Hempaguard Ultima is Hempel’s new unique silicone hull coating two-layer system
Hempel A/S
Lundtoftegårdsvej 91
DK-2800 Kgs. Lyngby
Denmark
2 Lifting the Lid
Alexander Enström, Executive Vice President and Head of Marine at Hempel talks about why he believes Hempaguard Ultima is one of Hempel’s most significant innovations to date.
8 Up Front
Interesting tank and pipe solutions provided by Belzona, Carboline and PPG.
16 Analysis
Safety first sophisticated stripping carried out by Walco Industries.
26 Spotlight
A turnkey paint shop system for Airbus subsidiary Premium Aerotec.
30 In Focus
A cornucopia of marine coating projects from PPG, Nor-Maali, Jotun and AkzoNobel’s International.
38 Update
Hexigone Inhibitors upscales its anti-corrosion additive manufacture.
42 Review
New standards in safety, performance, and reliability from VIP Coatings. 54 News
The latest products, appointments and industry news.
68 Corrodere Academy
The latest articles, news and directory listing from Corrodere Academy.
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.
Publisher: Andrew Deere andrew.deere@mpigroup.co.uk
LIFTING THE LID
Accelerating maritime energy efficiency with Hempaguard Ultima
In connection with the launch of Hempel’s groundbreaking new silicone hull coating system, Hempaguard Ultima, Protective Coatings Expert met up with Alexander Enström, Executive Vice President and Head of Marine at Hempel A/S, to talk about why he believes that this is one of Hempel’s most significant innovations to date.
Hempaguard Ultima has been designed to safeguard vessels from fouling with a unique two-layer system, enabling our customers to reach their sustainability objectives while also achieving operational excellence.
Q. Hi Alexander, and thank you for taking the time to meet with us. Before we dive into your new product, let’s briefly set the scene. In your experience, what are currently some of the major pain points of Hempel’s customers in the maritime industry?
A. Hi Mark, and thanks for having me. I’m very excited to talk about Hempaguard Ultima – and one of the reasons for this, to your point, is actually because of our customers and what we know this product will be able to do for them – superior performance and up to 21% in fuel savings, among other things.
There is no doubt that it has been a volatile year for the maritime industry however, and we see a consistent focus from our customers on improving performance and accelerating the sustainability journey of the industry as a whole. In the media, we see a lot of discussions about, and focus on, the green fuels that will help improve the sustainability profiles of vessels in the future, but the reality is that improving energy efficiency is what will make a difference here and now. Even when we have the infrastructure and more widespread adoption of green fuels, the availability and cost will require shipowners and operators to be as vigilant about performance and energy efficiency as ever.
Q. So how do coatings fit into this focus from customers?
A. Shipowners and operators have a myriad of options to choose from when it comes to the energy efficiency of their ships. But of all the technology available, silicone hull coatings come out on top. Silicone hull coatings are the lowest-hanging fruit for the shipping industry to accelerate decarbonisation. In general, every ship has to come in to drydock for a new coat
of paint every five years, so this isn’t a new add-on technology they have to go out and acquire, and it requires no retro-fitting of ships.
Q. What makes Hempel’s coating solutions unique compared to other hull coatings currently on the market?
A. Hempel’s silicone hull coating for the maritime industry, Hempaguard, was launched in 2013, so we have more than 10 years’ experience with a market-leading premium antifouling based on silicone technology. It has been applied more than 4,000 times and, recently, its performance when it comes to the reduction of CO2 emissions and fuel performance has been third-party verified and validated by DNV.
We are, however, always looking for ways to optimise our products for our customers, and that is why we are launching the next generation of silicone hull coatings: Hempaguard Ultima. It has been designed to safeguard vessels from fouling with a unique two-layer system, enabling our customers to reach their sustainability objectives while also achieving operational excellence. Hempaguard Ultima combines the proven performance of Hempaguard X7 with our revolutionary new biocide-free silicone topcoat, Hempaguard XL.
Q. How does this new solution contribute to the maritime industry’s decarbonisation efforts?
A. Decarbonisation in the maritime industry is a complex challenge that requires multiple strategies, and Hempaguard Ultima plays a crucial role in this effort. With Hempaguard Ultima, a vessel’s hull is able to achieve a more stable surface smoothness, even into the fourth or fifth year of the docking cycle. This reduces the risk of fouling after long service periods, even when the coating’s hydrogel and biocide can start losing some effectiveness. By reducing hull drag, the coating directly lowers fuel consumption, which is one of the largest sources of carbon emissions in shipping. Over time, the cumulative effect of reduced fuel use across a fleet can lead to significant reductions in greenhouse gas emissions. Moreover, improved performance can help ship operators meet increasingly stringent regulations on emissions, such as those set by the International Maritime Organization (IMO), thereby supporting global climate goals.
Hempaguard Ultima enables 21% in fuel savings, but also a minimal speed loss of 0.9% and 6% out-of-dock speed increase.
Q. What are the potential cost savings and operational benefits that shipowners and operators can expect from using this new coating?
A. They can expect substantial cost savings from Hempaguard Ultima, due to its ability to improve fuel efficiency. With reduced drag, vessels require less power to maintain cruising
speed, leading to lower fuel consumption. As I previously mentioned, Hempaguard Ultima enables 21% in fuel savings, but also a minimal speed loss of 0.9% and 6% out-of-dock speed increase.
Over the lifespan of the coating, these savings can be significant, especially for vessels on long-haul routes. Additionally, the prolonged smoothness of the hull means less frequent maintenance and fewer drydockings, further reducing operational costs and minimising downtime. This combination of efficiency, durability and environmental compliance makes Hempaguard Ultima a valuable investment for shipowners looking to enhance performance while also supporting their sustainability commitments. ■
Just a few weeks in here.
Bring the outside into your lab with Atlas. Configurable to precisely simulate environmental conditions, our weathering instruments set the standard for accuracy and reliability. It’s no wonder that Atlas is the platform of choice for durability testing worldwide.
UP FRONT
COLD BONDING BRILLIANCE
In the heart of the Netherlands, two large tank farms chose cold bonding to face a daunting challenge: over 1,100 brackets needed to be installed on live, fully operational tanks filled with highly flammable liquids.
Belzona 1111 (Super Metal) mixed and ready to apply
Traditional welding was impossible as taking the sites offline and emptying the vessels would have required a costly shutdown which was not a viable option. So, seeking an alternative to welding, the customers chose Belzona’s innovative cold bonding solution.
The first client, a renowned global infrastructure provider, wished to make its operations more sustainable by installing solar panels on the top of its tanks. However, before the panels themselves could be installed, cable ducts and supports needed to be installed across the entire structure. The large number of panels required that around 500 brackets be cold bonded onto the live oil tanks, as hot work was out of the question.
The second client, a global leader in tank terminal operations, needed 660 brackets installed on live kerosene tanks. This was due to recent legislative changes that mandated the installation of extra fire extinguishing pipes. With safety as its top priority, the client sought a swift and dependable solution. It was crucial that the chosen method could install the brackets without disrupting the facility’s operations or incurring the expense of a shutdown.
Why choose Belzona?
For both sites, a hot work permit was out of the question so a cold bonding solution was required. At the first site, the kerosene tanks were filled and had an internal coating, meaning hot work was not an option. Similarly, at the second site the tanks were fully operational, so an alternative to welding was also required in this case.
Belzona offered a cold work solution that could be applied whilst the tanks were full and operational. Epoxy composite Belzona 1111 (Super Metal) was chosen for its high adhesion properties, as it can be applied and cured at ambient temperature using simple tools, making it ideal for this in-situ application. In addition to being less hazardous, this method ensures greater contact across the surface area of the bonded bracket compared to the limited contact of weld seams.
Super Metal application
First, the surfaces were suitably roughened to Swedish Standard Sa2½ (near white metal finish) with a 3 mil (75μm) profile to achieve maximum adhesion. By utilising ATEX closedloop vacuum grit blasting, optimal surface preparation was achieved whilst mitigating the hazards of airborne grit and debris. This method not only ensured safety but also maintained operational continuity by eliminating the need for temporary structures such as tents and additional scaffolding, which would have been required for conventional grit blasting. The closed-loop system therefore proved the most efficient solution for surface preparation on a live site.
Following completion of surface preparation, the team bonded the brackets onto the substrate using Belzona 1111 (Super Metal). Once the product was mixed, a layer was firmly applied to the prepared surfaces of both the tank and the underside of each bracket. The brackets could then be pushed into place with force, secured, and left to cure.
Successful cold bonding of over 1100 brackets at the two sites
Cold bonding success
Both applications were successful, leaving the clients delighted that the brackets had been securely installed without the need for welding, thereby avoiding the expense and hazards associated with a costly shutdown or dangerous hot work.
The first client has successfully installed its solar panels after cold bonding over 500
brackets with Belzona 1111 (Super Metal). This application was critical to the successful implementation, helping the customer achieve its sustainability goals. Similarly, the second client is now fully compliant with the new fire safety regulations. In each case, choosing Belzona as a welding alternative allowed for a safe and efficient installation, without the need for hot work. ■
THE CRUCIAL DIFFERENTIATOR
A major refinery turns to Carboline for faster, more efficient maintenance.
Spot surface prep and touchups weren’t going to work
Midstream oil and gas facilities operate under precisely calibrated processes. Those processes are easier to draft on paper, but quite complex to manage in reality.
Storage tank maintenance is one element of that complexity, presenting owners with a difficult conundrum: tanks last longer, are safer, and generate more revenue when they’re properly maintained, but proper maintenance requires taking them out of service.
An owner’s ensuing reluctance to go all-in on maintenance is unfortunate but understandable. However, for one refinery,
switching to a different tank exterior coating system has turned its tank maintenance tightrope into a walk in the park.
Tank condition
Tank 99 is one of dozens in a sprawling central Louisiana complex belonging to one of the world’s largest chemical and refining companies.
The 20-year-old cone roof type tank is 80ft (24.4m) in diameter and stands 46ft (14m) high. Maintenance leaders decided a new protective coating maintenance regime was warranted after an assessment of Tank 99 revealed that Tank 99 is one of
its cone roof had weathered for two decades, and had never been blasted or coated in the first place. Failures of a previous coating were widespread throughout the tank shell and a protective coating application used on repaired areas was incomplete.
Spot surface prep and touch-ups wouldn’t suffice. It was obvious a full recoat of Tank 99 was necessary. The owner’s existing coating manufacturer insisted that the work include blasting the shell and cone roof back to bare steel before installing a new coating system.
The owner wanted to avoid the added time and expense of a full blast, while still installing a coating system that would extend the tank’s service life for at least another generation. This prompted its investigation of alternative providers.
Sidestepping some surface prep
Upon inspecting Tank 99, a Carboline technical service representative saw that the owner could achieve both its asset protection and cost savings objectives at the same time.
Surface preparation prior to a recoat would be dramatically faster and easier if the owner specified a coating system anchored by Carbomastic 15, instead of the familiar zincepoxy-urethane corrosion protection package.
Carbomastic 15 is a unique lamellar aluminium-flake reinforced epoxy mastic developed for marginally prepared surfaces. Its aluminium pigmentation imparts exceptional barrier protection properties, even when applied over well-adhered prior finishes or tightly-adhering rust.
It also displays excellent wetting properties despite its relatively low solvent content. And with low-stress curing, Carbomastic 15 cures without applying so much tension to an underlying film that it would tear it off the substrate.
