (DFO) will be centrally positioned to provide a

coating, at the world’s leading trade fair for industrial coating technology,

point of contact for knowledge transfer and research information. The

answers to future challenges and questions will be available from

twelve exhibitors on the collective stand are aiming to build on the

specialists at the forefront of technological developments.

technological advances and economic success of the industrial coating industry and ensure long-term sustainability.

Extensive product and exhibitor directory is online

“For many years now, we have been expanding our unique,

A wealth of exciting innovations from exhibiting global industry leaders

interdisciplinary network of experts. Our members play an active

and established medium-sized companies can already be found in the

role on numerous expert committees, initiate new research projects,

digital Exhibitor and Product Directory on the PaintExpo website. An

conferences, joint ventures and much more”, explains Ernst-Hermann

interactive plan of the exhibition halls and a digital matchmaking tool to

Timmermann, Managing Director of DFO. “This ensures that the

establish contacts and arrange meetings are available to make it easier

standards defining the future of research, innovation and education

to plan a visit to the fair.

in the industry are regularly updated”, he adds. “PaintExpo is the ideal

Tickets are only available for purchase online

place for this”.

From today you can buy tickets for the fair or redeem your invitation

All the variety of the industrial coating industry in one place

in the online ticket shop at http://www.paintexpo.de/tickets. Worn as a

The products, solutions and services on display at PaintExpo cover the

entry to PaintExpo and allows them to avoid queues.

badge at the fair, the printed online ticket gives visitors quick and easy

entire spectrum of industrial coating. From wet coating and powder coating to coil coating, this unique global showcase for industrial coating

For further information: www.paintexpo.de

technology encompasses coating solutions for all industries, applications and materials. The spectrum ranges from surface treatment, coatings and spraying lines to final quality assurance.

Trade visitors from contract coating companies, automotive industries, vehicle assembly, machine tool production and plant construction to the plastics processing industry as well as the electronics and furniture industries will be able to find the coating products and services they

© image & art

© image & art

ipcm® Protective Coatings - 2022 APRIL - N. 41

49

ZOOM ON EVENTS

A Record-breaking Event Lies Ahead: the 4th IVS Industrial Valve Summit IVS – Industrial Valve Summit, the most important international event on industrial valve technologies and flow control solutions will take place on 25-26 May in Bergamo (Italy).

T

hree hundred exhibitors from 12 countries representing 4

and Storage (CSS) technologies, i.e. geological confinement of carbon

continents, to be hosted in the largest venue ever selected by the

dioxide.

fair’s organisers. Such record-breaking figures show the enthusiasm

IVS provides a showcase to discuss change and analyse the direction

with which the sector has greeted the 4th IVS – Industrial Valve Summit,

in which the market is moving, especially in the current, fast-evolving

the most important international event on industrial valve technologies

context. In 2020, worldwide investments in the Oil&Gas industry went

and flow control solutions. IVS 2022 was presented just a few days ago

down by approximately 30%. Recovery in 2021 has been moderate, yet

in Milan, at Palazzo delle Stelline: sponsored by Confindustria Bergamo

insufficient to restore pre-pandemic levels. This has resulted in a fall in

and Promoberg, it will take place in Bergamo on 25 and 26 May.

revenues for businesses in the sector (-11%). However, already in 2021,

The programme of the conference section of the Summit bears further

Italian exports have grown at the same rate as (or even at a higher rate

testimony to the interest that operators along the entire chain have

than) that of competitors in over 60% of the top 100 global markets.

shown: a record-breaking number of scientific contributions has

These figures were gathered by Osservatorio IVS-Prometeia in “The

been submitted, yielding a rich set of specialist conferences, debate

Oil & Gas Valve Industry in Italy”, which will be thoroughly presented at

opportunities and technical meetings. This year, the Summit will host

the Summit opening conference. The research captures the state of

workshops, labs and panels alongside its five breakout sessions.

the art of the sector in Italy, boasting 255 businesses, 11,400 workers

The great interest raised by the energy transition has attracted the

and a value of production of 3.2 billion euros. Italy leads the list of EU

focus of the industry. At the forefront are the challenges of hydrogen,

manufacturers: almost 2 out of 5 Oil&Gas valves in Europe are made

which needs new infrastructures for transport and distribution. The

in Italy. Namely, the industrial district where over 90% of the sector’s

event will open on 24 May with a round table, the first of its kind,

national production originates is based in a range of 100 km from the

focussing on the role of hydrogen in the upcoming decarbonisation

Province of Bergamo.

scenarios. Conferences will also discuss the new applications of the latest innovations, such as additive manufacturing and Carbon Capture

© photolombardi@gmail.com

50

N. 41 - 2022 APRIL - ipcm® Protective Coatings

For further information: https://industrialvalvesummit.com © photolombardi@gmail.com

ZOOM ON EVENTS

© Easyfairs

Paint & Coating News and Innovation Coming to StocExpo StocExpo 2022 will take place on 23-25 May in Rotterdam Ahoy (Netherlands).

S

tocExpo 2022, the largest and longest running international bulk

present new durable, flexible sealants and sealing systems for tanks and

liquid storage event, returns to the Rotterdam Ahoy on 23 - 25 May.

tank parks on stand B18 on the StocExpo exhibition floor.

On display at the exhibition floor will be paint and coating news and

We also expect to see innovations from:

innovations from…

• Concrete Canvas (Stand C2)

Canadian robotics company, Confined Space Robotics, specialists in

• Presserv (Stand I7)

remote solutions for abrasive blasting and coating projects. The company

• Trisoplast Mineral Liners (Stand E32)

has been shortlisted in the Innovative Technology category of the Global

• PPG Coatings Europe (Stand B13)

Tank Storage Awards 2022, and its ALPHA1 Blast arm, a robotic abrasive

• Mascoat (Stand F14)

blasting system that reduces human exposure to confined spaces, will be

• Sherwin Williams (Stand E28).

on display on the exhibition floor in pod C on stand C29.

StocExpo is expected to bring together thousands of visitors and over 100

Coatings, linings and fireproofing specialists, Carboline, has a new

exhibitors from the global tank storage industry. The event will host the

Managing Director and will be celebrating its 75th anniversary at StocExpo

Global Tank Storage Awards, there will be an innovation trail hosted by

this year. Its Plastite and Phenoline novolac epoxy coating for internal tank

Sprint Robotics, and a future-focused conference hosted by Tank Storage

lining products, and its Rustbond primer/sealer range, will all be on display

Magazine, as well as numerous networking opportunities.

on the exhibition floor on stand K7.

Petrochemical sealant specialists, Saba Adhesives and Sealants, will

For further information: www.stocexpo.com/en/

ipcm® Protective Coatings - 2022 APRIL - N. 41

51

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