PCE Magazine: October - December 2023

IN THIS ISSUE:

Lifting the Lid

Teknos has provided paints and coatings for a newly commissioned nuclear power plant

Up Front

How OnAim Conservation has restored the World War II operations map on the USS Texas

Analysis

An alternative polyurea lining solution for a swimming pool and smaller hydrotherapy pool

The Leading Protective Coatings Magazine October – December 2023

Scan this QR code to read this and past editions.

Contact us today

+44 1252 732 220 info@pce-international.com

pce-international.com

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IN THIS ISSUE:

PROTECTIVE COATINGS INTERNATIONAL

2

Lifting the Lid

Up Front

Teknos has provided paints and coatings for a newly commissioned nuclear power plant

How OnAim Conservation has restored the World War II operations map on the USS Texas

Analysis

An alternative polyurea lining solution for a swimming pool and smaller hydrotherapy pool

The Leading Protective Coatings Magazine October – December 2023

OCTOBER – DECEMBER 2023

Scan this QR code to read this and past editions.

Contact us today

+44 1252 732 220 info@pce-international.com

4

pce-international.com

The energy sector is in transition, accelerated by the energy crisis in Europe. Both hydrogen and nuclear energy have a part to play, with Teknos providing paints and coatings for the newly-commissioned Olkiluoto 3 nuclear power plant in Finland.

Takkatie 3, P.O. Box 107 FI-00370 Helsinki Finland +358 9 506 091

Lifting the Lid

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Teknos helps enable the energy transformation.

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Up Front The careful steps taken by OnAim Conservation to fully reveal what remained of a World War II operations map, rectify the damage and restore it on the USS Texas.

Analysis Polyurea provides an alternative lining solution for a swimming pool and smaller hydrotherapy pool with intricate details.

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Update Environmental Product Declarations explained by Bob Dirks, Global Segment Manager, and Sencan Kizilkaya, Global Product Manager for AkzoNobel’s Powder Coatings (Architecture) and Bob Glendenning, Fire Design Engineering Manager of Sherwin-Williams Protective & Marine Coatings.

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Review The Heureka bridge in Finland is painted with Nor-Maali’s SILKO paint system, Cortec provides aboveground storage tank protection, HMG provides the paint for a classic tractor restoration and SIFCO looks at the advantages of selective electroplating in electric motors.

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Spotlight Marine coatings are put under the spotlight with flashes from GIT Coatings, Selektope, AkzoNobel, PPG.

CONTENTS PCE OCTOBER – DECEMBER 2023

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76

News The latest products, appointments and industry news.

In Focus In an EV plant construction, specifiers must get creative to stop water vapour transfer (WVT), explains Richie Cropp, Northeast Subject Matter Expert for Dudick, Inc, and a new floor for a heavy use area in a waste recycling is supplied in double-quick time.

Editor: Mark Langdon mark@pce-international.com Contributing Editor: Mike Garside mike@pce-international.com Advertisement Manager: Nick Carugati nick@pce-international.com Production Manager: Tatum Le Patourel tatum@satzuma-creative.co.uk Designer: Fiona Andreanelli fiona.andreanelli@mpigroup.co.uk Accounts: Claire Long claire.long@mpigroup.co.uk Publisher: Andrew Deere andrew.deere@mpigroup.co.uk

MPI Group Peel House, Upper South View Farnham, Surrey GU9 7JN, England Tel: +44 (0) 1252 732220 Email: info@mpigroup.co.uk www.mpigroup.co.uk MPI Group, as a body, is not responsible for any opinions expressed in PCE by contributors. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without prior permission of MPI Group. © Marine Publications International Ltd 2021

IN THIS ISSUE:

PROTECTIVE COATINGS INTERNATIONAL

2

Lifting the Lid

Up Front

Teknos has provided paints and coatings for a newly commissioned nuclear power plant

How OnAim Conservation has restored the World War II operations map on the USS Texas

Analysis

An alternative polyurea lining solution for a swimming pool and smaller hydrotherapy pool

The Leading Protective Coatings Magazine October – December 2023

OCTOBER – DECEMBER 2023

Scan this QR code to read this and past editions.

Contact us today

+44 1252 732 220 info@pce-international.com

4

pce-international.com

The energy sector is in transition, accelerated by the energy crisis in Europe. Both hydrogen and nuclear energy have a part to play, with Teknos providing paints and coatings for the newly-commissioned Olkiluoto 3 nuclear power plant in Finland.

Takkatie 3, P.O. Box 107 FI-00370 Helsinki Finland +358 9 506 091

Lifting the Lid

44

Teknos helps enable the energy transformation.

10

Whilst many factors are beyond manufacturers’ control, identifying paints and coatings that offer next-level protection for important transformer metal components is within their purview, explains Maria Lamorey, Commercial Strategy Manager, PPG.

Up Front The careful steps taken by OnAim Conservation to fully reveal what remained of a World War II operations map, rectify the damage and restore it on the USS Texas.

Analysis

50

Update Environmental Product Declarations explained by Bob Dirks, Global Segment Manager, and Sencan Kizilkaya, Global Product Manager for AkzoNobel’s Powder Coatings (Architecture) and Bob Glendenning, Fire Design Engineering Manager of Sherwin-Williams Protective & Marine Coatings.

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CONTENTS PCE OCTOBER – DECEMBER 2023

36

The Heureka bridge in Finland is painted with Nor-Maali’s SILKO paint system, Cortec provides aboveground storage tank protection, HMG provides the paint for a classic tractor restoration and SIFCO looks at the advantages of selective electroplating in electric motors.

Spotlight Marine coatings are put under the spotlight with flashes from GIT Coatings, Selektope, AkzoNobel, PPG.

In Focus In an EV plant construction, specifiers must get creative to stop water vapour transfer (WVT), explains Richie Cropp, Northeast Subject Matter Expert for Dudick, Inc, and a new floor for a heavy use area in a waste recycling is supplied in double-quick time.

Editor: Mark Langdon mark@pce-international.com Contributing Editor: Mike Garside mike@pce-international.com Advertisement Manager: Nick Carugati nick@pce-international.com Production Manager: Tatum Le Patourel tatum@satzuma-creative.co.uk Designer: Fiona Andreanelli fiona.andreanelli@mpigroup.co.uk Accounts: Claire Long claire.long@mpigroup.co.uk Publisher: Andrew Deere andrew.deere@mpigroup.co.uk

Review

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News The latest products, appointments and industry news.

MPI Group Peel House, Upper South View Farnham, Surrey GU9 7JN, England Tel: +44 (0) 1252 732220 Email: info@mpigroup.co.uk www.mpigroup.co.uk MPI Group, as a body, is not responsible for any opinions expressed in PCE by contributors. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without prior permission of MPI Group. © Marine Publications International Ltd 2021

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LIFTING THE LID

Enabling the energy TRANSFORMATION

LIFTING THE LID PCE OCTOBER – DECEMBER 2023

The energy sector is in transition, accelerated by the energy crisis in Europe. From the perspective of climate, there is a need to move from burning fossil fuels to using renewable energy. As Teknos explains, both hydrogen and nuclear energy have a part to play.

 Teknos has provided paints and coatings for the newlycommissioned Olkiluoto 3 nuclear power plant in Finland

LIFTING THE LID PCE OCTOBER – DECEMBER 2023

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t the centre of the green transition is hydrogen, a clean-burning molecule that can be found everywhere in nature. Renewable and low-carbon hydrogen has been determined as crucial for meeting the Paris Agreement goals on reducing greenhouse gas emissions.

As a result, the global hydrogen market is predicted to grow significantly over the coming years. The European Hydrogen Backbone (EHB) vision shows that by 2030, there will be five pan-European hydrogen supply and import corridors with almost 28,000km of initial pipelines, connecting industrial clusters, ports, and hydrogen valleys. With a strong focus on sustainability and innovation, coatings manufacturer Teknos is looking to ensure that its products meet the needs of the future energy industry.

LIFTING THE LID PCE OCTOBER – DECEMBER 2023

Coating solutions for the hydrogen industry On the way towards the visions for hydrogen, there are still several uncertainties to tackle.

For example, the challenge in transporting and storing hydrogen in pipelines – hydrogen may have a detrimental effect on the steel surface of the pipes.

“Green hydrogen can contribute to the growing energy demand, but we need to overcome some challenges,” says Andreas Karpow, R&D Manager Energy Teknos Group.

“Hydrogen degrades the mechanical properties of most metals, accelerating fatigue and decreasing the fracture resistance of pipes, especially at dynamic pressure variations, which can cause pipeline parts to fail. Coatings can protect steel against the impact of hydrogen and in addition, can significantly decrease the friction inside the pipe for more efficient transfer of gas.”

Third-party solutions Teknos has a long history and track record in developing high-quality coating solutions for the energy sector. Drawing from this experience, it is a natural step for Teknos to expand into the hydrogen arena. Teknos is undertaking research with its products to ensure the safety and durability of future hydrogen infrastructure.

“We are proactively searching for solutions to support the hydrogen industry using our extensive experience gained from many years supporting the energy sector,” explains Karpow.

In 2022, Teknos worked with Mulheim Pipecoatings GmbH as part of EUROPIPE GmbH’s hydrogen research programme, in which different Teknos coatings were tested in pure hydrogen to evaluate their suitability for use in hydrogen transport. In the project, Teknopox 3296-06 and Teknopox 3297-00 coating systems performed well when tested in the pure hydrogen environment; no blistering,

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NUCLEAR COATINGS Teknos has also provided paints and coatings for the newly-commissioned Olkiluoto 3 nuclear power plant in Finland.

Nuclear power plants must be managed safely throughout their lifecycle, which places special requirements on the coatings.

Teknos has a long track record in meeting the technical requirements set for these coatings.

LIFTING THE LID PCE OCTOBER – DECEMBER 2023

degradation or reduction of adhesion was observed.

“Coating EUROPIPE’s pipes internally with Teknos coatings was an important milestone, indicating that our coating solutions can be used for hydrogen pipelines, supporting the transition toward green energy and demonstrating our strong commitment to sustainability,” says Karpow.

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LIFTING THE LID PCE OCTOBER – DECEMBER 2023

 The paints used in nuclear power plants are high-class special products

Teknos has been providing coatings for nuclear power plants since the 1970s and most recently provided coatings for almost all the steel and concrete surfaces in Olkiluoto 3, located in the municipality of Eurajoki in Western Finland.

Olkiluoto 3 is the second EPR-type power plant to be completed in the world, with a capacity of 1,600 MW. It is owned by

Teollisuuden Voima (TVO) and was supplied by the Areva-Siemens consortium.

Heavy testing to ensure safety The paints used in nuclear power plants are high-class special products and their quality is verified by extensive testing. At Olkiluoto 3, testing began at the early stages of the project.

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met all the technical requirements, including the demanding Design Basis Accident (DBA) test. The DBA test verifies that the coatings used in the containment internal structures at the nuclear facility are designed and built to withstand accidents without unfavourable effects on accident management. Design against DBA events ensures that there is no loss of the systems, structures, and components necessary to ensure public health and safety.