A simplified plan for Tank 99 was agreed:
. Surface prep would consist of SSPC-SP WJ-1 water jetting at 10,000 psi (70 mPa)
. Application of a primer coat of Carbomastic 15 at 4-6 mils (102-152μm) DFT
. A second Carbomastic 15 coat of the same thickness
. A finish coat of Carbocrylic 3359 DTMC at 2-3 mils (51-76μm) DFT
Carbocrylic 3359 DTMC is a versatile waterbased acrylic finish coat with exceptional
By shortening maintenance outages and extending storage tank service life, this owner’s operations are made more consistently reliable.
weathering characteristics. It can be applied direct to metal or over compatible primers and is widely used in tank exterior, piping, and structural steel applications.
Another important characteristic of Carbocrylic 3359 DTMC is its dry-fall characteristics. Dry-fall refers to the dry, easyto-clean result of a coating that lands on an unintended surface in the event of overspray.
A much tougher process is required to clean wet-falling products, and avoiding this was essential because residential neighbourhoods lie immediately adjacent to the refinery.
A similar coating system was specified for adjacent pipe racks, where two coats of Carbomastic 15 were applied followed by one coat of Carbothane 134 HG. Carbothane 134 HG is a high-gloss, thin-film urethane topcoat widely regarded throughout industrial applications for its excellent weathering properties.
This alternative again sidestepped the need for a full blast back to bare steel, and it also resolved a known issue with the present manufacturer’s topcoat, which had difficulty fully curing at high thicknesses.
Efficient, effective coating programme
Tank 99 is one of a total of four tanks for which this new corrosion protection programme was specified. And more may follow.
By turning to a system based on Carbomastic 15, the owner has increased tank maintenance efficiency and achieved significant savings in terms of time and cost. That means longer periods in profitable service as a result, but the positive impacts do not end there.
By shortening maintenance outages and extending storage tank service life, this owner’s operations are made more consistently reliable. In an environment where fragile supply chains are prone to flinch at the drop of a hat, achieving greater stability is a crucial differentiator. ■
CRITICAL ASSET PROTECTION
PPG has launched PPG PITT-THERM 909 spray-on insulation coating for oil and gas infrastructure industries.
PPG Pitt-Therm 909 can be applied in thicknesses of up to 250 mils (6.35mm) per coat
PPG has launched PPG PITT-THERM 909 spray-on insulation (SOI) coating. This silicone-based coating is designed for highheat environments in the oil and gas, chemical, petrochemical and other critical infrastructure industries, where it provides improved safety, asset protection and operational efficiency compared to traditional thermal insulative materials.
Conventional waterborne acrylic or epoxy-based SOI coatings cannot be used on equipment operating above 350°F (177°C).
Silicone-based PPG Pitt-Therm 909 coating offers much greater temperature resistance: thermal testing shows that it endures continuous and cyclic temperatures as high as 500°F, and by reducing heat transfer, external surfaces remain safe to touch at up to 310°F, significantly reducing the risk of burns.
Application testing of PPG Pitt-Therm 909 coating has also shown that fewer coats are necessary compared with traditional SOI coatings, providing operational efficiency benefits for customers. It can be applied in thicknesses of up to 250 mils (6.35mm) per coat, and depending on the specific application requirements, only one or two coats are needed, substantially cutting down the time and cost of the insulation process. Despite the reduced number of layers, it can achieve a higher total coating thickness of up to 500 mils and cure times are comparable to competing products.
Significant advantage
Application to both hot and cold substrates is also viable, allowing assets to remain in service during application – a significant advantage over traditional methods that require operational shutdowns.
“PPG Pitt-Therm 909 coating represents our team’s ongoing commitment to advancing industry standards through innovation,” explains Bill Pernice, PPG Global Segment Director, Oil and Gas, Protective and Marine Coatings. “This solution tackles the industry’s long-standing challenges by delivering high heat resistance and water-repelling properties, elevating safety and performance in demanding environments.”
PPG Pitt-Therm 909 coating also addresses critical challenges of traditional mechanical insulation systems, notably their susceptibility to moisture absorption and corrosion under insulation (CUI).
Water-repellent PPG Pitt-Therm 909 has demonstrated exceptional corrosion resistance in rigorous testing. Results show that it is an optimal solution for CUI prevention for reduced maintenance costs, operational shutdowns and safety incidents.
PPG Pitt-Therm 909 coating, available in the US and Canada, meets requirements for the American Society for Testing and Materials (ASTM) E84 Class A fire rating. ■
Elevate your coatings expertise with
SPECIAL OFFER SAVE£78
When you purchase both Fitz’s Atlas of coating surveys and Fitz’s Atlas of coating defects. Only £300 for both (usually £189 each)
Streamline your coating surveys with Fitz’s Atlas of coating surveys - a handy guide containing comprehensive detail and visual assessment for coatings evaluation.
Understand coating defects with Fitz’s Atlas 2, providing a detailed visual guide with a a description of the defect, probable causes, how to prevent it and how to repair it.
To order visit
Walco Industries was recently involved in a project to remove lead paint from a Martha A. Black-class light icebreaker at a client’s drydock
SAFETY FIRST IN SOPHISTICATED STRIPPING SOLUTIONS
Walco Industries was recently called in to carry out two very different projects; one involving lead-based paint removal and the other stripping rubber from a vessel housing a combination of acid, steam and a uranium ore product.
Paint removal covered multiple decks on the vessel, plus the funnel, bridge, stairs, handrails and other parts
Walco Industries Ltd, headquartered on Vancouver Island in British Columbia, Canada, was recently involved in a project to remove lead paint from a Martha A. Black-class light icebreaker at a client’s drydock. This was to be done at a pressure of 40,000 psi, so Walco brought in its portable decontamination trailer and four 40K pumps. The scope of work covered multiple decks on the vessel, plus the funnel, bridge, stairs, handrails and other parts.
Lead paint management was one of the primary concerns, along with the use of 40K water jetting. Occupational lead exposure continues to be an important health concern in both Canada and the US, and based on the numbers provided by the US’s OSHA (Occupational Safety and Health Administration), there appear to be significant issues related to lead paint management, as well as health concerns, at shipyards across the country.
The area was shielded with mesh and polythene sheeting to capture any flying debris and mist and debris within the containment. Water and lead were collected, filtered, reused in the cleaning process and eventually collected for treatment.
Employee safety was of the utmost importance. Safe work procedures were reviewed, with training carried out for lead hazards/handling and daily ‘toolbox talks’ to review scope and any hazards for the upcoming day, along with any concerns from the previous day. Each employee was fit-tested with a fullface mask combined with P-100 HEPA filter. The crew also wore Tychem suits under their rainwear to prevent skin being exposed to lead. As the crew was rotated, they were required to rinse off and make their way directly to the decontamination unit to follow the donning and doffing procedures and decontamination. The process required was posted within the decontamination unit and discussed in the procedures and toolbox talks. Daily audits were either done by HSE or by the supervisor in charge. These audits also involved the workers, who also signed off as participants.
Removal process
Paint removal was accomplished using four 40,000 psi pumps and four guns running continuously to get the project completed on schedule. Ultra-high pressure is preferred over lower pressures due to its lower volume of
Paint removal was carried out at a pressure of 40,000 psi
water and ability to remove multiple layers of paint in one or two passes with an orbital jet. This method removes residuals such as salts, chlorides and other unwanted substances from the metal, ensuring better paint application and longevity. It also reduces exposure to lead from airborne contaminants for the water jetting technician and others working in the area.
The job was a success and was completed with no incidents or concerns, and stayed on budget.
CONTAMINATED LINER REMOVAL
Walco Industries also recently provided a solution for a unique task at a facility in northern Canada. The task was to strip a liner of an unknown rubber type from a vessel that houses a combination of acid, steam and a uranium ore product. The dimensions of the vessel were 21ft x 29ft (6.4m x 8.84m).
The obvious main concern was how to remove or reduce the allowable exposure (micro-sieverts) to radiation to stay within the federal Canadian Nuclear Safety and Control Act, and secondly to complete the project within a demanding timeframe.
The complicated nature of this endeavour prompted Walco to carefully consider and evaluate potential methodologies. Two prominent options were deliberated: the use of robotics and the use of 3-D tooling. Given the short assignment timeline, the cost implications associated with decontaminating or replacing robotics, and the exposure potential while operating the robotics safely and efficiently, the company obtained approval to employ the 3-D tooling method (360° rotation using high-pressure water jetting) for the bulk of the liner removal.
3-D tool design
The 3-D tool is designed for many applications and is used regularly in vessels such as the one in question. Due to the size of the tank, the placement of the mixing blades, the baffle locations and the speed at which an employee can position the equipment, an arm length of 18 inches (45.72cm) was chosen with the tooling. This allows for a 3ft (91.44cm) span reach. Keeping in mind the effectiveness of water jetting from distance (dependent on nozzle size), the optimal distance away from the walls of the vessel required no further than 6-10 inches (15.24-25.4cm). If the tool is too far away from the walls, the cutting power starts to decrease.
Sections mapped out
Looking from the top of the vessel, areas were mapped out in sections like a clock for 6 x 6-inch (15.24cm x 15.24cm) access holes. Due to the four baffles, proper calculations for the method were a requirement. These baffles were positioned at 12:00, 15:00, 18:00 and 21:00 of the clock, making for four sections, each with three access points. These access points were designated to the clock’s half-hour marks (i.e. 12:30, 13:30, 14:30, etc; 12 in total) cut at roughly 24 inches (60.96cm) away from the walls of the vessel. This design would allow the tool to drop in from the top three times per section, give an allowable overlap between the tool’s rotations and stay within six inches (152mm) of the walls. The full rotation of the tool with the intended nozzle size was calculated at 45 minutes per rotation. Knowing the height of the tank at 29ft (8.84m) and the extension arms for the 3-D tool, it was decided that each lift of the system would be 3ft (.0914m) to maximise efficiency in speed and overlap.
Radiation exposure
Because of the problematic issues of radiation exposure, it was determined that the manual method of lowering/lifting the tooling was the most efficient.
This was because the initial tank exposure readings were so strong that they would only permit the worker to complete approximately 15 minutes of work before he/she reached the daily/weekly allowable exposure limit. Each 1/3 of a section took roughly 6.75 hours to complete, or two to three days to complete a baffle-to-baffle area. Manual lifting only exposed the worker for two-to-fiveminute intervals, and the exposures for the surrounding area allowed a worker to operate for three to five hours instead of 15 minutes.
After each section was completed, visual confirmation was made to verify cleanliness before rigging the next area of the vessel.
One of the lessons learned was that as the liner fell to the floor and piled up, it greatly increased the radiation hazards to the workers at the floor level. Where at first the levels were at an acceptable degree to allow for 15 minutes, there were now increased exposure levels, dropping the allowable exposure time to as low as 45 seconds at the vessel entrance near the floor.
After learning this, the customer assumed responsibility for removing any debris on the floor during off-shift hours for Walco’s crew
(removal was completed following Walco’s recommendation of vacuum systems), resulting in a gradual increase in the permissible work time around the tanks as the project advanced.
After eliminating 90-95% of the liner using the 3-D tooling system, the workers acquired the flexibility to dedicate more than two hours at a time to finalise touch-ups and remove the remaining 5% of the liner by hand from inside the tank. Scaffolding was erected roughly 22ft (6.7m) high, sectioned off to create four levels inside the space for inspection. The workers would start the final cleanup using water jetting methods by hand from the top level of the scaffold, rinsing on their way down.