“Teknos is well known as a high-quality paint manufacturer – furthermore, known as an experienced supplier of painting materials for OL 1 and OL 2 plants,” says Kai Wienert, Bernhard Goldkuhle GmbH & Co. KG, the Turbine Island painting contractor at the plant site. “Finally, Teknos is the single domestic supplier for all required painting systems.”

In addition to supplying the paint and coating products, Teknos provided technical support for the project. “In addition to on-time deliveries and competent guidance, Teknos was also available to support and solve problems at the construction site,” explains Wienert.

STRICT REQUIREMENTS AND HIGH QUALITY Nuclear energy is a strictly regulated industry.

In Finland, Radiation and Nuclear Safety Authority STUK sets the requirements for coatings used in nuclear power plants.

The requirements are related to radiation and chemical resistance, decontamination, durability under operating conditions and postulated accident conditions as well as fire technical properties.

“Due to the intricate nature of the modern nuclear power plant, the requirements are very high,” emphasises Välilä. “Safety always comes first at nuclear power plants and all the set requirements must be fulfilled.”

Nuclear power plants have an operating lifetime of several decades. During the lifetime, the condition of the paints and coatings are subject to regular in-service inspections and possible repairs are conducted based on the needs identified in these inspections.

“It is important that the paint on the surfaces of nuclear power plants does not need to be maintained continuously and that the surfaces are easy to clean. Coatings used in nuclear power plant units need to meet extremely high durability requirements, to minimise the need for maintenance – the less the coating requires repairing – the better it is,” concludes Välilä. ■

LIFTING THE LID PCE OCTOBER – DECEMBER 2023

“The testing of suitable coating systems started in 2004 with several potential paint suppliers,” explains Jori Välilä, Manager of OL3 civil quality control at TVO. “This made it possible for the Olkiluoto 3 plant supplier to choose coatings for the plant in the early stages of the project.”

During the time of the testing, Teknos was one of the paint suppliers whose coatings systems

UP FRONT PCE OCTOBER – DECEMBER 2023

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UP FRONT

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CONSERVING A WORLD WAR II RELIC

UP FRONT PCE OCTOBER – DECEMBER 2023

The last surviving Dreadnought-class battleship, USS Texas, is being painstakingly restored in Galveston, Texas. In the course of the work, a World War II operations map was discovered on a cabin wall, having been painted over and later cut into.

Described here are the careful steps taken by Ariane Roesch and Zak Miano, who own OnAim Conservation, to fully reveal what remained of the map, rectify the damage and restore it as best possible using modern materials to its original state.

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 The only known historic photo of the map

UP FRONT PCE OCTOBER – DECEMBER 2023

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ommissioned in 1914, the battleship USS Texas is credited with the introduction and innovation in gunnery, aviation and radar. It is the last surviving dreadnought and the only battleship still in existence that fought in both World War I and World War II. It is currently undergoing a major refit by Gulf Copper in the US after the shipyard retrieved and purchased a large floating drydock that had been sunk, broken over its length and cut in half during salvage in the Bahamas.

The approximately 8ft x 8ft (2.4 x 2.4m) map of the WWII Atlantic theatre was painted on a bulkhead in the captain’s cabin after September 1944 (based on references in the map). It shows the ports of call USS Texas made during WWII (white dots with anchors in them), where she performed shore bombardment (noted by little explosions), national capitals (yellow triangles), and a few surprise discoveries as the map was conserved.

Some time after 1966, which is when the only known historic photo of the map was taken, the map, along with the rest of the captain’s cabin, was painted white. That act was not great, but not terrible either. What was truly terrible is that a window was cut into the bulkhead right in the middle of the map some time in the late 1970s, after the map and compartment were painted white.

The Battleship Texas Foundation believes that because the map had been painted over and knowledge of the map lost, those who made that decision did not know it was there.

Fast forward to around 2000, when the map began to reveal itself as the white paint began to flake off and the map was rediscovered during the planning for the captain’s cabin restoration. When the captain’s cabin was restored, the window was welded up and the

map was partially uncovered, exposing the Mediterranean and most of Europe. In 2009, the 1966 picture of Chief McKeown with the map in the background was discovered, which spurred a lot of excitement about what possibly survived. However, due to budgetary constraints no real conservation treatments could be carried out on the map.

The map then sat partially uncovered and untouched until last summer. In partnership with TPWD (Texas Parks & Wildlife Department) Cultural Resources, OnAim Conservation was hired to stabilise the remaining paint on the

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Before beginning the first phase, which was to stabilise the map in its current state, the captain’s cabin was first cleaned and wiped down to prevent dust accumulation. An AC unit was also installed to regulate the temperature surrounding the map wall. Once the work area was prepared, OnAim began testing two adhesives and their compatibility with a methylene chloride base paint stripper using paint chip samples acquired from the map. The B-72 adhesive solution and PC universal glue adhesives were graded on their evaporation rate and overall quality. During testing, the B-72 adhesive reacted adversely with the base paint stripper and resulted in an undesirable high evaporation rate, whereas the PC universal glue had no adverse reactions with the paint stripper and showed a low evaporation rate which would provide ample work time. OnAim concluded that the PC universal glue yielded the best results and was chosen as the desired adhesive for the procedure.

OnAim removed the protective wood frame from the wall to begin applying the PC universal

bulkhead, just prior to the tow to Galveston.

This initial step preserved what remained and protected it from any vibrations from the tow and/or shipyard work.

Conservation procedures The restoration of the Atlantic theatre map in the captain’s quarters was completed in three phases over the course of a year and a half, starting when the battleship was still at its old location by the San Jacinto monument in Texas and completed after its journey to drydock in Galveston for repair.

 A window was cut into the bulkhead right in the middle of the map some time in the late 1970s

UP FRONT PCE OCTOBER – DECEMBER 2023

Phase I: Stabilisation

UP FRONT PCE OCTOBER – DECEMBER 2023

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glue to the flaking paint layers of the map. The process began by diluting the glue in distilled water and applying the solution between the cracks of the flaking paint surface using a small paintbrush. Larger paint flakes were treated using a monojet syringe to apply the solution behind the paint. Any excess glue was removed by blotting the surface with a damp rag. OnAim then used a heated tacking iron (between 250-300°F) to set and adhere the flaking paint flat onto the surface. To prevent the adhesive from sticking to the iron and pulling paint, silicone relief paper was placed between iron and paint. This process was repeated until the surface was fully consolidated.

After the adhesive cured, the map wall was cleaned with a solution containing 50ml of

distilled water and 5ml of Vulpex museum-grade liquid soap. It was applied using a clean rag then wiped down with distilled water between each scrubbing. The sections of the map that were visible (top right corner) were cleaned with extra caution to avoid removing any of its parts. Once the surface was fully clean and dry, OnAim applied two coats of a varnishing solution containing 25ml of satin Damar varnish and 5ml of distilled turpentine to the visible sections of the map and the compass rose (bottom right section), using a natural hair oil brush to seal the surface and create a sacrificial layer.

As part of this first phase of stabilising the Atlantic theatre map, OnAim conducted various tests to prepare for the following two phases:

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husband Zak Miano, owns OnAim Conservation.

“We tested three commonly bought paint strippers to remove paint on the Atlantic theatre map: CitriStrip, Klean Strip, Strypeeze (with methylene chloride), and 100% methylene chloride. Out of all, the CitriStrip gave the best results due to its non-toxic gelatinous nature that works well on vertical surfaces, plus its easy clean-up using mineral spirits, soap and water. Since it is non-toxic it also does not need a well-ventilated room, making it easier to environmentally-control the space. A thick layer has to be applied for it to work.”

 Glue was applied to the flaking paint layers of the map

Paint sample analysis: Ignite Diagnostic Solutions removed a variety of paint chips to analyse, each with about 14 layers of paint. Under OnAim’s directive, the goal was to analyse not only the abundant ‘green’ paint, but primarily the ‘red’ paint used to demarcate land masses on the map, as well as the ‘bluegrey’ paint that demarcated the water.

Based on the 1939 Navy paint formula library, the ‘red’ paint sample matched most closely with the red lead formula, matching the makeup of the paint suppliers National Starch and Goodrich. The ‘green’ sample (middle layer) most closely matched the ‘semi-flat’ formula.

Based on the data, it was concluded that the ‘green’ sample (top layer) matched the ‘light green gloss’ formula, and the ‘green sample’ (bottom layer) matched the ‘green motor boat’ formula. The ‘blue-grey’ sample matched the ‘blue stripping paint’ formula.

a paint removal analysis to decide on the best type of product for the chemical removal of the top layer of paint that is overlaying the map, and a paint analysis conducted by Ignite Diagnostic Solutions LLC to identify the original colours used on the map and compare them to the 1939 Navy paint formulas to see which was the closest match.

Chemical paint removal analysis: “Due to the age of the paint and possible chemical makeup, we were thinking that only a chemical stripper containing methylene chloride would yield the desired results since it is easily controlled and has a shorter wait time,” explains Ariane Roesch, who with her

Using the results of the paint analysis and paint stripper tests, OnAim applied CitriStrip to remove the top white layer of paint that had been sealing the map. This process consisted of first allowing a 3”x 3” (76 x 76mm) thick layer of citrus strip to sit on the paint layer for an average of 15 minutes. After an allotted time, a scalpel was utilised to carefully scrape away the white layer. OnAim then used a #0000 steel wool pad soaked in an aqueous solution of Dawn to neutralise the stripper and gently scrub away leftover residue, any remaining paint then being scraped away with a scalpel.

This method proved to be the best to ensure that a minimal part of the original layers would be compromised. Rust blooms and other structurally-compromising issues throughout the mural were addressed at this time.

UP FRONT PCE OCTOBER – DECEMBER 2023

Phase II: Paint removal

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 The lettering was found on the left panel just above where the window was cut out

Once the remainder of the map was exposed, it was thoroughly cleaned with an aqueous solution of Dawn and then the mural was documented in detail. Damar varnish was applied to the entire surface to protect this original layer.

UP FRONT PCE OCTOBER – DECEMBER 2023

Findings OnAim was able to uncover quite a bit of the original map, with really only the cut-out window and any heat-damaged metal parts being areas that were a complete loss. “While the reveal itself was amazing, there were two unique findings that altered our expectations of what the final map would look like,” says Roesch. One was the surprising find of lettering on the left panel just above where the window was cut.

Starting with an ‘N’ and ending in ‘h’, it was clear that it said ‘North’. “After some research, we found that most maps read North Atlantic Ocean when looking at Earth with just this section showing,” explains Zak Miano. “Anything north of the equator is considered North Atlantic, and looking at the USS Texas map, the floor is just a bit further south than the equator. After discussing the addition with TPWD and The Battleship Texas Foundation, all parties agreed that ‘Atlantic Ocean’ should be added.”

“The other find was the state of Texas, in an orange hue, superimposed over Africa with the compass rose situated over the Panhandle and West Texas,” explains Roesch. “While parts of the compass rose were already exposed and one could see a faint outline of Africa before stripping the top white layer, there had been no indication that Texas was somehow incorporated on the map.”

Phase III: Restoration The third and final phase was to restore the map through paint infill, using the newly unearthed original parts as guides to complete the full map, as well as historical maps of that era to assist with layout and content.