PPE requirements
Within the vessel, workers had to adhere to strict PPE requirements. No radiation particles from the liner were to contact the skin or enter the body. This was done by using chemical protective garments, full-face Powered Air Purifying Respirator (PAPR) with P100 filtration, full rubber gear (over the top of the chemical protection garments) and rubber gloves with nitrile gloves underneath. Each seam was ducttaped to prevent water or hazards from entering.
A ‘buddy check’ system was established after the worker donned his personal protective equipment to ensure that no spots were missed or skin could be exposed to the environment. These methods for proper donning and doffing equipment were used every time entry was made. The use of decontamination rooms and daily urination screening was completed for each worker entering the vessel to ensure no individual was exposed to contaminants.
Crews working within the building housing the vessels had to wear a personal dosimeter (EPD) to control their levels daily. All equipment to leave the site had to adhere to Canadian Nuclear Standards; thus, it was decontaminated and scanned for radiation particles before leaving the site and was only given the ‘all clear’ to leave after passing the rigorous testing.
The project was completed with 100% of the liner removed within the timeframe allowed. The major success of the assignment was there were no health and safety concerns or incidents. With help from the customer and supporting members of the team, the project was completed without any extreme delays, overcoming the complications uranium exposure creates. ■
Walco Industries stripped a liner of an unknown rubber type from a vessel that houses a combination of acid, steam and a uranium ore product
Airbus flight transformation
Premium Aerotec commissions Dürr to provide energy-efficient surface protection for the new rear centre tank of the Airbus A321XLR.
The fuel tank integrated into the fuselage of the Airbus A321XLR is the key component in transforming the former shortand mediumhaul planes into the new longhaul version
The exhaust air is purified with a flameless Oxi.X RV in accordance with the principle of regenerative thermal oxidation
Germany’s Dürr is currently building a paint shop as a turnkey system for Airbus subsidiary Premium Aerotec. It is the largest single project to date for the mechanical and plant engineering company in the Airbus Group.
Premium Aerotec is a world leader in the production of large and complex-shaped aircraft components. It manufactures fully assembled fuselage sections for the shells and the floor structure. The company’s capabilities range from the pressure hull right through to the rear fuselage. It is one of the most important tier-1 suppliers for aircraft manufacturers and supplies fuselage sections for the Airbus A320 and A330 families, as well as for the A350 XWB.
Dürr’s system will be used to coat the extra tank responsible for the long range of the new Airbus A321XLR.
For the first time, an all-electric exhaust purification system will also be integrated into a Premium Aerotec paint shop at its Augsburg site, which will help reduce CO2 emissions on the site.
The fuselage-integrated fuel tank of the Airbus A321XLR is the key component in transforming the earlier short- and mediumhaul planes into the new XLR (eXtra Long Range) long-haul version.
The rear centre tank extends capacity by 13,000 litres and adds up to 8,700km to the aircraft’s range. It is produced exclusively at Augsburg.
High requirements for surface protection and tightness
The Dürr turnkey project covers the entire tank coating process, from preparation and sealing to painting. The new paint shop consists of sealing, cleaning, and painting booths and also includes surface and leak testing. The requirements regarding corrosion and diffusion are high. The tank surface needs to withstand the extreme conditions on the underside of aircraft without risk of corroding.
Special air ducting system
To meet the high requirement for surface protection, painting booths need a consistent temperature and humidity. Conditioning air requires a lot of energy, especially for
Since the entire process is electrified, it can be operated with zero emissions, meaning no additional CO2, when using ‘green’ electricity.
paints that are applied manually. The use of recirculated air is not permitted, so the booths are operated with supply and exhaust air.
“To make the process more energy efficient for Airbus, we are implementing a component-specific air ducting system that greatly reduces the amount of air required, but still satisfies the safety requirements and standards,” explains Marc Furmannek, Key Account Manager at Dürr. “The less air that needs to be conditioned, the lower the energy consumption.”
Additionally, energy recovery systems are used that recycle 65% of the energy contained in the exhaust air, repurposing it for conditioning the fresh air and further minimising energy consumption.
Pollutant removal without additional CO2
For increased sustainability, Premium Aerotec opted for an all-electric exhaust air purification system in the form of Oxi.X RV. This system uses regenerative thermal oxidation with a flameless operating mode and a unique design. With the combustion process for purifying the exhaust air taking place entirely within the heat exchanger material, there is no open flame, resulting in especially low nitrogen oxide emissions. Since the entire process is electrified, it can be operated with zero emissions, meaning no additional CO2, when using ‘green’ electricity.
Increasing economic efficiency
The exhaust air streams produced contain a very low concentration of solvent. However, since the volume of exhaust air is high, a Sorpt.X CD is placed upstream of the Oxi.X RV to concentrate the exhaust air streams. This reduces the volume, thereby increasing the solvent concentration by up to 40 times. This technical effect means that the downstream Oxi.X RV can be smaller and needs no additional heating energy during solvent operation, positively affecting the cost-benefit ratio of the exhaust air purification. ■
FOCUS
A CORNUCOPIA OF COATING PROJECTS IN
Mein Schiff 7’s steel surfaces were protected with high-quality marine coatings supplied by Nor-Maali Oy
PPG enhances sustainability through electrostatic coatings, Nor-Maali protects Mein Schiff 7, Ignazio Messina selects Jotun as its partner for upcoming drydockings and International helps reduce carbon emissions on the Monna Lisa.
In an era in which environmental responsibility is paramount, the shipping industry faces increasing pressure to reduce its carbon footprint.
ForestWave Navigation, a progressive shipping company established in 2011, recently embarked on a project that showcases the potential of innovative coating technologies and application methods to significantly enhance vessel sustainability. This case study focuses on the application of PPG SigmaGlide 2390 to the Trito Navigator, a general cargo vessel, using electrostatic application techniques.
ForestWave has rapidly grown to manage a fleet of 35 ships, primarily operating in European waters and the Atlantic Basin. The company’s commitment to environmental stewardship led it to seek a hull coating solution that would reduce power consumption and carbon emissions without the release of biocides into marine ecosystems.
The challenge was multifaceted: find a coating that could deliver superior performance in terms of power savings, fuel efficiency and emissions reduction, while also utilising an application method that minimised environmental impact during the coating process itself. This is where the PPG SigmaGlide 2390 system, applied via electrostatic spraying, proved to be the ideal solution.
PPG SigmaGlide 2390 is a silicone-based, biocide-free fouling release coating that incorporates PPG’s innovative HydroReset technology. This technology creates an ultra-smooth hull surface with lower friction resistance, potentially reducing carbon emissions by up to 35%. The coating’s ability to maintain its performance over time, with up to 150 days of idle time protection, addresses the growing need for solutions that can adapt to changing shipping patterns and increased port times. However, the environmental benefits of PPG SigmaGlide 2390 extend beyond its in-service performance. The coating is designed to be compatible with electrostatic application methods, which represent a significant leap forward in sustainable coating practices. Electrostatic application works by negatively charging paint particles as they are sprayed, and are then attracted to the positive (grounded) hull surface.
The sustainability advantages of electrostatic application in comparison to traditional airless application are numerous and impactful:
. Increased transfer efficiency: Electrostatic spraying substantially improves the transfer efficiency of the coating process. Traditional airless spraying methods can result in significant overspray, with a considerable percentage of the coating not reaching the intended surface. Electrostatic application can achieve much higher transfer efficiencies, meaning more of the coating ends up on the hull where it’s needed.
. Reduced material consumption: The higher transfer efficiency directly translates to reduced paint consumption. In the case of the Trito Navigator, ForestWave reported a noticeable 15-20% reduction in material consumed.
. Improved worker safety: The reduction in overspray combined with the low VOC emissions of PPG SigmaGlide provide a much cleaner operation and an improved work environment for the applicators.
The PPG SigmaGlide 2390 system, applied via electrostatic spraying, proved to be the ideal solution
PPG SigmaGlide 2390 is a siliconebased, biocide-free fouling release coating that incorporates PPG’s innovative HydroReset technology
Jotun products such as Jotamastic 90, Jotacote Universal N10, and Hardtop AX were used on Mein Schiff 7
. Waste reduction: Less overspray means less waste generated during the coating process. You only have to look at the dock floors at the end of the project to see how much paint has been saved from disappearing into the environment. This reduces the environmental impact associated with waste disposal and cleaning processes in the shipyard.
. Saving time and costs: Electrostatic application can often be completed more efficiently than traditional methods. Due to the reduction in overspray and a cleaner operation, shipyards spend less time masking the vessel and covering the dock, saving valuable time and costs.
. Enhanced coating performance: The paint particles are precisely guided towards the grounded surface of the vessel, leading to an exceptionally even particle distribution and the formation of a uniform and smooth film. This improved coverage and smoothness can enhance the longevity and performance of the coating.
The application of PPG SigmaGlide 2390 to the Trito Navigator took place at the Odessos shipyard in Varna, Bulgaria. The process involved blasting the hull to prepare the surface, applying PPG SigmaPrime as a base coat, followed by
PPG SigmaGlide 790 as a tie coat, and finally the SigmaGlide 2390 as the topcoat. The use of electrostatic application for the SigmaGlide layers ensured that the environmental benefits began right from the application stage.
The results of this innovative coating and application approach are expected to be significant. ForestWave anticipates that with PPG SigmaGlide on its hull, the Trito Navigator will be able to operate at an average of one knot higher speed, while keeping a compliant Carbon Intensity Indicator (CII) rating. This improved performance is projected to contribute substantially to ForestWave’s plans for meeting IMO greenhouse gas emission reduction targets over the next decade.
In conclusion, the case of the Trito Navigator illustrates how the combination of advanced coating technology and innovative application methods can yield substantial sustainability benefits. Electrostatic application of PPG SigmaGlide not only enhances the coating’s inherent environmental advantages but also introduces a new level of sustainability to the application process itself. As the shipping industry continues to navigate the challenges of environmental regulation and sustainability expectations, PPG SigmaGlide will likely play an increasingly crucial role in shaping the future of marine coatings and vessel maintenance.
PROTECTING MEIN SCHIFF 7
The luxury cruiseship Mein Schiff 7, built by Meyer Turku, was completed in early June. The ship’s steel surfaces were protected with highquality marine coatings supplied by Nor-Maali Oy, including Jotun products Jotamastic 90, Jotacote Universal N10, and Hardtop AX.
Meyer Turku delivered the Mein Schiff 7 to the German-based cruise line TUI Cruises on June 10. The ship will sail in the North Sea, the Baltic and the northern Atlantic. All Mein Schiff ships in operation (seven in total) have been built in Turku, with the newest being the last in the series.
Construction of the 316m-long, 35.8m-wide vessel, with a passenger capacity of 2,894, began two years ago. The vessel runs on lowemission diesel and is equipped with Selective Catalytic Reduction systems to reduce nitrogen oxide emissions. In the future, the ship will also be able to operate on methanol as fuel.
Tui Cruises, founded in 2007, is a cruise company jointly owned by the German tourism company TUI AG and the American cruise operator Royal Caribbean Group. The company targets German-speaking customers seeking a premium cruise experience.