OnAim subcontracted Kati Ozanic, a local painter, teacher, and artistic director who has experience painting murals and could work within the confined area, to transcribe the missing parts of the map.

“OnAim and The Battleship Texas Foundation agreed that the paint infill should be done in such a way as to tell the story of the map, memorialise the actions that were taken, and not obscure what had occurred,” says Miano. “It was decided that anything that is added should match in colour to the original but would be set apart by having a smooth newly-painted appearance. Using the ship’s paint index from 1939, colours were matched and tinted accordingly. For example, the US east coast, which was completely lost due to the bulkhead viewing window being cut out, would be painted using a brown that matched the colour of the original land masses but would stand out due to its smooth, noncracked appearance.”

Kati Ozanic started by tracing all unveiled land masses on tracing paper. Using that as a reference, she tried to match it with various projections of maps. Judging by the expanding grid pattern painted along the edge, the original artist seemed to have had experience in maps and navigation. They had painted the map with an eye towards perspective and curvature of the globe. “This is why the land masses up top, like Canada, seem to be more stretched out and areas along the bottom, like Africa, seem to be more compact,” says Roesch.

Referencing the historical photo from 1966 and using both projections and visual artistic interpretation, Ozanic was able to finalise the land masses on the tracing paper. This tracing was then transferred onto the bulkhead using Saral transfer paper. Once transferred and outlined, areas were then painted in.

“The next step was to label the capitals, ports, and areas of interest, as well as mark any points of conflict with an explosion – just as things were demarcated on the original map,” says Miano. Using a tracing of the existing lettering, research was done regarding font type and size. OnAim settled on the American Type Founders (ATF) collection based on the map’s timeframe and considering what type of font would have been widely available.

ATF Alternate Gothic was used for labelling all cities and areas (32pt height, 25pt kerning).

The first letters of ‘North Atlantic Ocean’ most

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closely matched and are based on the ATF Livermore Script font. The remaining letters were created based on the forms of the original lettering on ‘North’.

Using the existing delineations on the compass rose, the missing parts were added and painted. The gradations per quadrant, as is faintly evident in the historical photo, are based on the various brown tones used in the map’s land masses. The light switch to the right had originally been painted a brown to blend in with the mural’s land masses. The metal housing was removed, cleaned, and stripped of existing paint before painting it again using the same colour as was used on the land masses.

Paint and varnish details OnAim utilised the 1941 ship colour swatches provided by the Battleship Texas Foundation to colour-match the colours used in the map painting. All exposed steel was first primed

using Sherwin-Williams Rust Beater red oxide primer. “We used Sherwin-Williams All Surface Enamel for the topcoat,” says Roesch. “While the colour-matched paint was close to the original colours, a Mixol tint system was used to tint them to be a closer match.”

OnAim used Damar varnish for a sacrificial sealant as well as a sealant tint. With a variation of grey, green, ochre, and yellow oxide tints in Damar varnish, OnAim used these for the dual purpose of sealing and ‘ageing’ the new paint so that the aesthetic differences between old and new were not too stark. That was then allowed to dry and then finally a clear coat of Damar varnish was applied to the whole of the painting. Damar varnish was used because it is both durable and easily reversible.

Whilst the stabilisation and conservation of the map has been completed, the restoration of the ‘superdreadnought’ USS Texas continues apace at Gulf Copper. ■

UP FRONT PCE OCTOBER – DECEMBER 2023

 The state of Texas, in an orange hue, superimposed over Africa with the compass rose situated over the Panhandle and West Texas

SPOTLIGHT PCE OCTOBER – DECEMBER 2023

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 XGIT-PROP was designed to withstand the rigorous conditions faced by propellers

SPOTLIGHT

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The shipping industry has long been searching for an environmentally-friendly solution to combat biofouling. Increased fuel consumption and greenhouse gas (GHG) emissions, slower ship operating speeds at constant power, and transfer of invasive aquatic species are problems that cost the shipping industry billions of dollars each year. Canadian company GIT Coatings has developed a graphene-based hard foul release solution to help shipowners save money on fuel and boost overall efficiency whilst having the smallest impact on the environment.

SPOTLIGHT PCE OCTOBER – DECEMBER 2023

A SEA CHANGE IN SUSTAINABLE SHIPPING

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SPOTLIGHT PCE OCTOBER – DECEMBER 2023

 Graphenebased hard foul release coatings are an environmentally friendly alternative to conventional toxic antifouling and soft foul release options

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or decades, antifouling coatings have been used by the marine industry to prevent the accumulation of marine organisms on ships’ hulls. However, they work by leaching toxic substances like copper, cuprous oxide and heavy metals. Additionally, they break down into microplastics through a shedding process, contributing to the increase of microplastic pollution in our oceans. In a study published in 2022, it was estimated that 1.9 million tonnes of paint end up in oceans and waterways every year, representing approximately 58% of all microplastics entering water, with some 18% estimated to come from the maintenance and operations of ships and offshore rigs alone.

In 2008, the use of TBT-containing antifouling coatings was banned by the International Maritime Organization (IMO) due to its detrimental impact on marine life. This led to innovations in fouling control coatings, including the development of soft foul release silicone-based coatings that rely on less invasive mechanisms for antifouling protection.

Although some silicone-based coatings are biocide-free and have been developed as an environmentally-friendly solution for marine vessels, they still contain silicone oils which are released into the ocean over time. Further to that, they cannot be cleaned without damage and require a more difficult application process.

Pioneering graphene in marine coatings In 2017, GIT Coatings started to pave the road to a new category of graphene-based marine coatings which present a viable option for the shipping industry to reach both their sustainability and profitability goals. These coatings are based on hard foul release technology and offer a full range of benefits for the shipping industry. Graphene is known for its high mechanical strength, low friction, and impressive toughness, which in addition to drag reduction makes it more resistant to mechanical damage compared to siliconebased coatings.

Graphene-based hard foul release coatings are an environmentally friendly alternative to conventional toxic antifouling and soft foul release options as they eliminate the need for biocides, fluoropolymers, and unbound silicone oil release. This new type of coating incorporates more sustainable chemistry and predominantly uses more durable materials. It has virtually zero volatile organic compounds (VOCs) compared with existing antifouling coatings that can contain up to 40% by volume and do not leach any substances into the water column. ​GIT Coatings was founded by two materials engineers, Mo Algermozi and Marciel Gaier, who met at Dalhousie University, Nova Scotia, while

SPOTLIGHT PCE OCTOBER – DECEMBER 2023

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propeller coating system, XGIT-PROP, and underwater noise-reducing XGIT-URN.

Navigating challenges with sustainable solutions

SPOTLIGHT PCE OCTOBER – DECEMBER 2023

 XGITFUEL offers considerable operational benefits for drydocks

researching graphene and its potential uses.

As they delved into various applications for this excellent material, the maritime industry with its rough and toxic coatings emerged as a sector ripe for disruption.

Recognising the industry’s shifting emphasis towards sustainable and efficient solutions, Algermozi and Gaier identified the significant role of hull coatings in enhancing ship efficiency by reducing drag. This revelation steered GIT Coatings towards the development of XGITFUEL, a patented low-friction hard foul release hull coating which is gaining interest from shipowners across the globe. The company has later expanded its product line with a durable

Having coated more than 100 oceangoing vessels with its graphene-based coatings in 2023 and expanding its presence globally, GIT Coatings demonstrates a compelling growth trajectory.

GIT’s graphene-based hull coating XGITFUEL has been independently validated and type-approved by the well-recognised ship classification society Lloyd’s Register.

LR’s study, carried out in 2021 and 2022, demonstrated an efficiency improvement of over 10% compared with traditional coatings.

In addition, the Center for Corrosion and Biofouling Control at Florida Tech confirmed XGIT-FUEL’s exceptional foul-release capabilities and its superior durability during cleaning, which might be needed after extended vessel idling periods. This coating also aligns perfectly with proactive hull grooming, a practice recently endorsed by the IMO in its latest biofouling management guidelines.

XGIT-FUEL also offers considerable operational benefits for drydocks. It requires fewer layers than alternatives, its application is more efficient, and its low VOC content enhances safety for workers while reducing environmental impact. Furthermore, the temperature range for applying XGIT-FUEL is from -5 to 40°C, which exceeds that of other high-performance coatings. This broadens the application period and enables shipowners to boost the efficiency of vessels scheduled for winter drydockings. This in turn accelerates the marine industry’s move towards decarbonisation.

XGIT-PROP, a graphene-based propeller coating system, was designed to withstand the rigorous conditions faced by propellers.

Combining a strong adhesive primer with a hard foul release topcoat, XGIT-PROP overcomes the shortcomings of conventional soft foul release coatings that often peel away from propeller blades, and ensures the propeller’s surface stays smooth over the drydocking cycle. In a study presented by one of the world’s leading tanker operators, Stolt Tankers, it was proved that XGIT-PROP has the potential to reduce fuel consumption by up to 4%.

Recently, the shipping industry has started to address the issue of underwater radiated noise, a form of waterborne emission that can adversely impact whales and various marine species. GIT Coatings has formulated a unique coating, XGIT-URN, to combat this environmental challenge. Applied between

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the anticorrosive primer and the topcoat, XGIT-URN has been proved to minimise the noise and frequencies emitted from the hull.

Following successful pilot tests with Transport Canada in 2020, this coating has been adopted on numerous vessels operating in environmentally sensitive areas.

GIT Coatings has been at the forefront of revolutionising the marine coatings industry. With a commitment to delivering environmentally friendly, efficient, and economically viable solutions, the company is helping shipowners in achieving their sustainability goals.

Having coated more than 100 oceangoing vessels with its graphene-based coatings in 2023 and expanding its presence globally, GIT Coatings demonstrates a compelling growth trajectory. This momentum is set to continue, especially with plans to transition to a fully automated, carbon-neutral production facility in 2024.

GIT Coatings’ active participation in the International Maritime Organization and other significant industry working groups signifies the company’s leadership and commitment to a sustainable maritime future. Adoption and endorsements from industry leaders such as Eastern Pacific Shipping, Stolt Tankers and Kotug amongst many others further emphasise the effectiveness and potential of GIT Coatings’ innovations. ■

SPOTLIGHT PCE OCTOBER – DECEMBER 2023

Leading the wave of change

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PROTECTING GLOBAL MERCY

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 Global Mercy’s hull and niche areas treated with Selektope have remained completely free of barnacle fouling

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SPOTLIGHT PCE OCTOBER – DECEMBER 2023

The barnacle-repelling antifouling biotechnology Selektope has successfully faced its toughest challenge to date, protecting the hull and niche areas of the world’s largest hospital ship while docked for extensive periods in warm waters, at high risk of barnacle fouling.

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 The vertical sides and flat bottom hull areas of Global Mercy were coated with Seaquantum Pro Ace containing Selektope in September 2020

SPOTLIGHT PCE OCTOBER – DECEMBER 2023

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recent underwater hull inspection confirmed that even though Global Mercy spent more than 22 months stationary and at risk from barnacle fouling since delivery to Mercy Ships in August 2021, the vessel’s hull and niche areas treated with Selektope have remained completely free of barnacle fouling.

Uncoated surfaces of the vessel, including the azimuth propellers and bow thrusters, were found to be covered with biofouling, by both soft and hard fouling species. Barnacle fouling was also present in areas where the coating surface was impaired, such as the bulbous bow and where anchor damage had occurred. This confirms the elevated hard-fouling pressures in waters that Global Mercy frequented while delivering medical help from the port of Dakar, Senegal, or while docked for maintenance at the Granadilla de Abona port in Tenerife.

Ultimate trial Selektope is an active agent ingredient added to marine coatings in nano-molar concentrations (approximately 0.1% per wet weight of paint) that is characterised by its first-of-its-kind bio-repellent mode of action which keeps a ship’s hull free from barnacles with non-fatal effect on the target organism.

When released from the antifouling coating, the organic, non-metal compound temporarily activates the swimming behaviour of barnacle larvae, making it impossible for them to settle on the hull and transform into the calcareous adult stage of their lifecycle.

The vertical sides and flat bottom hull areas of Global Mercy were coated with the antifouling coating Seaquantum Pro Ace containing Selektope in September 2020. When floated, the vessel underwent extensive outfitting for a period of 300 days. If the vessel’s idling time during outfitting is also considered, the barnacle fouling protection delivered by Selektope spans more than 32 months of static performance in total.

“The past 32 months have served as the ultimate trial for Selektope: to protect a ship that is static in the barnacle fouling hotspots for many months at a time,” says Philip Chaabane, CEO of I-Tech AB. In support of the charity’s vital work, I-Tech AB donated the required volumes of Selektope to Mercy Ships for use in the antifouling coating applied to the vessel.

“The most recent hull inspection has confirmed that our technology is doing its job as a key component of the hard-fouling protection delivered by the antifouling coating system,” Chaabane continues. “We are proud partners to the Mercy Ships organisation and grateful that we have the opportunity to help them to eliminate costs associated with hard biofouling accumulation, in support of the charity’s incredible mission to help humanity.”

Mercy Ships is a charitable organisation whose volunteers provide medical treatment and undertake urgent operations onboard hospital ships docked at local ports in some of the poorest countries in the world. The charity currently operates two vessels, the converted passenger ship Africa Mercy and the purposebuilt hospital ship Global Mercy. ■

POWDER COATINGS APPLICATION Due to high industry demand, led by advancements in Coating technology, the Corrodere Academy have introduced a course in Powder Coating Application. As part of the Train the painter programme this course will be made available globally.

FOR MORE INFORMATION PLEASE CONTACT THE CORRODERE ACADEMY:

info@corrodere.com | +44 (0)1252 732 236 | corrodere.com

SPOTLIGHT PCE OCTOBER – DECEMBER 2023

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AkzoNobel’s yacht coatings business opens the first phase of a world-class testing and training centre in the UK.

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NEW TESTING & TRAINING CENTRE

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AkzoNobel has invested in a new extension of the Yacht Paint Application Centre (YPAC) located in Southampton, UK, to provide new innovative products, applications and techniques to professional and DIY applicators.

The project has been split into three phases and is due to be completed in 2025.

In early spring 2023, two new spray booths and an adjoining laboratory were brought online as part of the first phase of development. This offers an opportunity for applicators to work with AkzoNobel to help improve their efficiency and enhance their application skills while also increasing capacity for the onsite R&D team to fast-track new product development and improve response times to customer queries.

Phase two, due to begin in 2024, will include a pioneering climatic control spray booth with the ability to raise and lower temperature and humidity to replicate climatic conditions anywhere in the world.

Further developments

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SPOTLIGHT PCE OCTOBER – DECEMBER 2023

wlgrip and International, two of AkzoNobel’s leading yacht brands, continue to set the standard in customer support and innovation with a new Application Research Centre (ARC). The centre offers a cutting-edge location to trial and test products, systems and technology alongside first-rate product application training.

Further developments in line with market trends will be implemented in 2025.

The new facility, designed in combination with long-term technology product roadmaps, will also explore how robotic applications could be used to help improve productivity and repeatable quality.

The original Southampton YPAC opened in 2008 and has completed training on a

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achieved ensuring 95% of materials replaced have been either repurposed or recycled.

“The team behind the project have brought innovation to the planning and execution of the build and the finish is outstanding. The site pushes the boundaries and will further establish AkzoNobel’s position in the heart of the yacht community for years to come.” ■

SPOTLIGHT PCE OCTOBER – DECEMBER 2023

variety of products and skills for more than 600 trainees. The centre has a long history of developing industry-leading products and systems for Awlgrip and International and the laboratories have put many leading products to the test. They include Awlcraft SE, Perfection Pro, Awlgrip HDT, Awlfair SF, One UP, Toplac Plus, Awlcraft 3000 and next-generation fouling control products like B-Free Explore.

Alongside new product development, the facility is renowned for working with industry partners such as spray gun manufacturers and sandpaper suppliers to ensure the latest technology and equipment is tested.

“The ARC will set a new standard of research and development and training,” says Jemma Lampkin, AkzoNobel’s Yacht Commercial Director.

“We are passionate about connecting our research and technical teams with applicators who want to be best in class by improving their product, technical and application knowledge with state of the art equipment.

“The testing facility is first class. Yacht paint has to stand up to the most challenging conditions from the elements, and being able to evaluate the impact of regional climate variations will inform and improve new product development and innovation in application technique for the next 20 years and beyond.”

Site manager and R&D Section Leader Gareth Thomas said: “This is a huge redevelopment project with enormous ambition

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PROTECTING A EUROPEAN SEA LOCK FABRICATED IN CHINA

Arjan van Vliet, PPG KAM/Segment Sales Manager Infrastructure Europe, discusses the unique challenges of coating a new sea lock on the Belgium-Netherlands border.

SPOTLIGHT PCE OCTOBER – DECEMBER 2023

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ext year, a new sea lock, the Nieuwe Sluis, will open at Terneuzen, the Netherlands, near the border with Belgium. The current locks are causing a bottleneck for shipping and the new facility, built at a cost of around €1bn, will improve access to the ports of Ghent (Belgium) and Terneuzen, and smooth the path of shipping between the Netherlands, Belgium and France.

The owner of the sea lock is the FlemishDutch Scheldt Commission, and construction was carried out by the Aannemerscombinatie Sassevaart, a joint venture of contractors BAM Infra, Stadsbader Contractors, DEME and van Laere NV. The facility posed a unique coatings challenge, not only for the technical requirements of corrosion protection and colour stability, but also because it was fabricated in a Chinese yard with the sections then being shipped to the site in Terneuzen.

“We needed to provide highly durable coating systems to protect the new lock against the very demanding saltwater environment and in addition provide a long-lasting topcoat with excellent colour and gloss retention,” explains van Vliet. “With construction in China managed from the Benelux region, the project faced several engineering, procedural and logistical challenges. These all required effective coordination and communication to ensure the project’s successful execution.”

SPOTLIGHT PCE OCTOBER – DECEMBER 2023

Highly resilient coating system For the lock’s bridges, PPG provided a highly resilient coating system composed of PPG Sigmazinc 109 HS primer, PPG Sigmacover 410 general-purpose epoxy buildcoat, and PPG Sigmadur 550 topcoat, a glossy, acrylic polyurethane finish. The lock gates received two layers of PPG Sigmashield 880 multipurpose, surface-tolerant epoxy and a PPG Sigmadur 550 finish on the splash zone and exposed parts of the gates.

“The durable PPG Sigmadur 550 highgloss topcoat has excellent colour and gloss retention properties and is resistant to atmospheric exposure conditions,” says van Vliet. “It is ideally suited to harsh environments where aesthetic appearance is also important.

The PPG Sigmashield 880 coating is specifically designed for offshore splash zones with superior resistance to abrasion, impact, corrosion and seawater, prolonging service life and protecting assets in some of the world’s most severe environments.”

We needed to provide highly durable coating systems to protect the new lock against the very demanding saltwater environment and in addition provide a long-lasting topcoat with excellent colour and gloss retention.

Cross-border support PPG’s integrated, cross-border technical support with direct contacts in Benelux and China helped to ensure that the complex project went smoothly. Through close collaboration with the subcontractor, PPG achieved quality assurance and monitored the application process of the products.

This comprehensive support ensured that the coatings were applied correctly and in accordance with the specified requirements.

The company also benefited from its recent experience at the OpenIJ sea lock project in the Netherlands.

“Thanks to that experience gained on the OpenIJ lock in IJmuiden, we provided Sassevaart with the support and expertise to overcome any challenges faced during the Nieuwe Sluis project,” says van Vliet. “The customer also benefited from our expertise in corrosion protection in China, Belgium and the Netherlands.”

Extended protection In addition to the aesthetic appearance of the new lock, the bridges and lock gates will be protected against the harsh climatic conditions in Terneuzen for an extended period. PPG provides a coating quality guarantee of up to seven years after the project’s completion by the Chinese subcontractor. As evidence of the system’s durability, the subcontractor has demonstrated the performance of the PPG Sigmadur 550 coating through exhaustive testing.

“We are very pleased to have contributed to the accomplishment of this essential lock development, which will enhance the safety and efficiency of water transport in the region,” says van Vliet. “Our teams across the globe worked hard to overcome the challenges during application and deliver a high-quality result.” ■

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IN FOCUS PCE OCTOBER – DECEMBER 2023

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IN FOCUS

AN ELECTRIFYING CONCRETE ISSUE

In EV plant construction, specifiers must get creative to stop water vapour transfer (WVT), explains Richie Cropp, Northeast Subject Matter Expert for Dudick, Inc.

IN FOCUS PCE OCTOBER – DECEMBER 2023

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s construction of electric vehicles (EVs) and associated battery manufacturing facilities ramps up, one thing is clear: carmakers, governments and the market all want these complex factories commissioned quickly.

It’s easy to see why – with the dollar value attached to these projects, what builder wouldn’t work their hardest to finish under budget and pocket a percentage of the savings?

And then there’s the strong demand among practically all stakeholders to reduce reliance on fossil fuels. Even the notoriously risk-averse automotive OEMs are shelling out billions to help build these facilities – a clue that they are confident in a significant return on the investment.

Finally, governments have lately become generous in incentivising the rapid scale-up of EV and battery manufacturing capacity. Grants and cheap loans make it a no-brainer for ownership groups to race to qualify for a seat directly in front of the public money hose.

What’s all this got to do with stopping WVT? Concrete flooring is instrumental to the anatomy of EV assembly plants, battery manufacturing facilities, and battery recycling operations. This sector’s building boom will draw in a greater and greater share of specifiers who are probably unfamiliar with the phenomenon, much less what they can do to prevent it under intense deadline pressure.

I see a knowledge gap opening up. Let’s try to close it.

IN FOCUS PCE OCTOBER – DECEMBER 2023

Coating ‘green’ concrete: A red flag?

New concrete contains water, and it won’t cure unless that water escapes.

If a concrete floor coating is applied before the concrete cures, WVT is likely to occur. The water must go somewhere, and it takes the path of least resistance. Often, that is upward through a concrete slab. If a coating is applied to it too soon, WVT can lead to blisters and bubbles that indicate it has come unstuck from the substrate.