Technical support from Nor-Maali
The ship’s steel surface coatings were supplied by Nor-Maali Oy in collaboration with Jotun. Due to the high-quality products and inspection services provided by Nor-Maali, the Mein Schiff 7 has durable and easy-to-maintain paint surfaces.
The total amount of paint supplied by NorMaali for steel surfaces was approximately 375,000 litres. About half of this was epoxies, with Jotamastic 90 being the most used product. Over 40,000 litres of two-component weather-resistant topcoats, such as Hardtop AX, were used. Approximately 40,000 litres of single-component products were also used for the ship’s interior.
The products used for painting the ship’s tanks varied depending on the tank’s purpose: Jotacote Universal N10 for ballast tanks, Marathon 2:1 for grey water tanks, Tankguard DW for potable water tanks, and Chemflake Special for the bioreactor.
Environmentally friendly
Since the ship was designed to be environmentally friendly and methanol-ready, the tanks also needed to store methanol.
Methanol’s aggressiveness imposes high demands on the coating used in the tanks, and many types of paint cannot withstand this stress. Tankguard Zinc, a two-component, moisture curing inorganic zinc ethyl silicate coating was chosen. Tankguard Zinc is particularly suitable for alcohol solvents, such as for use in methanol tanks, and has excellent resistance to chemical stress.
Tankguard Zinc is a user-friendly product because it produces minimal spray mist. Additionally, the product has a good mud cracking resistance. The recommended film thickness for Tankguard Zinc is 110-250μm WFT.
Currently, Meyer Turku is building the next Icon-class ships Star of the Seas and Legend of the Seas, as well as offshore patrol vessels for the Finnish Border Guard.
SUSTAINABLE VESSEL SOLUTIONS
Given the common commitment to sustainable operations, Ignazio Messina has selected Jotun as its partner for its upcoming drydockings.
“By continuously developing and innovating sustainable products and solutions, our clean shipping commitment contributes to protecting biodiversity, preserving fuel, and reducing carbon emissions,” explains Giulia Nebbia, Marine Area Manager at Jotun. “Our customers reduced emissions by 10.4 million tonnes of CO2 in 2023, based on ISO 19030 calculations. We are thrilled that Ignazio Messina has selected us to protect their vessels.”
Jotun’s customised solution responds to Messina’s challenging trade in warm waters with moderate speed in an uncertain geographical scenario. The tailored hull coatings system with SeaQuantum (Silyl Acrylate antifouling) and SeaQuest Endura (FRC Biocidal antifouling) will
Inspection services were provided by Nor-Maali
Ignazio Messina has selected Jotun as its partner for upcoming drydockings
protect the Messina vessels, granting the best hull performance and cooperating with the sustainable target required.
Jotun Hull Performance Solutions (HPS) combine state-of-the-art antifouling and application technologies with high-end technical service. The performance and impact on vessel energy efficiency can be tracked and measured with transparent methods (ISO 19030), and additional high-performance guarantees that can secure return on investment.
“Jotun coating systems selected by Ignazio Messina & C. for vessels Jolly Oro and Jolly Argento will reduce emissions by about 20,000 tonnes of CO2 during the vessels’ service period,” says Nebbia. She adds: “We are proud to support Ignazio Messina & C. in in-service hull control with the Jotun Hullkeeper programme.”
Digital monitoring is an essential element of hull performance to maintain a clean hull. The ability to identify fouling risks in advance will help to save fuel, reduce GHG emissions, and protect biodiversity. The HullKeeper programme utilises Jotun’s in-house developed fouling risk algorithm and combines data from different sources to make fouling control and efficiency predictable, enabling shipowners to take control by making better decisions faster.
Jolly Oro and Jolly Argento will join the Hullkeeper programme after their drydocking, allowing Ignazio Messina & C. to monitor the fouling pressure on the hulls, maximising the coatings performance results.
COATING CUTTING EMISSIONS
International, AkzoNobel’s marine coatings brand, has announced that a new cable-laying vessel, the Monna Lisa, owned by Prysmian, is to be coated in its Intergard 7500 primer and Intersmooth 7465Si antifouling solution.
The decision to apply the coatings is estimated to reduce the vessel’s carbon emissions (CO2) by 672 tonnes over the drydocking period and lower Volatile Organic Compounds (VOCs) by more than 11 tonnes during construction.
By utilising Intergard 7500, a high solids universal primer, the shipyard can reduce VOC emissions during application and significantly reduce packaging by eliminating over 1,000 waste tins.
Intergard 7500, an aluminium-containing pure epoxy product, offers superior corrosion protection and abrasion resistance, leading to significant maintenance cost savings for shipowners compared with other modified epoxy universal primers, especially when applied during newbuilding.
Intersmooth 7465Si, the chosen fouling control solution, is a low-friction, self-polishing copolymer antifouling, which will keep a smooth clean hull in operation for the owner, minimising fuel consumption and associated CO2 emissions.
Increasing pressure
Shipowners are facing increasing regulatory pressures to reduce lifecycle greenhouse gas emissions, with the International Maritime Organization announcing new carbon targets for the fleet last year.
International and the owner reviewed different coating options and scenarios using the company’s Intertrac Vision prediction tool to optimise and select the best scheme to deliver the optimal economic solution while maximising the sustainability benefits.
Prysmian says that the decision to choose both coatings for the vessel was to help meet its sustainability commitments during construction and in operation.
The Monna Lisa will be the second newbuild vessel owned by Prysmian that will use coatings from International, further reinforcing the partnership between the two companies and with the shipbuilder, Vard Group.
The Monna Lisa is expected to be completed and enter into service at the beginning of 2025.
Sustainable solution
“As our customers continue to search for more sustainable solutions to help meet their decarbonisation goals, we are pleased to officially introduce our high-performing
Thanks to the good collaboration with AkzoNobel and Vard Group, we at Prysmian are proud to introduce Intergard 7500 to the European market with our Monna Lisa vessel.
universal primer Intergard 7500 solution to the European market,” says Primoz Pungartnik, Regional Commercial Director, Marine & Protective Coatings EMEA at AkzoNobel. “This has a volume of solids of 80% and VOC of 298g/lt, which is 17% higher solids and 37% less VOC than the previously used primer.
“Now in the European market, the Monna Lisa will be the first of many vessels to choose Intergard 7500 as shipyards look to reduce their environmental footprint, while increasing overall shipyard productivity as shipowners look to reduce through-life maintenance costs.
“We are grateful to our partners at Prysmian and Vard Group for placing their continued trust in International Marine Coatings.”
“The selection of marine coatings is one of the several areas where the Monna Lisa is setting new benchmarks in terms of environmental footprint,” says Leoni Davide, New Building Vessel Manager at Prysmian. “Thanks to the good collaboration with AkzoNobel and Vard Group, we at Prysmian are proud to introduce Intergard 7500 to the European market with our Monna Lisa vessel.” ■
Monna Lisa is to be coated in the Intergard 7500 primer and Intersmooth 7465Si antifouling solution
Hexigone’s corrosion inhibitors help to reduce corrosion damage on boats, vessels, cars, planes, oil tanks and buildings and have applications across a wide range of industries
UPSCALING CORROSION INHIBITOR MANUFACTURE
Port Talbot, Wales-based firm Hexigone Inhibitors, which specialises in patented micro-reservoir technology that is added to paints and protective coatings to prevent corrosion, has signed a string of international deals in India, Mexico, the US and across south and central America.
Exports now account for 90% of our turnover, and since 2021 we have up-scaled our manufacturing processes by 3,000% and grown our headcount by 50%.
Hexigone is using its patented products to address a multi-trillion-pound global problem. Its corrosion inhibitors help to reduce corrosion damage on boats, vessels, cars, planes, oil tanks and buildings and have applications across a wide range of industries including construction, renewables, marine and aerospace.
The company launched its export strategy three years ago after being spun out of Swansea University. It was founded by Dr Patrick Dodds in response to growing industry demand for safe alternatives to hexavalent chromate – the most widely used corrosion inhibitor – which was banned in Europe in 2019 as a known human carcinogen.
Zinc phosphate inhibitors have emerged as a replacement in recent years. However, the manufacturing process for zinc phosphate is energy intensive, involving strip-mined raw materials that can leach into the environment from the coating. The demand for a resourceconscious, high-performance alternative is evident, and Hexigone is well positioned to address this.
This has been evidenced in recent months where Hexigone has signed a string of export deals in countries including India, Mexico, the US and across South and Central America, with a significant number more in the pipeline across the globe.
“Exports now account for 90% of our turnover, and since 2021 we have up-scaled
our manufacturing processes by 3,000% and grown our headcount by 50%,” explains Dodds, speaking about the company’s export success. “We’re travelling all over the world to meet new clients and have some enormously exciting and significant deals about to go over the line.
“India is a massive market for us,” says Dodds. “The growth rate is so rapid and the investment in their infrastructure is unrivalled. You cannot believe just how much is going on there.
“In fact regions where there are quicker decision-making processes have become big markets for us. In the UK it can take over four years to get a decision from a client, but in territories like India and Turkey, which we’re also entering, it’s less than 12 months from first conversations to completion.
“The industry is moving at a significant pace and the opportunities are endless when you consider that any metal asset needs coating for protection. However, it’s also an enormously secretive sector, with all clients insisting on the strictest confidentiality over all aspects of their operations in this space.”
Safer and more sustainable Dodds worked in collaboration with industry leaders to develop safer and more sustainable inhibitors. The result is a product proven to be over 10 times more effective than marketleading alternatives and has even outperformed hexavalent chromate and the now leading anticorrosion inhibitor, zinc phosphate.
The Welsh government has provided Hexigone with support in recent years to help the business on its export journey, including financial backing and the opportunity to attend trade missions all around the world, enabling it to connect and build relationships with potential customers and partners in target markets.
“Last year they supported us with attending the European Coatings Show in Nuremburg, as well as Paint India,” said Dodds. “They are also currently helping us to find distributors in Columbia via a consultant in the region who is doing background checks and assessing reputations in the local markets.”
Hexigone has also recently attended the American Coatings Show in Indianapolis, Paintistanbul & Turkcoat in Istanbul, and the Latin American Coatings Show in Mexico City.
“We’ve got a great product – we know that,” says Dodds. “So we need get it out there into as many markets and sectors as possible. The global export markets create limitless possibilities.” ■
PCE October - December 2024 Issue
The Leading Protective Coatings Magazine
SPECIAL EDITORIAL FEATURES:
• Metallisation
• Bridges
• Floor Coatings
• Polyurea/Polyurethane
Focus: Marine
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
New standards in safety, performance, & reliability
VIP Coatings has introduced its ‘BeSafe’ Concept, which it claims revolutionises surface protection solutions.
The Fountain Area of Buddha Sandstone Statue, Vietnam is one of VIP Coatings’ projects
Polyurea coatings have become integral in various industries, from construction, leisure and hospitality to automotive, due to their exceptional durability, versatility and rapid curing properties. VIP Coatings is a leading provider of high-performance surface protection systems for waterproofing, flooring, roofing, as well as industrial coating needs, including the OEM sector.
Now the company is proud to unveil its ‘BeSafe’ Concept, setting new standards in safety, performance and reliability. Under the visionary leadership of Alexander Voelkel, CEO, VIP Coatings continues to innovate from its headquarters near Munich, Germany, with a global reach extending across Europe, the Middle East and Asia, serving a diverse clientele worldwide.