ASTM’s D4263 (plastic sheet), F1869 (calcium chloride), and F2170 (relative humidity) testing methods were developed to help applicators be certain concrete is sufficiently dry before applying a coating.

Construction teams have been frustrated

by the basic facts of concrete’s cure process for about as long as concrete has existed.

Thoughtful phasing and staging of construction has traditionally helped sidestep the frustration, and to a degree it still does. But today, that’s not enough.

More and more construction programmes emphasise working over ‘green’ concrete, which has empowered specifiers with greater latitude in selecting more costly specialty concrete formulas containing quick-cure additives or densifying agents so that curing time is reduced.

Schedule savings beat material savings every time – right?

Here’s the problem: Just as additives influence concrete cure characteristics, concrete formulas influence the application and performance of protective coatings.

For one example, some curing accelerators are made of materials containing crystalline structures that reduce the porosity of concrete. Is the specified floor coating formula compatible with the concrete? Will it stick?

For another, the addition of densifying agents reduces the amount of water needed in a concrete mix. Less water needing to escape means a faster cure, which allows crews to

resume work on newly-poured concrete sooner.

But denser concrete also makes it much harder and more time-intensive to achieve the proper surface profile a coating needs to adhere properly. Does the schedule account for those added labour hours? Does the budget accommodate the extra equipment and materials that are warranted?

And don’t forget about the possibility that additives will influence the compressive strength of concrete. Some concrete floor coating manufacturers – my own employer included – refuse to allow application of their products unless compressive strength testing results exceed 250 psi (1,724 kPa).

Innovations have a role Innovations in protective coating technology have a role to play. One which I find particularly exciting is Dudick’s Vapor-Stop. The product depends on water to cure properly. Want to guess where that water comes from? Of course, it isn’t the universal solution to WVT – nothing is.

The point is, if it’s still risky to work over green concrete, then at least it’s less of a red flag today than in the past. Project management has improved with the adoption of more coordinated construction delivery

methods. And construction teams today are equipped with more advanced materials that allow them to turn old ways of thinking and building upside down.

But the big question remains – Where, really, are the savings?

In EV and EV battery facility construction, today’s specifier plays a critical – if perhaps hidden – role in securing fast, efficient, and profitable construction delivery. But they will not find the answer here.

They will find it when they leverage the emerging coalitions of specialty concrete coating manufacturers and applicators who work together to bring better overall value to construction projects.

So it’s up to people like me to say – we’re here and here to help. ■ Richie Cropp has 18 years of industry experience in the resinous flooring and high-performance coatings industry.

He has worked on several highprofile projects for the US National Institutes of Health, the Department of Homeland Security, USDA, and various pharmaceutical companies during his time at Dudick, Inc. – A Division of Carboline.

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Waste recycling flooring upgrade

IN FOCUS PCE OCTOBER – DECEMBER 2023

A new floor for a heavy use area supplied in double-quick time.

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IN FOCUS PCE OCTOBER – DECEMBER 2023

 The slab to be repaired was saw-cut and broken out to the required minimum depth using robotic demolition

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The solution Corroless Eastern proposed the application of one of the most durable forms of industrial resin flooring available, in the form of Master Builders Solutions Ucrete IF. This is a polyurethane screed which is already amongst the toughest forms of industrial flooring and is further reinforced with the addition of iron filings to give additional abrasion resistance.

Due to the severe erosion of the concrete, it was necessary to first conduct extensive slab repairs and a concrete overlay.

Initially, the perimeter of the area of the slab to be repaired was saw-cut and broken out to the required minimum depth using robotic demolition. This was then transitioned using robotic breakers and surface planers.

The entire slab received a heavy profile using a scabbling method to provide a profile for the repair materials to adhere to. Prior to installing the new concrete, the slab was primed using an SBR slurry to promote adhesion, and the concrete was laid onto this whilst still wet.

Given the programme constraints, an extremely fast curing concrete mix was supplied by Hanson Cement in the form of their Fast Track material. A design was employed which would have the compressive and

cohesive strength to be prepared the very next day. This material was also fibre-reinforced for additional crack resistance.

To minimise the risk of fracture in the new concrete, Corroless Eastern prepared the concrete by vacuum-contained rack blasting the next day to ensure any surface laitance was removed and ensuring excellent adhesion of the new industrial resin flooring.

Polyurethane cement materials are perfect for application onto recently installed concrete as they have few limitations with regard to the moisture content of the substrate, which is particularly important on industrial resin flooring applications such as this where time is constrained.

By contrast, most epoxy flooring systems would require multiple primer layers to tolerate such high moisture concentrations in the concrete, adding days to the programme.

Ucrete materials All areas to be treated were primed using Master Builders Solutions Ucrete Primer FS. This fast-curing primer can be applied and overlaid in the same day.

Master Builders Solutions Ucrete IF was applied by trowel to a target thickness of 12mm for additional wear resistance. Existing expansion joints in the concrete slab were reflected in the new resin flooring finish as per best resin flooring practice.

All the works were completed within the allocated week and the floor was returned to service the following week, supported by the fast-curing nature of Ucrete materials. ■

 All the works were completed within the allocated week

IN FOCUS PCE OCTOBER – DECEMBER 2023

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he loading shovels at a waste recycling centre had eroded the original concrete slab to such a point that the shovels were prone to catching on the floor and abruptly halting, which presented a safety hazard.

The plant had daily incoming loads, which meant that any industrial flooring repairs had to be undertaken in an extremely narrow window.

ANALYSIS PCE OCTOBER – DECEMBER 2023

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 The bund area polyurea applied, with sealant to the top edge

ANALYSIS

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SOLUTION An alternative lining for a swimming pool and smaller hydrotherapy pool with intricate details.

ANALYSIS PCE OCTOBER – DECEMBER 2023

A polyurea lining

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& The hydrotherapy pool prepared and primed

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quascapes is a high-end swimming pool design and installation contractor. The company has developed innovative pool construction methods that offer significant improvements covering speed of construction, reduced structural load and reduced carbon dioxide emission from construction.

One of the swimming pool construction methods developed makes use of high-density expanded polystyrene modules that are assembled on site to form the pool structure.

These polystyrene modules are coated off site with a reinforced render prior to delivery on site and assembly. Watertightness had previously been achieved either using cementitious render systems or glass reinforced plastic – GRP/fibreglass, with the GRP solution having disadvantages such as odour and slow installation speed.

Aquascapes had worked with Mapei GB to develop an improved swimming pool lining methodology using polyurea material, with some of the key benefits including improved elasticity and speed of installation.

The subject of this application consisted of a hydrotherapy pool and a larger swimming pool, with the hydrotherapy pool having many intricate details and nozzles.

The solution

ANALYSIS PCE OCTOBER – DECEMBER 2023

Aquascapes’s own installers applied a Mapei-approved fairing coat to the internal surfaces of the pool to provide a smooth and uniform surface suitable for polyurea application. A key consideration for this project was the uniformity of the finish, as the pool would be finished with mosaic tiles after the polyurea application.

The polyurea waterproofing was also extended into the concrete bund areas surrounding the pool, which were prepared by vacuum-controlled diamond grinding. The same fairing coat was also applied to the block walls to provide a uniform surface for polyurea application.

Anchor chases were cut in the bunded area blockwork and carefully around skimmer outlets in the pool – taking great care not to penetrate fully through the previously off-siteapplied reinforced render.

Coating application Following climatic testing and monitoring of the substrate moisture content as part of Corroless Eastern’s standard quality assurance procedures, all surfaces were primed using Mapei SN applied by brush and roller.

The primer was applied in two coats as per the company’s standard polyurea application process. The reason for this is that polyurea is applied at 70-80°C and exotherms once mixed.

The consequence of this is that any entrapped air within the substrate expands and causes pin holes if the substrate being coated is not fully sealed. The way to mitigate this as far as possible is to apply two coats of primer and ensure that the substrate temperature is either stable or falling.

The second coat of primer was fully blinded using a quartz aggregate to provide an excellent mechanical anchor for the subsequent polyurea membrane to adhere to.

This also serves to remove the time restriction

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ANALYSIS PCE OCTOBER – DECEMBER 2023

 Applying the Mapei polyurea to the bund area

ANALYSIS PCE OCTOBER – DECEMBER 2023

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 The bund area polyurea applied, with sealant to the top edge

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A seamless finish As Mapei Purtop 1000 can elongate 300%, it makes it particularly suitable for application to modular constructions such as these swimming pools.

The bunded areas were checked for porosity

by DC Holiday spark testing as per Corroless Eastern’s standard quality assurance. Because of the non-conductive construction of the pool areas themselves, this was not possible in these areas and a thorough visual inspection had to be undertaken instead.

The polyurea swimming pool linings were finished using an overspray method, which provided a light texture in order to promote adhesion of the subsequent epoxy tile adhesive.

Termination points both in the pools and the bunded areas were sealed using a mastic compound to ensure a seamless finish and protect the edge of the waterproofing membrane.

Within 48 hours of completion the pools were filled in order to conduct a leak/drop test. Again this showed how the rapid curing properties of polyurea, as well as accelerating installation, also allow a quicker return to service than other systems employed in this area. ■

 The hydrotherapy pool with polyurea applied

ANALYSIS PCE OCTOBER – DECEMBER 2023

of the overcoat window, giving time to mask off items not to be coated etc.

Masking was in itself a significant task for this project, given the tight tolerance required for the waterproofing membrane around the extensive nozzles and penetrations in the hydrotherapy pool.

“When applying polyurea you cannot use conventional masking tape, as the rapid gel time of the material (sub eight seconds typically) means that the membrane forms over the tape and the high tensile properties of the polyurea make it extremely difficult to remove,” states Corroless Eastern.

Instead, a wire-edged tape called Wiretrim is used at any termination points, which once spraying is complete is removed and cuts through the polyurea from the underside, giving a neat edge.

Mapei Purtop 1000 was then spray-applied using Corroless Eastern’s own plural spray units to a minimum thickness of 2mm. All of the company’s applicators are trained on the Polyurea Development Association’s applicator course to ensure that this brilliant, but also potentially challenging, material is applied correctly.

UPDATE PCE OCTOBER – DECEMBER 2023

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UPDATE

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ENVIRONMENTAL PRODUCT DECLARATIONS EXPLAINED

 Bob Dirks, Global Segment Manager for AkzoNobel’s Powder Coatings (Architecture)

 Sencan Kizilkaya, AkzoNobel’s Global Product Manager for Powder Coatings (Architecture)

UPDATE PCE OCTOBER – DECEMBER 2023

One way AkzoNobel is helping its customers find solutions that reduce the environmental impact of the built environment is to create transparency around the environmental footprint of its products. The company does this through environmental product declarations (EPDs). AkzoNobel has EPDs for more than 200 products for buildings. It means it can provide an easy one-stop-shop paints and coatings solution for sustainable building projects, because EPDs of various products can be combined into a single project.

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UPDATE PCE OCTOBER – DECEMBER 2023

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ob Dirks, Global Segment Manager for AkzoNobel’s Powder Coatings (Architecture) business explains: “An EPD, or Environmental Product Declaration, is a comprehensive and standardised document that provides transparent and independently verified information about the environmental impact of a product throughout its entire lifecycle. It covers various lifecycle assessment (LCA) stages, from raw material extraction to production, distribution, product use, disposal and recycling.”

An EPD is based on the results of a lifecycle assessment and scientific approach used to assess environmental footprint in line with the internationally recognised ISO 14040 standard series. The declaration is drawn up according to a guideline which sets out standardised analysis and comparison rules for all types of building materials and products.

There are also specific standards for developing the declarations and labels that the LCA is used to support. In the context of EPDs, this is commonly the ISO 14025: Environmental labels and declarations – Type III environmental declarations. The standards ensure the calculations behind the LCA and EPD are methodologically solid.

“EPDs hold great significance as they enable us to communicate information transparently to our customers, based on the environmental performance of our powder coatings,” says Sencan Kizilkaya, AkzoNobel’s Global Product Manager for Powder Coatings (Architecture).

“EPDs contribute to obtaining green building certification credits, such as LEED (Materials and Resources) and BREEAM (Materials) certified building projects. We’re very proud in Powder Coatings to have EPDs for our Interpon D architectural coatings.”

The verification process for EPDs involves a thorough evaluation and evaluation by independent third-party LCA practitioners who specialise in lifecycle assessments and environmental analysis. “These practitioners ensure the information presented is accurate, reliable and compliant with established standards and guidelines,” says Dirks. “Assessments cover various environmental factors, including global warming potential, water, material and energy usage, greenhouse gas emissions, resource depletion and waste generation.”

EPDs undergo periodic reviews to ensure the accuracy and relevance of the information provided to meet industry needs. “AkzoNobel

is committed to upholding the highest standards of transparency and environmental responsibility,” adds Kizilkaya. “Therefore, we strive to review and renew our EPDs regularly, typically every five years or as required by industry practices and evolving sustainability guidelines. We’re proud that we were the first powder coatings company to provide an EPD in our industry in 2015, this was renewed in 2018. Our latest, published in mid-2023, will be valid for five years, which is in line with the EN15804+A2 norm for construction products.

This norm harmonises the structure for EPDs in the construction sector, making the information transparent and comparable.”

Can EPDs be compared?

“In theory it’s possible, but in practice, you’ll very likely compare apples with pears,” says Dirks. “There are many aspects to consider.

For example, they must be based on the same Product Category Rules (PCRs), including the same version number, or be based on fully aligned PCRs or versions of PCRs. They must also cover products with identical functions, technical performances or use; have equivalent system boundaries (scope and cradle-to-gate); have equivalent content declarations; and be valid at the time of comparison. Furthermore, EPDs within the same product category – but registered in different EPD programmes or not compliant with EN15804 – may not be comparable.”

Why not just one standard?

“The most up-to-date standard is EN15804+A2,” says Kizilkaya. “This new A2 norm brings additional environmental impact categories. Since EPDs are valid for up to five years, comparing one EPD with another requires attention to PCRs, as previously mentioned.

In addition to the identical properties listed, methods of data collection, allocation methods, cut-off rules and impact assessment methods (including the same version of characterisation factors) have an impact on EPDs. Taking all of this into consideration, EPDs can slightly vary from another company’s.”

Why are EPDs so important?

“The EPD allows our customers to make informed choices aligned with their sustainability objectives, based on transparent and reliable third-party information,” explains Dirks. “At the same time, the Powder Coatings

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business is fully aligned with the company’s sustainability goals – which are at the core of our business strategy. This includes carbon footprint reduction and environmental preservation. Our sustainability journey encompasses continuous learning, setting

ambitious goals, fostering transparency through (among other parameters) EPDs, and implementing improvements to reduce our carbon footprint. By embracing these pillars, we empower positive change, fostering a more sustainable future.” ■

UPDATE PCE OCTOBER – DECEMBER 2023

 30 Hudson Yards uses AkzoNobel’s high performance Interpon D architectural powder coatings

UPDATE PCE OCTOBER – DECEMBER 2023

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ENGAGE EARLY TO SOLVE PUZZLE OF THE BUILDING SAFETY ACT

UPDATE PCE OCTOBER – DECEMBER 2023

The terms of the new UK Building Safety Act 2022 became enforceable from October 1, 2023.

Here, Bob Glendenning, Fire Design Engineering Manager of Sherwin-Williams Protective & Marine Coatings, looks at how early engagement can help engineers and those in the supply chain negotiate their way through the challenges the Act presents.

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he new Building Safety Act 2022 (BSA) has been developed as a new framework for the design, construction and occupation of ‘higher risk’ buildings. These buildings are defined as being a minimum of 18m or seven storeys in height and including at least two domestic premises.

These new regulations required that all existing occupied high-risk buildings should be registered with the new Building Safety Regulator (BSR) from April 6, 2023 and no later than October 1, 2023. The BSR is an independent body that forms part of the UK Health and Safety Executive, and aims to raise building safety standards and the performance of buildings whilst also monitoring the competence of regulators and industry professionals.

The reality of this new legislation is that under the terms of the Act, a Principal Accountable Person who fails to register an occupied higherrisk building ‘without a reasonable excuse’ will be liable to either a fine or imprisonment for a term not exceeding two years.

The Principal Accountable Person is described as the organisation or person who owns, or has responsibility for, the building. It may also be an organisation or person who is responsible for maintaining the common parts of a building, for example corridors or lobbies.

UPDATE PCE OCTOBER – DECEMBER 2023

Engaging multiple stakeholders is key At Sherwin-Williams, our policy of early engagement and collaboration between all parties aims to clarify any points up front before they become a problem, with the subsequent knock-on effect on time and cost.

It is proven that engaging multiple stakeholders – including designers, fabricators and applicators – early and consistently throughout the process is key to delivering a successful, safe and cost-efficient solution.

Working together, we share knowledge and help our clients to reach their goals; after all we are all now part of this renewed responsibility.

We want to help our customers to capture relevant data on the use of our intumescent coatings so that they can provide information digitally on safety and quality to their own customers. This information also provides a sound basis for future decision-making.

The government-named Golden Thread will be a digital record of all aspects of the fire protection installed in higher-risk buildings, including application records, theoretical product thickness,

data sheets and anything relevant relating to the fire protection provision for structural steel.

By following the requirements as set out in the Golden Thread, those involved can be assured that they are creating a safe, efficient building.

Under the terms of the Act, the term ‘competence’ is a core requirement. As part of this part of the Act, the BSR has introduced an Industry Competency Committee whose role will be to monitor and improve industry competence.

This will be done by regularly publishing guidance and advice available to the industry.

The three Gateways The Golden Thread runs through what is known as three gateways of the process. All three gateways are important from the outset to completion and occupation of a building so that end users can be assured of compliance, quality and safety and have confidence in the products used to provide fire and life safety – in particular ‘safety critical’ components.

For the protection of structural steel with intumescent coatings, the different parts of the engineering community and the supply chain will need to understand more detail of certain Gateways than others. For example, structural engineers, designers and specifiers will be more concerned with the requirements under Gateway 1 and parts of 2. Applicators will need to understand parts of Gateways 2 and 3, while fabricators will need to understand the wider picture across all three Gateways.

Gateway 1 – covering the planning stage. This has been in force since August 1, 2021 and sets out the framework for the second and third stages. Applicants need to demonstrate that fire safety matters have been incorporated into the planning stage for all buildings.

If a fire statement is required to be submitted with a planning application, it will be an issue for consideration for the Local Planning Authority (LPA) when reaching its decision on the application. Contractors should take note that if the LPA considers the statement inadequate it can refuse the application.

Gateway 2 – submitting Building Control approval to the Regulator to enable construction to start.

This should include written declarations covering the competency of the main contractor, designer, a description of works and plans and a planning statement from Gateway 1.

Importantly, there should be information

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about how evidence is being captured to maintain the Golden Thread. The Regulator has a 12-week period to approve or reject these Building Control applications or to approve subject to fulfilment of certain requirements.

the lifetime of a building, and will be highly valuable should anything happen during its occupation.

Think of it as future-proofing life safety.

Projects using fire protection coatings offered by Sherwin-Williams in EMEAI include London’s The Shard and the Leadenhall Building, known as The Cheesegrater; Azerbaijan’s Flame Towers; the UnipolSai tower in Milan and the Y-Towers in Amsterdam. ■

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Gateway 3 – providing information to ensure the building is safe for occupation. There is a requirement to submit a completion certificate application and provide updated plans.

These plans should reflect the scale of the higher-risk building, key building information, a list of mandatory incident reporting and signed declarations from the main contractor and principal designer that the works and building Measures and records comply with Building Regulations. environmental conditions Finally, confirmation that the all-important information for the n NEW Larger 2.8” impact resistant Golden Thread has been handed color touchscreen with redesigned over to the accountable person keypad for quick menu navigation should also be declared.

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Remember – responsibility lies with us all. Nobody in the supply chain can absolve themselves.

The Accountable Person must have assessed all building safety risks and taken all reasonable steps to control them, give the safety case report to the Regulator on request and apply for a building assessment certificate. Remember, the information required for the Golden Thread needs to be accurate, easily understandable, up-to-date, readily accessible and in a digital format.

We should emphasise that it is the responsibility of each Principal Accountable Person to provide the right information to the supply chain – including those bidding for the intumescent fire protection package – who in turn are then responsible for all information being passed on to us being accurate if we at Sherwin-Williams are to provide guidance.

Also, bear in mind that this commitment to best practice and gathering of evidence of compliance is not just for the short term but for

NEW Magnetic probe attaches to steel structures for monitoring climatic conditions

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UPDATE PCE OCTOBER – DECEMBER 2023

We all have a responsibility

Weatherproof, dustproof, and water-resistant—IP65-rated enclosure n Fast response precision sensors provide accurate, repeatable readings n Auto Log mode—automatically records environmental parameters at user-selected intervals

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REVIEW

FINNISHED BRIDGE REPAINT

REVIEW PCE OCTOBER – DECEMBER 2023

Korkal Oy has repainted the Heureka light traffic bridge in Tikkurila, Finland with Nor-Maali’s SILKO paint system LIVI B.2+ Normastic 405 x2 – Normadur 65 HS.

REVIEW PCE OCTOBER – DECEMBER 2023

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 Two coats of Nor-Maali’s SILKO Normastic 405 were applied

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REVIEW PCE OCTOBER – DECEMBER 2023

he Heureka light traffic bridge located Korroosiotyö Korkal (Corrosion in Tikkurila runs from Tikkurilanti over work Korkal), founded in the Keravanjoki to Heureka. Tikkurila is a district and major region of the municipality 1992, specialises in painting of Vantaa, Finland. Located in the eastern half infrastructure, petrochemicals of the Helsinki conurbation, some 16km (10m) north of the capital’s downtown district, it is the and maintenance painting. administrative and commercial hub of Vantaa.

The bridge is a cable-stayed bridge and was completed in 1989.

Korkal Oy repainted the Heureka bridge during the summer of 2023 as part of the bridge’s wider restoration work, with lighting and parts of the bridge’s structures also being renewed. Bridge vibration is being reduced by installing dampers, and the entire renovation should be completed in December 2023.

The bridge was partially painted during the renovation work, with the painting system used being Nor-Maali’s LIVI B2+ system Normastic 405 x2 – Normadur 65 HS, including 310 µm DFT.