“At VIP Coatings, ‘BeSafe’ means being a one-stop shop for our customers, providing
one solution, one point of contact, and one warranty,” says Voelkel. “Our mission is to deliver hi-tech sustainable systems for specific coating requirements, with a focus on supply and apply solutions that serve direct asset owners. This concept ensures peace of mind for our clients since we as a supplier are responsible for project specification, product manufacturing, qualified application and aftersales service, while providing a warranty for the complete package.”
The ‘BeSafe’ Concept represents VIP Coatings’ integrated system approach to surface protection, encompassing a comprehensive range of solutions tailored to meet the evolving needs of industries worldwide. From substrate repair and preparation to high-performance coatings and aesthetic finishes, the ‘BeSafe’ Concept offers a holistic approach to surface protection,
VIP Coatings also worked on the Baia Kristal Lagoon, Colombia
ensuring durability, longevity and visual appeal. It’s not just about being another polyurea supplier, VIP says, but about being a solution provider.
“Our commitment to delivering cuttingedge solutions that prioritise safety and performance is at the heart of the ‘BeSafe’ Concept,” says Voelkel. “With our global presence and integrated approach, we are dedicated to providing our customers with the highest quality surface protection solutions that exceed expectations. Additionally, we always have in mind that time is money, and therefore our coatings convince by fast processing times as well as long lifecycles. That makes polyurea the most economic and sustainable solution.
“Asset owners will always try to avoid any shutdowns for renovations or maintenance since they would lead to direct and indirect costs, especially if these renovations are to be carried out during the high season. Hence, it will be always of great interest to do it once and do it right from the beginning to avoid shutdowns and keep running maintenance-free.”
Alongside the ‘BeSafe’ holistic approach, VIP also offers its Polyurea Hot Spray Systems to its VIP-approved applicator network across the globe. Together with local distributors, developers and asset owners, VIP helps by specifying its systems, such as Leisureline, Liquishield, VIPShield or Cleancoat, for a large variety of projects in all corners of the world. Its roller-applied coating systems and joint fillers complement the product offering.
VIP is focused on very specific applications and markets, and in this context supplies the optimum composition of certified products instead of a one-size-fits-all solution, which is always a compromise. VIP’s specific system solutions are:
Leisureline: Spray-applied and seamless instant curing solutions for containment and long-term substrate protection of valuable water park/lagoon/resort pool assets.
Liquishield: This system makes it easy for consulting engineers to specify a complete liquid containment solution from one manufacturer. The range covers primary and secondary containment of chemical liquids, abrasive slurries and drinking water.
The ‘BeSafe’ Concept represents VIP Coatings’ integrated system approach to surface protection, encompassing a comprehensive range of solutions tailored to meet the evolving needs of industries worldwide.
VIPShield: Roof sealing and insulating coating system for commercial roofs. It eliminates the need for thick concrete screeds and can be applied directly to the construction concrete or directly to steel roofing structures.
Cleancoat: Seamless and hot-spray-applied protective coating for walls and ceilings in slaughterhouses, cold rooms and food warehouses. It is easy to clean, aesthetic, durable and time-saving.
Quickdeck: Flexible coating system based on high quality industrial-grade pure polyurea technology. It is made for parking garages and roof parking spaces with high anti-skid and anti-slip properties.
OEM Lining Systems: High performance lining systems for protection, reinforcement and finish of surface technologies in emergency vehicles, public transport and military, private and leisure vehicles or commercial and construction vehicles.
As a solution provider, VIP Coatings offers a range of services to support its customers:
Project advice: VIP works closely with clients and consulting teams to analyse challenges and design fully integrated solutions tailored to specific needs.
Solution implementation: Through a network of ‘VIP Approved Applicators’, VIP ensures that its solutions are applied correctly and effectively, with extensive training provided as part of the ‘BeSafe’ Concept.
Technical services: VIP Approved Applicators adhere to strict application protocols and documentation standards, with on-site
technical supervision and quality assurance services available to ensure the highest level of performance and customer satisfaction.
With the introduction of the ‘BeSafe’ Concept, VIP Coatings reaffirms its commitment to innovation, quality and customer satisfaction. By offering comprehensive solutions and expert support, VIP Coatings continues to be the preferred partner for industries seeking reliable surface protection solutions worldwide.
VIP Coatings has also noticed that there is a growing emphasis on environmentally friendly products and practices in the construction
Training and certification programmes are not just about acquiring knowledge; they are an investment in expertise that directly influences the quality and longevity of polyurea applications.
industry. As a result, manufacturers are developing eco-friendly polyurea formulations with low VOC (volatile organic compound) content to meet sustainability requirements and regulations. VIP’s aliphatic systems also reduce the impact on the environment, as one single coat is all that is needed for a longlasting, highly aesthetic and sustainable finish.
Investing in expertise
“Our commitment to delivering cutting-edge coating solutions goes hand-in-hand with our dedication to nurturing a highly skilled workforce,” says Voelkel. “Training and certification programmes are not just about acquiring knowledge; they are an investment in expertise that directly influences the quality and longevity of polyurea applications.”
For the future, VIP Coatings continues to specialise in polyurea and polyaspartic technology, with a regional focus on waterproofing, roofing and industrial flooring. Additionally, it aims to grow specific OEM markets in defined regions and develop distribution as a new channel for ‘non-project’related retail products. ■
The AVA Resort in Mexico was another project that VIP Coatings was involved with
A lithium mining evaporation pool
Polymeric solutions for lithium mining maintenance
As the global demand for lithium continues to surge, driven by the rise of electric vehicles and renewable energy technologies, the maintenance challenges faced by lithium mining operations have become increasingly critical, explains Alexander Ruiz from Belzona.
Belzona, a leader in industrial protective coatings headquartered in Miami Lakes, Florida, is addressing these challenges head-on with its innovative polymeric solutions. Designed to combat corrosion, abrasion and chemical damage, Belzona’s coatings are playing a pivotal role in extending the life of critical mining equipment, supporting the industry’s efforts to meet growing demands while promoting sustainability.
Batteries are a highly sought-after product due to the ever-growing need for ‘green’ electric appliances and devices. Phones, solar panels and electric vehicles (EVs) all need batteries to operate, and this has led to an increase in the need for materials used to manufacture batteries. Lithium is one material whose need has increased tenfold. Some of the already large lithium mines in South America, Asia and Australia have had to expand to meet the high demands of energy and tech companies.
Lithium-ion batteries play an important role in reducing climate change. EVs reduce the need for petrol and diesel fuel. In addition, energy companies use lithium-ion batteries to store electricity generated from wind and solar farms to mitigate the use of energy generated from coal and natural gas. However, lithium mining does have its drawbacks. It is responsible for over 1.4 million US tons (1.3 million metric tons) of carbon annually. For every one US ton (0.9 metric ton) of mined lithium, 16.5 US tons (15 metric tons) of CO2 are released into the air.
Lithium mining impact
Additionally, the lithium mining process is very demanding on the surrounding environment. Part of the process involves extracting lithium from saltwater reserves. It risks polluting the local water sources, threatening humans and local animal and plant biodiversity. The batteries themselves can also be harmful to the environment. They can leach damaging chemicals and other byproducts into the environment when they are discarded. Mining can cause fires, water pollution, air pollution and health problems. Despite the negatives, the current process is the most cost-effective way to obtain lithium; however, other materials are being researched to manufacture greener batteries.
How is lithium mined?
The current lithium mining process involves drilling underground to access mineral-rich brine found under salt flats. The brine is then pumped into large evaporation pools at ground level. The sun slowly evaporates the brine pools over months or years, leaving behind minerals such as potassium, sodium and lithium. The lithium is then extracted in different ways, but usually involves a chemical process by which reagents are incorporated to form a saleable compound of lithium at a processing facility that can be transported to customers.
There are other less common lithium mining processes, such as extracting directly from
A chute coated with Belzona 1813
A pump repaired with Belzona
mineral ore. During this process, the mineral is extracted, heated and pulverised. Then, it is combined with reagents to create a slurry that is heated, filtered and concentrated via evaporation to produce a saleable lithium form.
Solving corrosion problems
Corrosion is a common maintenance problem found in lithium mines due to the presence of brine, a water-based solution high in minerals, especially salt. Brine accelerates corrosion because of an increase in dissolved ions, which allows electrons to move freely between the brine and metal substrate, causing rust. A metal object does not need to be submerged for corrosion to occur as increased moisture in the air and salt spray can also rust metal substrates.
A manufactured paint or coating can stop corrosion because it can prevent the ions from interacting with the metal substrate. Belzona polymeric coatings are applied on various
substrates of aluminium, steel, iron and more to stop the materials from corroding.
During lithium mining, equipment and assets often find themselves in the presence of brine or moisture. A pump is used to transport brine from the underground reservoir to the evaporation pools. The pump can suffer from rust and corrosion due to the mineral-rich water; however, a Belzona 1000 Series coating can prevent the piece from corroding. The coatings also repair the piece, as specific products such as metal repair epoxy paste Belzona 1111 (Super Metal), and corroded metal repair material Belzona 1121 (Super XL-Metal) can help rebuild metal loss. Rebuilding can reduce the need for a new part, and especially the downtime incurred waiting for a new part.
Other equipment in contact with water or moisture such as froth flotation cells, pressure leaching tanks, filters, centrifuges, evaporators, mixers-settlers/extraction columns and electrolysis equipment, can all potentially be
coated with a Belzona 1000 Series to protect them from further corrosion and replacement.
Solving abrasion and physical impact issues
The equipment may become physically damaged also as it deals with rough materials like mineral particles of varying sizes. Such particles can slowly eat into the surface of metal or rubber equipment. Pumps are an example of equipment that is physically damaged by solid particles, but conveyor
belts and loaders are also great examples of equipment made of different materials that suffer from similar damage. Both assets carry and transport lithium and other solid materials. During this phase of the lithium mining process, the assets endure harsh wear and tear, damaging their integrity. Holes will appear in conveyor belts and metal loss will slowly abrade the surface of the loader.
Belzona can provide a quick return-toservice with the Belzona 2000 Series, a product line engineered to repair flexible
components. Tears and abrasions on conveyor belts are repaired without the need for hot work with Belzona’s elastomer products, which provide a much-needed increase in durability, elasticity and tear resistance.
Additionally, loaders and other metal equipment such as filters, haul trucks, drills, crushers and grinding mills can be coated with Belzona 1000 Series to rebuild metal substrates that have abraded. Belzona 1311 (Ceramic R-Metal) and other products in the range can rebuild the equipment’s surface
while safeguarding it from further abrasion. The coating creates a sturdy barrier between the rough material and the substrate, and it is reinforced by the composition of the coating.
Chemical resistant and hightemperature coatings
Reagents are an important part of lithium mining. Usually, these reagents are strong chemicals such as sulfuric acid. Additionally, depending on the mining process, it can involve high-temperature reactions. Coatings in the Belzona 1000 and 4000 Series include products to protect assets during high-temperature operations or with chemicals. If there is a high concentration of sulfuric acid (98%), then Belzona 4311 or Belzona 4341 would be an appropriate choice. Lower concentrations can be resisted with other Belzona 4000 Series coatings; however, any coating performance is highly dependent on temperature.
Belzona 1511 (Super HT-Metal) and Belzona 1813 offer high-temperature resistance of up to 150°C (302°F) and 200°C (392°F) respectively. They have been formulated to protect metal surfaces from abrasive attack (Belzona 1813) and corrosive attack (Belzona 1511) at high temperatures and are resistant to a wide range of chemicals.