Korkal Oy Korroosiotyö Korkal (Corrosion work Korkal), founded in 1992, specialises in painting infrastructure, petrochemicals and maintenance painting. Typical work includes bridges, tanks and maintenance painting in factories.

The company may have been founded in 1992 but CEO Kalevi Kallionkieli has been working in

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 A final coat of Normadur 65 HS was applied

the industry for much longer and has extensive experience of project painting in Finland.

SILKO 3.351 painting systems for new and repainting are grouped according to the environmental stress classes (C3/C5/Im1-Im3) according to the standard SFS-EN ISO 129442. For new and repainting of bridges, the durability requirement (SFS-EN ISO 12944-1) is class VH (very high, over 25 years).

The Norwegian Railways Agency uses its own codes beginning with LIVI to mark the painting systems, and the systems are grouped into three different groups: LIVI A, LIVI B and LIVI C. Group LIVI A includes painting systems that use zinc-based primers. These painting systems are primarily used for painting new bridges. LIVI B includes non-zinc-based painting systems. These are primarily used in repair sites and other special sites. The LIVI C group includes painting systems for hot-dip and spray-galvanized surfaces.

The Finnish Railways Agency maintains a separate list, which contains paint manufacturers’ painting systems that the Agency has assessed as suitable for use. Only painting systems assessed by the Finnish Railways Agency as suitable for their use may be used at their sites in accordance with the SILKO 3.351 instruction. ■

REVIEW PCE OCTOBER – DECEMBER 2023

SILKO painting systems

REVIEW PCE OCTOBER – DECEMBER 2023

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TANK BOTTOM

PROTECTION

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REVIEW PCE OCTOBER – DECEMBER 2023

Thousands of aboveground storage tanks (ASTs) around the world face the challenge of achieving safety and longevity. Not least among concerns is the corrosion that attacks hidden tank bottoms and can lead to costly repairs or dangerous leaks. Whilst the characteristics of these environments make corrosion protection difficult, the nature of CorroLogic VpCI technology makes it a formidable opponent and logical solution to soil-side corrosion.

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he cost of building, maintaining, and repairing an AST can be astronomical – not to mention the value of the hundreds or thousands of gallons of liquid stored inside. Yet many of these ASTs are located in extremely harsh conditions such as the Middle East where high temperatures, humidity, coastal salt air, and sabkha soil (high mineral content) surround tanks with a medley of corrosion threats. A further problem is that cathodic protection (CP), often the go-to option for AST bottom protection, can only protect areas of the tank bottom in direct contact with the CP tank pad. Any dips, bumps, or other irregularities in the less-than-perfectly-smooth tank bottom will be out of contact with the CP and therefore unprotected. Corrosion on these bottoms can be catastrophic, ranging from minor leaks to widespread pollution or even explosions. In addition to physical dangers, loss of stored resources or the tanks themselves can be a huge cost.

Vapour phase protection CorroLogic VpCI for ASTs has been a rising technology since the 1990s. The key to its flexibility and effectiveness is the behaviour of vapour phase corrosion inhibitors (VCI/ VpCI), which can be applied in multiple forms (such as powder and slurry) and are ideal for enclosed spaces. Once beneath the tank floor, they diffuse throughout the void space and are attracted to metal surfaces where they form a protective molecular layer. This offers protection even in hard-to-reach pockets formed by tank bottom irregularities that may keep the metal out of contact with the CP current.

REVIEW PCE OCTOBER – DECEMBER 2023

Keep tanks in service Another huge advantage of CorroLogic is that it can be applied underneath the tank bottom at any stage in the AST service life.

CorroLogic VpCI for ASTs has been a rising technology since the 1990s. The key to its flexibility and effectiveness is the behaviour of vapour phase corrosion inhibitors (VCI/VpCI), which can be applied in multiple forms and are ideal for enclosed spaces.

Applying it to new tanks is naturally the best option because it will be easier to access the interstitial space; plus, it is more beneficial to inhibit corrosion before it has a chance to start.

However, CorroLogic Powder and CorroLogic Slurry can be injected under the tank bottom and allowed to diffuse throughout the interstitial space even after the AST has been filled. The tank does not have to be emptied, let alone disassembled, in order to protect it.

This provides a major cost saving and recourse, for example, if the CP system needs to be replaced but retrofitting is too expensive.

An industry standard Given the benefits and effectiveness of CorroLogic, it is not surprising that using VCIs to protect ASTs has become an industry standard.

This fact is evidenced by the publication of API Technical Report 655, Vapor Corrosion Inhibitors for Storage Tanks, in 2021. This report serves as a guide for tank owners and operators protecting their ASTs with amine-carboxylate VCIs, the same class of VCIs found in CorroLogic Powder and CorroLogic Slurry. As time goes on, more research is becoming available, with promising results on the benefits of CorroLogic and its compatibility with CP. For example, an article in Chemical Engineering shares results from the Cushing Terminal tank project, which found far fewer corrosion indications during the period of treatment with both CorroLogic and CP in contrast to the previous three years of CP-only protection. Most recently, AMPP SP21474-2023 has been released on External Corrosion Control of On-Grade Carbon Steel Storage Tank Bottoms, with a section covering use of VCIs. While many tank owners are familiar with CP and will continue to use it, applying CorroLogic as a complementary form of protection at any stage in a tank’s service life makes a lot of sense. ■

REVIEW PCE OCTOBER – DECEMBER 2023

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CLASSIC TRACTOR RESTORATION

REVIEW PCE OCTOBER – DECEMBER 2023

Classic Vintage Tractor Restorations, known for their exceptional craftsmanship in restoring vintage agricultural machinery, have proudly unveiled their latest masterpiece – a stunning restoration of a red Massey Ferguson 35X Multi-Power tractor. This remarkable restoration was made possible with the help of HMG Paints’ Acrythane SC601.

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 Acrythane SC601 is a high solids 2K acrylic cured with isocyanate hardener, known for its outstanding properties

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REVIEW PCE OCTOBER – DECEMBER 2023

ames Cardus, the skilled artisan behind Classic Vintage Tractor Restorations, along with his painter Peter, revived this classic tractor, breathing new life into an iconic piece of agricultural history. With a rich history and a passionate following, the Massey Ferguson 35X tractor deserved nothing but the best in its restoration journey.

“We have been using HMG Acrythane SC601 for many years now and are extremely happy with the excellent finish it produces as standard,” commented Cardus. “Even more so, our customers love the finish and happy customers are the most important thing for us.”

Striking finish Acrythane SC601 is a high solids 2K acrylic cured with isocyanate hardener, known for its outstanding properties, including rapid drying and simplicity of use. The tractor’s striking finish and exceptional durability were made possible thanks to this popular paint product which is ideal for the ACE (Agricultural and Construction Equipment) and restoration marketplaces.

Not only does Acrythane SC601 provide an impeccable finish, but it also offers excellent protection against harsh weather conditions and atmospheric pollution. Its resilience ensures that the red Massey Ferguson 35X will retain its beauty and functionality for years to come.

Available in a wide range of sheen level and colours, including 2,400 in the ColourBase Colour Box along with other Fleet, RAL & BS and automotive shades, it empowers craftsmen like James Cardus to bring their visions to life with precision and perfection.

“It’s wonderful to see our paint being used on projects like this and brilliant to see the engagement on social media about the project,” says Paddy Dyson, HMG Paints Marketing Manager. “To receive over 7,000 likes on the teaser picture of the painted bonnet shows just how amazing this project was and passionate the restoration community is. The work James and his painter Peter have done is testament to their attention to detail and we’re delighted he chose Acrythane SC601 as his topcoat of choice.”

Classic Vintage Tractor Restorations has garnered a substantial following on social media, with a popular Facebook page and a YouTube channel where enthusiasts can witness the transformation of iconic machines like the red Massey Ferguson 35X and other famous brands including County, David Brown, Ford and more. In fact, they even restored a blue County 1474 which went on to be sold for £200,000 at auction and was described in the auction catalogue as ‘arguably be one of the best County 1474 restorations ever completed’. ■

REVIEW PCE OCTOBER – DECEMBER 2023

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The advantages of selective electroplating in electric motors

REVIEW PCE OCTOBER – DECEMBER 2023

Electric motors are a crucial component in numerous industries, from automotive to manufacturing, and their performance and longevity play a crucial role in the overall efficiency of various systems. Selective electroplating has emerged as a valuable technique to enhance the functionality and durability of electric motors. Tom DiCillo – Midwest Territory Sales Manager, SIFCO ASC, explores the importance of selective electroplating for electric motors and its advantages to their performance.

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REVIEW PCE OCTOBER – DECEMBER 2023

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lectric motors in industrial settings often run continuously or for extended periods, leading to increased mechanical stress and wear on components. The constant rotation and friction can cause the degradation of internal parts over time. High temperatures and excessive heat can lead to the deterioration of insulation materials, bearing lubricants, and other critical components, reducing efficiency and increasing wear.

Selective electroplating primarily serves to replenish metal in a component’s worn areas, allowing for the complete part to be salvaged and reused. This technique involves the targeted deposition of metal onto the worn sections, effectively restoring the part’s functionality and extending its operational lifespan. By precisely applying metal only where it is needed, selective plating offers a cost-effective and sustainable solution for maintaining and refurbishing various industrial components, reducing the overall environmental impact associated with replacement. This protects the motor’s lifespan, enhances reliability, and ensures consistent performance. Additionally, selective electroplating reduces downtime significantly, enhancing productivity in industrial processes.

Application with extreme precision The process is performed with extreme precision. Technicians use specialised equipment and techniques to deposit a specific layer of metal onto only a component’s damaged or worn area. This precision ensures that only the necessary repairs are made, avoiding unnecessary alterations to the rest of the part. One of the critical advantages of selective electroplating is its ability to maintain the original dimensions and tolerances of the component. Because only the affected area is plated, there is minimal alteration to the overall shape or size of the part. This is crucial in electric motor repair, as deviations from original specifications can negatively impact motor performance and efficiency.

Selective electroplating can be applied to components with intricate or complex geometries that are challenging to reproduce through traditional machining or replacement methods. It allows for precise metal deposition in hard-to-reach areas and is a highly effective repair technique in electric motor maintenance and other industries. It excels in providing localised, precise, and efficient repairs, thereby conserving materials, reducing costs, and ensuring the repaired components meet or

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exceed their original specifications. This makes it a valuable tool for prolonging the life and reliability of electric motors in various industrial applications.

Main areas of application

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The SIFCO Process focuses on several primary application areas, such as bearing housing, commutators, and rotor journals. End bells, which house the bearings that support the motor shaft, experience fretting corrosion during operation. The SIFCO Process is used to plate these bores to size with nickel deposit.

Plating a worn bearing housing can take less than thirty minutes and is a cost-effective alternative to machining the bore oversized and pressing in a pre-machined sleeve or flame spraying and machining to the print dimension.

DC motor and generator slip rings can develop copper oxide films, which reduce electrical conductivity and cause arcing and pitting, especially during locked motor start-up. Corrosive environments can also cause excessive damage and shorten life. Worn or corroded contact areas can be quickly restored to factory-like condition. Copper can be built back to dimension, and a silver conductivity and protective layer can be added during the same plating operation.