Greener lithium mining
Lithium mining is integral to the production of batteries that power a variety of essential green technologies, from EVs to renewable energy storage systems. Despite its significant environmental footprint, including carbon emissions and potential water pollution, advancements in mining processes and material science are making strides toward mitigating these impacts. One of the critical challenges faced by the industry is the maintenance of equipment exposed to harsh conditions, such as corrosion, abrasion and chemical attack.
Belzona’s range of polymeric solutions offers robust protection and repair options for mining equipment. By preventing corrosion, repairing physical damage and providing chemical and high-temperature resistance, these solutions not only extend the lifespan of critical assets but also enhance operational efficiency and safety. As the demand for lithium continues to rise, the application of innovative maintenance solutions like Belzona’s will be crucial in supporting sustainable mining practices and the transition to a greener, more sustainable future. ■
AKZONOBEL GIVES DRINKS CAN INDUSTRY A TASTE OF THINGS TO COME
Beverage can makers are set to benefit from AkzoNobel’s thirst for innovation, following the launch of new high-performance internal coating technology free of all bisphenols, styrene, PFAS and formaldehyde.
The company’s packaging coatings business has developed Accelshield 300, an inside spray coating for beverage cans which goes well beyond established technologies in the industry to deliver advanced corrosion protection, flexibility and sensory performance.
The latest addition to AkzoNobel’s growing portfolio of next-generation can coatings, Accelshield 300 is designed to help customers navigate the future regulatory landscape. The new technology
has been approved by the US Food and Drug Administration (FDA) and key beverage brands, and is also compliant with current and future EU regulations restricting the presence of intentionally added bisphenols, such as bisphenol A (BPA) and bisphenol F (BPF).
“Our Accelshield 300 technology is further proof of our commitment to helping customers make the transition to a bisphenolfree world,” explains Chris Bradford, Marketing Director at AkzoNobel’s Industrial Coatings business. “We’re providing the market with a more sustainable alternative that comes with even better performance, and because it far exceeds current regulations, we’re confident this will be a long-term solution.”
As well as providing enhanced production efficiency by curing rapidly –helping to reduce both energy costs and consumption –laboratory and brand testing have also revealed that the Accelshield 300 technology offers improved flavour performance, compared with earlier solutions on the market. Another major benefit is that it seamlessly integrates into existing production lines.
The introduction of the new product closely follows the launch of Accelshield 700 – a styrene-free and bisphenolfree beverage end internal coating – and the Accelstyle 100 and 200 overprint varnishes for two-piece aluminium beverage cans, which are free of bisphenols, styrene and PFAS.
CARBON REPORTING AND REDUCTION PLANS
As one of the leading specialist contractors in the UK, Concrete Repairs Limited (CRL) offers comprehensive and sustainable services to inspect, repair, rehabilitate and strengthen structural concrete assets in various sectors, including highways, water, marine, nuclear and power.
To expedite its sustainability and social value aims and goals, CRL recently entered a partnership with Tunley Environmental. Following the measurement principles BS EN ISO 14064-1 and the Greenhouse protocol for SERC reporting, CRL and Tunley will work together to accurately baseline existing carbon usage and produce a targeted carbon reduction plan for the business.
“CRL are delighted to be working with Tunley Environmental to develop our carbon reporting and subsequent reduction plans, as well as the production of lifecycle assessments for our repair processes that will be used in conjunction with procedures for PAS2080,” says Steve Jones, Southern Regional Director at CRL.
“We are pleased to join forces with CRL, supporting them in their sustainability journey,” said Dr William Beer, CEO at Tunley Environmental. “It’s brilliant to have the opportunity to work with such a well renowned company in the repair and refurbishment industry.”
As proud supporters of the Institution of Civil Engineers, CRL’s work strongly incorporates the guidelines laid down by ICE’s Carbon Project Initiative. This will include working with Tunley
Environmental to gain PAS2080 accreditation for the project management of carbon in infrastructure, incorporating lifecycle assessments in line with ISO 14067 to demonstrate the carbon credentials of asset maintenance using repairs, coatings and corrosion control systems.
With Tunley Environmental in partnership, CRL looks forward to delivering significant
change and furthering its sustainable and social value initiatives, backed up by quality data and meaningful assessments.
NEW BELZONA APPOINTMENT
Belzona UK has announced that Jérémie Maillard has been appointed Managing Director.
Maillard is the newest appointment following the
creation of Belzona UK as an independent distributorship in January 2024, servicing the UK with industrial repair and maintenance solutions.
With 18 years within the Belzona community, Maillard’s expertise ranges from mechanical and chemical engineering to business development and sales. Beginning his career in 2006, providing technical advice
Jérémie Maillard has been appointed Managing Director of Belzona UK CRL and Tunley will work together to accurately baseline existing carbon usage and produce a targeted carbon reduction plan for the business
Jetstream has increased the maximum power input for its 3000 Series UNx bareshaft pump
and training to international distributors, he went on to offer commercial support to increase Belzona’s market penetration in Europe and Africa.
More recently, Maillard was instrumental in establishing an independent Belzona distributorship in Germany, overseeing the North Rhine-Westphalia, Saarland, Rhineland-Palatinate, Hesse and Thuringia regions. With this experience, he is ideally placed to provide a new vision for the domestic UK market.
“We want to strengthen our position in the field of composite repairs and specialist protective coatings
and assist the key industries present in the UK,” says Maillard. “Our aim is to offer end users the opportunity to use Belzona solutions either themselves, via our own application team, or via a trained contractor.”
INCREASED WATER BLASTING POWER
Jetstream of Houston, a leading manufacturer of industrial high-pressure water blasting equipment, parts and accessories, has increased the maximum power input for its 3000 Series UNx bareshaft pump to 200hp (149kW). To correspond with the boost in horsepower, Jetstream
has also developed a larger plunger size for the pump, which is now able to achieve a flow rate of 7.6gpm (28.8lpm) at 40,000 psi (2,758 bar). This offers contractors greater power for a more diverse range of industrial cleaning and surface preparation jobs, and an ideal flow rate for single-operator setups.
“We’re constantly enhancing our water blasting equipment to offer solutions that provide the optimal combination of power, pressure and flow rate to match the growing number of water blasting applications,” says Jordan Koster, Jetstream Product and Marketing Manager. “This upgraded pump meets the global demand for high-power pumps in a compact size.”
Now compatible with power input ranging from 80-200 horsepower (60-149kW), the 3000 Series pump is well suited for tasks that demand advanced capabilities without sacrificing space. The pump can produce pressures ranging from 6,800-40,000 psi (469-2,758 bar) and offers the ability to quickly change between operating pressures
Resicoat has launched an innovative powder coatings technology for EV battery systems
in the field with Jetstream’s proven fluid end design. The 3000 Series is a triplex pump featuring three plungers available in varying diameters to produce the optimal flow rate for a full range of water blasting jobs.
Paired with Jetstream’s FXG2 Tornado Gun, the 3000 Series delivers 40,000 psi for surface preparation. The Tornado Gun features an airpowered motor that regulates rotation speed of the nozzle head and a quick-change cartridge for reliable operation and easy maintenance in the field. This Jetstream tool demolishes plaster faster than chipping, finishing in hours what chipping would take days to accomplish. It is also highly efficient for paint booth and tank cleaning as well as coating and stripe removal.
NEW POWDER COATINGS TECHNOLOGY FOR EV BATTERIES
AkzoNobel’s Resicoat brand has launched an innovative powder coatings technology which provides improved electrical protection for electric vehicle (EV) battery systems in just one spray. There is growing demand in the EV market for coatings with a high dielectric strength to help increase the safety of battery systems. AkzoNobel’s powder coatings business has risen to this challenge by creating a solution allowing customers to reach the required film thickness with a single spray – helping to increase efficiency and productivity. Available in China, the new technology is suitable for battery system parts such as cooling plates, side plates and battery covers (enclosures).
“We’ve developed innovative technology which addresses a clear need within the industry and helps to improve safety,” explains Jeff Jirak, Director of AkzoNobel’s Powder Coatings business. “It’s an important breakthrough which means customers no
longer have to spray twice or more to achieve the right thickness for providing high dielectric strength.”
The technology’s ability to build a consistent film with one-time application also means the entire process is more efficient in terms
Coating Thickness Gages
Design and Features
n NEW Larger 2 8” impact resistant color touchscreen and redesigned keypad for quick menu navigation
n NEW Weatherproof, dustproof, and water-resistant IP65-rated enclosure
n NEW Updated user interface retains the same layout and menus
n NEW Up to 30% longer batter y life
n NEW On-gage help explains menu items at the touch of a button
n NEW Ergonomic design with durable rubberized grip
of increasing speed and production capacity, reducing man hours and improving asset utilisation.
“Thanks to decades of knowledge and non-stop innovation, we understand how exceptional powder coatings, combined with the right application technique, can provide consistent electrical insulation throughout the life of key battery system components,” continues Jirak. “It’s further proof of our commitment to supporting our customers through partnerships and product development to create, fuel and protect the innovations of the future.”
As well as boosting the safety of EV battery systems, AkzoNobel’s newly-developed
one-spray technology provides resistance against thermal shock, water immersion and chemicals.
“Working with customers throughout the value chain has put us in a unique position to understand the needs of the market,” adds Jirak. “Our strong global footprint means they can benefit from our ability to deliver consistency in product and service worldwide.”
AkzoNobel’s Resicoat powder coatings range has been helping to solve the challenge of electrical insulation across various industries since the 1960s. In 2023, a dedicated range of Resicoat EV powder coatings was launched, specifically designed to help improve the safety and performance of EV
components such as battery systems and electric motors.
INTERPON DELIVERS A COOL ANSWER
AkzoNobel Powder Coatings has launched Interpon D2525
Low Solar Absorption, a powder coating that enables architects to imagine and deliver projects that create better and more sustainable environments by tackling the unwanted build-up of heat from the sun’s rays.
Whereas most traditional coatings absorb heat, Interpon’s D2525 low solar absorption technology addresses the challenge of global warming and increased urbanisation, as well as the need to reduce the carbon footprint of buildings in warm cities.
AkzoNobel Powder Coatings has launched Interpon D2525
Low Solar Absorptio
Interpon D2525 Low Solar Absorption contains a special pigment that helps reflect a large part of the near infrared radiation (NIR), which makes up over 50% of the total irradiated solar energy, from any aluminium substrate it coats. Measured against total solar reflectance (TSR - the measurement for the reflective performance of a coated surface), the Interpon D2525
Low Solar Absorption achieves an exceptional value of up to 65%. This has a dual effect: it reduces the thermal stress on the coated surface, thereby increasing the lifetime of the coated parts and contributing to the sustainability of the project, and it prevents the unwanted build-up of heat being deflected from the
coated surface into a building, creating so-called ‘urban heat islands’ that are particularly noticeable in more denselypacked built environments.
Recommended for any new construction or renovated building envelope, Interpon D2525 Low Solar Absorption helps architects design more comfortable spaces in which to live and work, and better enjoy the warm summer weather. It also means that air conditioning units don’t have to work as hard to keep buildings cool and therefore consume less energy, adding a further benefit to its sustainability credentials.
The new coating also has all the ‘traditional’ benefits of a powder coating in that it is free of Volatile Organic
Compounds (VOCs), and as part of the super-durable Interpon D2000 family, it is available in a range of different colours and finishes that can be customised on request.
Bob Dirks, Global Segment Manager Architectural, AkzoNobel Powder Coatings, says the Interpon D2525 Low Solar Absorption is a win-win for architects championing creative thinking. “Challenging environments need robust innovation that can handle the heat over the long term and, crucially, deliver on sustainability,” he observes.
“With our LSA range we’re proud to be giving architects a new way of creating better environments that allow people to enjoy the sun and its benefits and deliver spaces
in which they can thrive for generations to come. When the heat is on, architects know they can trust Interpon to deliver.”
Interpon D2525 Low Solar Absorption is supported by an Environmental Product Declaration (EPD) – an independent verification of a product’s environmental impact across its whole lifespan, from initial production to end-of-life disposal or recycling. And it contributes benefits to some of the leading green building schemes, such as LEED (Materials and Resources) and BREEAM (Materials) certified building projects.
NEW MARKETS FOR REDOX ONE COAT
Interpon Redox One Coat powder coatings from AkzoNobel are at the heart of a new drive by Trestles, the Czech-based metal shelving manufacturer, to break into the global gates and fences sector with products that deliver exceptional levels of quality, durability and anticorrosion performance at an affordable price.
While powder coatings traditionally require a primer layer for corrosion protection, followed by a topcoat for gloss and UV protection, Interpon Redox One Coat enables Trestles to reach corrosion protection up to C4M and high UV durability in a single coat that requires only a base chemical pre-treatment.
Since only one coat is needed, application costs are reduced, energy bills are less, and production volumes are increased, while the product quality and appearance remain at the highest level. “To stand out from the competition we
Hydrosol QD Primer is an alkyd-based, quick-drying primer
need to have the best quality, and since Redox One Coat can be applied to both stainless steel and zinc steel, we are able to deliver the quality our customers are looking for at the price they are willing to pay,” says Daniel Molnár, Procurement Manager.
Interpon Redox One Coat was recommended by AkzoNobel’s Technical Services team and chosen only after tests against samples from other manufacturers. “In salt spray tests, Interpon Redox One Coat performed the best in protecting our products against corrosion,” Molnár continues. “We also tested it on different steel surfaces, as well as some beta products we currently have on trial, with excellent results. We wanted to be sure the product would perform, even in rain or snow, and since using Redox One Coat there have been no complaints.”
With almost three decades of manufacturing expertise, Trestles now manufactures more than 1.6 million products a year and works across
more than 30 countries, exporting 95% of its total production to other European countries. Molnár says that having a global supplier like AkzoNobel as a partner is a key advantage to keeping its four powder coating lines running. “AkzoNobel not only has the products and colours we need, but the technical support we receive is certainly one of the reasons why we continue to be one of the most important manufacturers in the entire EU.”
NEW HYBRID COATINGS RANGE
HMG Paints has announced the launch of Hydrosol, a new range of hybrid coatings designed for the metal fabrication marketplace. These innovative protective coatings bring together the superior performance of solvent-based paints with the environmental advantages of water-based products, allowing users the opportunity to reduce their VOC output without compromising in performance. The first product in this range
is Hydrosol QD Primer, which is an alkyd-based, quick-drying primer designed for ultimate versatility and efficiency. It boasts outstanding adhesion, superior moisture resistance and exceptional corrosion protection, thanks to the incorporation of modified zinc phosphate. Ideal for use on suitably prepared structural steel, chassis and steel fabrications, this primer can be applied effortlessly using either roller, airless or conventional spray methods.
Early adopters of Hydrosol QD Primer are already identifying benefits including increased coverage compared to competitor products and improved efficiency in application. A key reason for this is the 55% volume of solids of Hydrosol QD Primer in comparison to approximately 40% for competitor equivalents.
“Our new Hydrosol QD Primer represents a significant advancement in protective coatings and is a testament to the work done by our R&D team to bring innovations
to the market,” says Paddy Dyson, Marketing Manager of HMG Paints. “This product not only meets the high performance standards our customers expect from us, but also aligns with our commitment to environmental sustainability. It is the first piece of the jigsaw in our Hydrosol brand, with a variety of exciting products set to join this range in the near future.”
The second product to join the range will be Hydrosol Compliant DTM, a directto-metal paint which users can apply directly to bare or primed metal surfaces. Being PG6/23 11 compliant, the product is ideal as a single-coat primer finish for use on stillages, skips, containers, agricultural and construction equipment and machinery. With lower VOCs in comparison to solvent-based equivalent products and available in a range of colours including RAL & BS, this next product in the Hydrosol range will be the ideal choice for OEMs and refinishers.
ULTRA-FAST AIRDRY CLEAR COAT
ProXL, a leading provider of refinishing and painting products for the automotive and industrial sectors, has added to its range of ultra-fast-drying clear coats with XPRESS305. Perfect for all automotive SMART (Small, Medium Area Repair Technology) technicians, XPRESS305 is perhaps, the world’s quickest air-drying clear coat, making it ideal for busy mobile SMART and body shop-based repair professionals who no longer require a heated booth or infrared lighting.
XPRESS305 joins ProXL’s market-leading, innovative and cost-effective XPRESS clear coat range. Sitting below its established bigger brothers XPRESS405 and XPRESS605, XPRESS305 air dries at 20°C in just 30 minutes. It combines excellent flow out and ease of blending and polishing if required. XPRESS305 also offers superior weathering, featuring ProXL’s advanced anti-scratch
technology, with a greater than 90% gloss retention (2,000 hours in accordance with Weather Ometer (WOM) Atlas Ci-65 test).
XPRESS305 can be used in a range of environments, both inside and out, giving excellent results straight from the gun. Maximising productivity, it delivers unrivalled ease of application and a water clear finish when cured. In intense UV resistance tests, XPRESS305 has proven its robust nature, with no cracking or loss of adhesion.
“XPRESS305 provides the ease of use, quick turnaround and cost-saving benefits associated with the rest of the XPRESS range but specifically aimed at SMART repairers everywhere,” says Charlie Bruce, Technical & NPD, ProXL.
SENSORY ANALYTICS ACQUISITION
Industrial Physics, a global packaging and material test and measurement provider, has announced the acquisition of US-based coating thickness measurement specialist Sensory Analytics, the supplier of industry-leading SpecMetrix.
The addition of SpecMetrix to Industrial Physics’ expanding family of specialist testing brands further increases the range of quality testing solutions available to end markets across the world. North Carolina-based Sensory Analytics delivers advanced systems for realtime coating thickness and film layer measurement. These are used by professionals across packaging, coil coating and other global industrial applications.
Upon completion of the acquisition, Industrial
HMG Paints has launched a new range of hybrid coatings called Hydrosol
Physics customers will be able to measure the absolute thickness of coatings down to sub-micron levels more precisely, using advanced technology systems easily configured to measure webs, coils, flat sheets, small samples or finished parts.
“We greatly value the unmatched SpecMetrix technology, systems and Sensory’s inherent dedication to customer support, which will support our purpose at Industrial Physics to protect the integrity of brands and products,” says Barry Lyon, CEO at Industrial Physics. “Now, together, we can provide an even stronger range of offerings to our customers.”
“We are proud to be joining Industrial Physics and collaborating to offer SpecMetrix coating thickness measurement systems to manufacturing leaders worldwide,” says Greg Frisby, CEO of Sensory Analytics. “With industrial process digitalisation demand growing rapidly, it is critical that packaging and other industrial professionals get better data in real time to ensure that safety and quality of products is not compromised. As part of Industrial Physics, we will
have greater resources and global infrastructure to deliver our high-impact technology and process data to meet increasing global customer demand.”
SHORTLIST ANNOUNCED FOR BCF AWARDS
The British Coatings Federation (BCF) has announced the shortlist for its 2024 awards.
Entries were judged over several days by an independent panel of judges in each category.
“The competition was really strong again this year, perhaps one of the strongest ever with over 70 entries, so all the companies who made the shortlist can be extremely proud of their achievements,” says BCF CEO Tom Bowtell. “It was also fantastic to see such growing interest across all the award categories, which really showed diversity, innovation and entrepreneurship across the board. We are especially pleased with the number of entries for our individual awards, particularly the Apprentice and Young Leader of the Year categories, as the BCF continues to look to the next generation to shape our future and careers outreach through our Coatings NextGen Council.”
The winners will be announced at the awards dinner on 6 November at The Principal, York.
NEW PRESIDENT AT CARBOLINE
Carboline has recently appointed Juanjo Ardid as its eighth president, succeeding Chris Tiernay, who had led the company since late 2016.
“I’m humbled that Carboline and RPM International trust me
to lead this organisation,” says Ardid. “Carboline’s reputation precedes it, and its company culture is unique in this or any industry. It is an honour to become a part of it.”
Ardid had been employed by PPG since 1993 before joining Carboline. He was most recently based in Pittsburgh, Pennsylvania, US as Vice President of Protective and Marine Coatings for the US and Canada. Other prior roles include General Manager for Global Automotive Adhesives and Sealants as well as Market Director roles for Europe, Middle East, and Africa automotive markets. He is a native of Barcelona, Spain.
“Carboline’s future is a global future,” says Ardid. “I will apply my experience to the task of unifying and growing our international footprint so that more owners can access Carboline’s industry-best asset and infrastructure protection solutions.”
Tiernay led Carboline to some of its strongest financial performances in its history despite roller-coaster market cycles and persistent volatility stemming from the Covid-19 pandemic. He steps back from his leadership role to provide direct, localised guidance in support of Carboline’s overall growth strategy.
“Being this company’s president was the pinnacle and privilege of my career. But after 39 years in the coatings industry and nearly eight years as Carboline’s president, it’s time for something new,” Tiernay said. “I’m touched by the outpouring of warmth and kind words from Carboline colleagues, family, and friends and I’m excited about what this new chapter brings for Carboline and myself.”
Juanjo Ardid
AKZONOBEL STRENGTHENS CARBON REDUCTION COMMITMENT
Architectural customers can now take advantage of a superdurable low-bake powder coating developed by AkzoNobel, which helps to protect building surfaces in more challenging environments.
Having launched a standard durability option in 2023, the newly introduced Interpon D2525 Low-E range has been specifically designed to withstand conditions in more extreme locations, such as those exposed to harsh weather. Backed by an Environmental Product Declaration (EPD), it can also improve longevity in standard environments.
Using industry-first technology introduced by the company in the standard durability option last year, the new range can be cured at temperatures as low as 150°C, whilst still delivering the supreme levels of quality and
performance demanded by customers in the buildings and construction sector.
“This latest innovation reflects our commitment to listening to customers and providing them with a range that combines several benefits, such as longer durability and lower cure but without compromising on aesthetics,” says Bob Dirks, Global Segment Manager for Architecture at AkzoNobel’s Powder Coatings business. “It also supports the need for a collective responsibility towards a more sustainable future and highlights our commitment to sustainability throughout the value chain.”
Interpon D2525 Low-E can either be cured at a lower temperature (150°C compared with a standard curing temperature between 180°C and 200°C) – cutting energy consumption by as much as 20% – or it can be cured up to 25% faster than conventional powders, allowing for more products to be coated in less time and improving the
efficiency of the coating line. As well as supporting customers in reducing their carbon emissions, it will help AkzoNobel achieve its own ambition of reducing carbon emissions across the value chain by 50% by 2030.