Some operators approach selective plating cautiously due to using chemicals labelled as ‘hazardous.’ In reality though, selective plating is a safe process that requires only standard personal protective equipment and a common-sense approach to health and safety. The particular application of chemicals minimises waste and disposal requirements, which makes it the preferred choice.

that selective electroplating offers. By targeting specific areas, manufacturers can reduce the use of plating chemicals and materials, minimising waste and the associated environmental impact. Furthermore, selective plating is a permanent repair. The ability to restore and prolong the life of electric motor components through selective electroplating reduces the need for frequent replacements,

Measures the concentration of soluble salts on metal surfaces using the Bresle method

There is also the contribution to environmental sustainability

temperature, conductivity (µs/cm) and surface density n Easy 1-2-3 gage interface guides users through the Bresle method n Includes PosiSoft suite of software for viewing and reporting data

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REVIEW PCE OCTOBER – DECEMBER 2023

Environmentally sustainable

n Displays test duration, sample

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leading to reduced waste generation and resource consumption.

REVIEW PCE OCTOBER – DECEMBER 2023

Specialised training Education and training in selective electroplating play a big part in the maintenance and longevity of electric motors.

With years of experience and expertise, SIFCO ASC has developed a comprehensive training programme tailored to the unique needs of selective electroplating applications.

The training course encompasses theoretical knowledge and practical hands-on experience, ensuring participants understand selective electroplating principles, processes and best practices. However, selective electroplating, like welding and thermal spray, requires a welltrained operator.

However, this industry is experiencing a skills gap as older operators retire, resulting in losing plating experts. To address this, SIFCO ASC offers a re-education course to train or re-train operators on the proper use and benefits of selective electroplating at facilities that previously used the SIFCO Process but have lost their operators due to retirement or employee turnover.

SIFCO ASC combines application knowledge acquired through global research and development investment, engineering expertise, and practical insights from the company’s service technicians to provide comprehensive training. Whether for those

who have previously purchased SIFCO ASC equipment or newcomers to the technology, full training is available to ensure a thorough understanding of the process and achieve successful repairs.

Highly-skilled instructors lead the training sessions with advanced teaching methods and state-of-the-art equipment. This enables participants to develop the skills necessary for precision plating in targeted areas. Whether achieving selective plating on complex geometries, repairing critical components, or enhancing product performance, SIFCO ASC’s training programme equips individuals with the proficiency and confidence needed to excel in selective electroplating.

Trusted and recommended repair method The world relies on electric motors for transportation, infrastructure development and industrial improvements. Therefore, efficiency is paramount. Selecting the correct maintenance and repair solution can lower costs, enhance performance, and minimise failures. The SIFCO Process, a trusted and recommended repair method endorsed by the Electrical Apparatus Service Association (EASA) and meeting various industry, military, Aerospace Material Specifications and federal specifications, offers superior finishes and many benefits, including quality, durability, cost savings, portability, and time savings. ■

Where the Industry Meets Surfex is the UK’s event for the paints, inks, coatings and surface technology industry featuring a large exhibition running alongside a comprehensive programme of scientific, technical and topical industry content.

With extensive access to a whole spectrum of suppliers, scientists and industry experts, Surfex delivers the ideal meeting place to develop new ideas, source solutions to technical challenges, find inspiration, enhance knowledge and address key issues.

Visit www.surfex.co.uk to find out more and investigate exactly what you can achieve at Surfex.

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Coventry Building Society Arena

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FIRST OF ITS KIND TRAINING DIVISION

NEWS PCE OCTOBER – DECEMBER 2023

Liverpool based PSI Global have launched a training facility following their affiliate membership with Train the Painter.

PSI Global Group are pleased to announce the launch of the new PSI Global Training Limited.

The new division offers the first Train the Painter training facility to be located in Liverpool and the North West, and has been created to bring high quality training to individuals and companies.

Following PSI Global Recruitment becoming the first agency affiliate member of Train the Painter in August 2022, the decision was made

by Industrial and Marine Director Rebecca Law to start the new training division.

“The idea came from the regular skills gap we were seeing in the Industrial Services sector,” explained Law. “We’re constantly looking at ways we can give back to the communities each of our projects are based in, and this

felt like a great way to get more people back into work while giving them the skills needed to start a new career.”

Giving back Through the continued support of the local communities PSI Global is involved in came the Community Initiative. The Initiative, which forms part of PSI Global Training, focuses on giving back to these communities while helping to build skills for the future to benefit the local economy. The goal is to create a sustainable and impactful programme that empowers individuals and strengthens communities.

The Community Initiative brings together businesses, training, and individuals to address local challenges, foster innovation, and drive positive change. The first session took place in Rosyth, and included employability workshops, an induction with our local client, and a five-day Train the Painter course with PSI Global’s own trainer. This

was followed by nine weeks of on-the-job work experience.

Training options Train the Painter is part of the Corrodere Academy, with courses designed to give workers the essential skills needed to work on-site as an Industrial Painter. The Train the Painter courses offered through PSI Global Training can be done as a blended learning option (e-learning and practical in person) or all classroom based. Additionally, the facility will be used to upskill current Train the Painter cards and run trade tests with our dedicated Train the Painter trainer before sending the workers to site.

The new training division has now opened their facility in Liverpool and are taking bookings for anyone interested in obtaining their Train the Painter qualifications.

Further information about each course offered, as well as course bookings, can be found at psiglobalrecruitment.com/ psi-global-training.

NEWS PCE OCTOBER – DECEMBER 2023

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EVONIK PROTECTS FACADES While the formulation of exterior paints may differ around the world, the challenge of protecting buildings from environmental impact seems universal. With the new additive TEGO Guard 9000 from Evonik Coating Additives, it is possible to protect building facades from the moment of application.

“The application of facade paints has been highly dependent on the weather, as newly applied facade coatings had traditionally long drying times, making them more vulnerable to water and dirt,” says Ellen Reuter, Head of the Decorative market segment for the EMEA region. “Evonik’s new TEGO Guard 9000 addresses this key customer pain-point by improving the stabilisation of paint ingredients in facade coatings and providing almost

While conventional high pigment volume concentration (PVC) exterior facade coatings typically take three hours or more to dry, the new ‘quick-set property’ of TEGO Guard 9000 technology enables high rain resistance just a few minutes after application. immediate protection against weathering,” she explains.

While conventional high pigment volume concentration (PVC) exterior facade coatings typically take three hours or more to dry, the new ‘quickset property’ of TEGO Guard 9000 technology enables high rain resistance just a few minutes after application.

The technology promotes electrostatic interaction between a cationic organic

polymer and the anionic paint ingredients in the coating formulation.

Additionally, the special formulation of TEGO Guard 9000 allows for customised addition to formulations without affecting storage stability. The additive can be used universally, regardless of the binder, PVC and colour selected, and is suitable for environmentally-friendly waterborne facade coatings.

PCE January - March 2024 Issue

The Leading Protective Coatings Magazine

SPECIAL EDITORIAL FEATURES: • Waterborne Coatings • Tank and Pipeline Coatings • Steel Protection • Renewables

Focus: Nano Technology Event Distribution:

AMI: Pipeline Coatings - Vienna 13-15 February Eurocoat - Paris 26-28 March

PCE will continue to showcase its regular features; Lifting the Lid, Upfront and Spotlight, as well as featuring the latest news and developments in marine and offshore coatings PCE International is published quarterly by MPI Group Peel house, Upper South View, Farnham, Surrey. GU9 7JN. UK To advertise in the magazine, on the website and /or newsletter contact Nick Carugati: nick@pce-international.com

Subscribe to receive PCE Magazine

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 Dan Devine Commercial Director

NEWS PCE OCTOBER – DECEMBER 2023

STRENGTHENED MARKET PRESENCE

 Sylvia Winkel Pettersson, Vice President Engineered Polymers at Nouryon

Speciality chemicals manufacturer and global distributor Devine Chemicals has doubled the size of its head office and opened a Research and Innovation Centre as it further strengthens its market presence.

The company has recently opened a Research and Innovation Centre in Lancashire in the UK to bolster its technical and development capabilities and has invested heavily in machinery, testing equipment and a new IT system. This facility will enable its team of technical specialists to drive innovation and push the boundaries through formulating and testing coatings and cementitious systems for its customers.

In addition, the company has acquired a second premises next to its head office in County Durham, North East England which has doubled its warehousing and production capacity. These new premises, along with its European office and warehouse facility in Heerhugowaard, Holland, forms an instrumental part of strengthening Devine Chemicals’ infrastructure and resources to its UK and EU customers.

“Over the past 12 months we have been on an exciting journey of growth and development and it is fantastic to see all the hard work come to fruition,” says Dan Devine, Commercial Director at Devine Chemicals.

“The new Research and Innovation Centre will enable us to continuously evolve our product portfolio and stay at the forefront of our industries.

“Furthermore, it provides us with the facilities and technology to collaborate with our customers, run trials and develop products to meet their specific requirements.”

PRODUCTION STARTED Nouryon, a global specialty chemicals leader, announced that it has started fullscale production at its new Expancel expandable microspheres plant in Green

Bay, Wisconsin, US. The launch of the new plant is an important milestone to better serve specialty additives customers in North America in the packaging, construction, mining, and automotive industries, and complements the company’s existing full-scale plant in Sundsvall, Sweden, and product expansion facilities in China and Brazil.

Expancel expandable microspheres are used as a lightweight filler and blowing agent to make products lighter, incorporate high-performing insulation properties or better reflect light to reduce energy consumption, cost, and environmental impact. These properties are valued across a number of applications including cool roof coatings and automotive coatings and body fillers.

Expancel expandable microspheres can also be used to enhance products in applications including kerbside recyclable packaging materials, freeze- and thaw-resistant concrete, as well as sealants and coatings applications in the construction industry where prevention of cracks and water absorption are essential to prolong the life of weatherexposed building materials.

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Nouryon is seeing a marked increase in demand for expandable microspheres, particularly in the packaging, construction, mining and automotive industries and we are pleased to open a fullscale manufacturing facility to support our customers in North America.

NEWS PCE OCTOBER – DECEMBER 2023

“Nouryon is seeing a marked increase in demand for expandable microspheres, particularly in the packaging, construction, mining and automotive industries and we are pleased to open a fullscale manufacturing facility to support our customers

in North America,” said Sylvia Winkel Pettersson, Vice President Engineered Polymers at Nouryon.

RAPESEED AND PINE ROSIN COATING KIA Motors is using bio-based paint supplied by AkzoNobel

for the inside of its new EV9 electric SUV. It’s the first time the vehicle manufacturer has specified an interior bio-based coating.

Two kinds of bio-rosin (rosin is a solid form of resin) have been used to create the product, one extracted from rapeseed, the other from pine rosin. The paint can be found on the EV9’s interior door switch panels, with AkzoNobel also supplying coatings for the rest of the interior.

“Both companies have a long history of developing more sustainable products and we’re proud to have played a role in helping KIA Motors achieve a notable production landmark,” says Patrick Bourguignon, Director of AkzoNobel’s Automotive and Specialty Coatings business. ■

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