It’s ideally suited to any architectural or industrial metal surface, both exterior and interior, such as facades, windows, pergolas, fencing, railings, metal office equipment and doors. Key features include excellent levels of durability to protect colour integrity and performance. Interpon customers can also receive help with calculating the benefits of using its Low-E products, with regards to energy and carbon savings or productivity increases.
The company’s architectural powder coatings feature on some of the world’s most famous buildings, including The Shard and Westminster Abbey in London, UK, the Bird’s Nest stadium in Beijing, China and La Sagrada Familia in Barcelona, Spain. ■
Powder coatings take the industry by storm
Powder coatings are a type of coating that is applied as a dry, fine powder to produce high quality and durable finishes. Unlike conventional liquid coatings and paints, which are typically applied via a brush or roller, powder coatings are applied as a free-flowing powder that streams smoothly and evenly. This application can either be conducted by electrostatic spraying or a fluidised bed dipping process, followed by a necessary heat (or UV) curing process.
Since their early development in the 1940s, powder coatings have come to take large swathes of the protective coatings industry by storm. Today, they enjoy a dominant position in a range of markets (including architectural, industrial and transport), and this dominance is only predicted to intensify. Indeed, whilst the current global powder coatings market stands at a significant $15.2 billion in 2024, this is projected to grow by a whopping $9 billion to reach $24.26 billion in a mere eight years’ time.
The soaring popularity of powder coatings can be attributed to their many advantages over alternative protective coating materials. Firstly – and perhaps most importantly, given our ongoing climate crisis – powder coatings are significantly more sustainable than their traditional liquid counterparts. This is in large part due to their exceptionally low (or often non-existent) Volatile Organic Content (VOC), eliminating the health hazards and air pollution associated with solvent emissions. Additionally, the limited overspray powder produced in the application process can be recycled and reused, ensuring minimal waste.
Powder coatings are often more economical options than their liquid counterparts. Whilst initial set-up costs can be high, their transfer efficiency is streets ahead of traditional liquid paint methods, reaching an impressive 95% when applied using the fluidised bed technique. Furthermore, the equipment used for powder coating requires relatively minimal maintenance, making it more convenient and cost-effective.
Remarkably, the huge environmental and economic benefits powder coatings bring do not lead to diminished performance. In fact, many powder coatings – when applied as a single layer and cured by heat – provide comparably exceptional durability, chemical resistance, toughness and flexibility. Taking all this into account, it appears evident that powder coatings constitute the future of the protective coatings industry.
It is in this context that Corrodere Academy is proud to announce its new Powder Coatings Application course. Expertly crafted, engaging and informative, the course is designed to ensure high-quality training is available within the industry – an availability that is essential as the powder coatings market continues to boom. Following the course’s launch, we sat down with Brendan Fitzsimons – Corrodere’s
Technical Director and leading industry expert –to hear his thoughts.
Q. What motivated Corrodere to design the Powder Coatings course?
A. Our primary goal is to address the rapidlygrowing demand within the industry, driven in large part by increasing sustainability concerns. As the industry expands, more and more manufacturers are looking to bring powder coating capabilities in-house. However, the surge in demand has outpaced the availability of skilled professionals. Many companies have invested in powder coating units but find themselves without the trained staff necessary to operate them effectively. This is where we step in, providing the high-quality training needed to equip these companies with the expertise required.
Q. Who is this course targeted at?
A. This course is primarily targeted at powder coating applicators and associated workers involved in the powder coating process. Our training is designed to be highly practical and hands-on, focusing on the real-world skills needed on the job rather than delving too deeply into technical or scientific theory. The theoretical components of the course are digestible, ensuring applicators gain the necessary knowledge without being overwhelmed by complex concepts.
The course will also be helpful for powder coating technical and sales staff from powder suppliers and equipment suppliers.
While the applicators are the primary recipients of this training, it’s essential for companies to recognise that powder coating is a team-driven process. From pre-cleaning to application, each step requires careful coordination and expertise. Therefore, it’s crucial for companies to invest in training across the entire team, ensuring that every stage of the process is executed with precision – a need our course is designed to fulfil.
Q. Why should industry professionals take the course?
A. As the powder coatings market continues to boom, skilled application of powder coatings is an increasingly vital proficiency for anyone in the industry. Corrodere’s course ensures that
students fully understand the many stages and intricacies of the powder coatings process, verifying their competence to carry out this high-skilled work effectively and safely.
For employers, offering the course to staff defends against potential costly coating failures by ensuring application is done correctly, first time around. Investing in training is also a way to boost job satisfaction (and, by extension, job performance), ensuring employees know they are rightly perceived as an invaluable resource. Any registered Train the painter company that is engaged in powder coating application canand should – deliver the course.
Q. How do you see the industry at large rating the Powder Coatings course?
A. Ultimately, we foresee our Powder Coatings course becoming an industry norm. The benefits of the course are simply innumerable for applicators, companies and clients alike. Applicators benefit from verifiable expertise and
enhanced confidence in their work; companies benefit from well-trained staff and an elevated reputation as a consequence of staff investment; clients benefit from knowing they are enlisting highly qualified trade personnel. Indeed, the failure of powder coatings can be costly – Corrodere’s course (the only one of its kind) ensures that rather than relying on reputation, companies and clients alike can trust their powder coating applicators to have certifiable, accredited skills and expertise.
Q. Who endorses the course?
A. We’re delighted to say that the British Coatings Federation (BCF) has endorsed the programme. Their endorsement highlights the high quality and necessity of the course, and we’re excited to be working with them on our industry-leading endeavour.
The Powder Coating Application course is available globally through the Corrodere Academy’s Train the painter programme. ■
Corrodere Academy provides globally recognised accredited training and qualifications to the protective coatings and corrosion control industry. Their aim is to raise standards throughout the industry worldwide and help our students learn, discover and succeed.
Here you will find the latest news & announcements from the Academy.
Corrodere Academy launch
Qualified
Coating Applicator Certification
Corrodere Academy recently launched its Qualified Coating Applicator (QCA) certification in the UK, a significant milestone in the coatings industry. This certification, which is independently approved by Lloyds Register, promises to set a new standard of quality and professionalism among coating applicators.
What is QCA Certification?
QCA certification is an independent third-party assessment designed to prove the competency of experienced coating operatives, spray painters, and abrasive blast cleaners. The key benefits of the QCA certification include:
• Standardising competency across the industry
• Streamlining the qualification process for experienced, advanced operatives
• Giving confidence to employers by simplifying the industry’s qualification processes
• Making a distinction between comprehensive training (TTP) and independent assessment (QCA)
• Independent assessment to meet the Norsok M501 2022 revision
Who is the QCA certification suitable for?
QCA certification is available globally to the coatings industry through Corrodere Academy’s network of Approved QCA Assessors. For less experienced coating operatives who wish to acquire a QCA qualification, the Train the painter course is a great starting point, allowing students to fully prepare for the final QCA independent assessment.
QCA launch event
The QCA launch event was held at 3t Training Services in Newcastle, one of Corrodere Academy’s affiliate providers. Craig Fyfe, Lead Instructor at 3t Training, and an Approved QCA Assessor, conducted the assessments.
The team from Ferrous Protection, one of Corrodere Academy’s registered companies, had 5 operatives taking part in certification. The assessments were thorough and covered essential skills in abrasive blasting, spray painting, and protective coating application. The team were assessed by Craig, who administered a testing process designed to evaluate the practical skills and knowledge required to meet the scrupulous QCA certification standards.
Prior to the day, the five team members from Ferrous Protection passed their online theoretical assessments, ensuring they were prepared to translate this knowledge into practice on the day. All five passed their practical assessments with flying colours, demonstrating not only their individual capabilities but also the high-quality level of training and experience they already held.
QCA certification – a step forward
The launch of QCA certification is a significant step forward for the coatings industry. It provides a clear benchmark for quality and competence, ensuring that certified applicators possess the necessary skills and knowledge to deliver quality results.
Here’s what Steven Slack, Director of Operations at Ferrous Protection had to say on how QCA Certification will impact the industry:
“QCA Certification will benefit the industry hugely. The fact that this must be done by the individual on their own under proctored exam conditions with no assistance will highlight any lack of knowledge. This will go hand in hand with the training card of Train the painter, because if there is a skills gap in painting, blasting or spraying, operatives can gain further training and re-sit the assessment. Operatives having passed QCA, will ensure our reputation at Ferrous Protection gets better and better, as we can be confident our employees have a strong understanding of the skills needed in this industry to complete jobs to a very high standard.”
If you would like to find out how to take certification or how to become an approved assessor, get in touch with Corrodere Academy: info@corrodere.com ■ corrodere.com ■ +44 (0)1252 732 236
Spotlight on our Registered Companies –Specialist Coatings and Inspection (SCI)
SCI – Specialist Coatings & Inspection are in their second year as a Registered Train the painter company. Specialising in the three key areas of coating service: surface preparation, surface treatment and surface protection and with extensive experience in the rail industry, delivering TTP courses in house is key to ensuring high standards of excellence to their clients.
Technical Director Cosmin Hincu has been involved with Train the painter for over four years and has been instrumental in bringing the programme to SCI. He has also completed a number of courses with the Corrodere Academy including ICorr Level 2 and 3, Thermal Metal Spray Inspection and Fireproofing Inspection.
Here’s what Cosmin had to say about the partnership with Train the painter…
“Any refurbishment or restoration work in the rail industry must be completed to high Network Rail Standards in order to contribute to a safe, high performing and costefficient railway system. Corrodere Academy and Train the painter lead the field in professional training for the surface treatment and coating industry, upholding strict standards across various sectors, including these essential Network Rail Standards. With this in mind, SCI are working with Corrodere Academy and Train the painter to achieve rail industry excellence in metallic structures refurbishment whilst remaining committed to safety and quality. Our team has years of experience working on highway structures to the requirements of CM431 and rail structures to Network Rail specifications.
SCI’s newly RISQS audited and verified RICCL codes highlight our dedication to providing top-tier consultancy, surveying, inspection, and surface treatment services, which have been developed over the past 12 years by Corrodere Academy. We are excited for this partnership to develop, providing SCI with the resources and training required to continue upskilling our workforce and improving the quality of our services.”
Visit specialistcoatings.net to find out more about their nationwide surface treatment and inspection services or to get in touch.
Rory Harries
We are thrilled to announce that our July student of the month award goes to Rory Harries, who works at Tema Protective Coatings Ltd.
Rory achieved great results on our ICorr Level 2 Coating Inspection courses and has also recently completed our Coating Supervisor course!
Here’s what Rory had to say about ICorr Level 2...
“As a professional stepping into the world of coating inspection, this course was a transformative experience for me. The depth of knowledge imparted through the advanced inspection techniques and specialised application methods was unparalleled. The course’s focus on both steel and non-steel substrates, including concrete, using non-destructive and destructive techniques, provided a comprehensive understanding that I could immediately apply in the field.
Completing this course has not only certified my skills but also given me the confidence to perform coating inspections on various substrates under indirect supervision. I can now effectively utilise destructive coating inspection equipment, understand environmental controls, and identify failure modes for a range of coatings and linings.
I highly recommend the Paint Inspector Level 2 course to anyone serious about advancing their career in coatings inspection. It’s a challenging yet rewarding journey that has equipped me with the tools to excel in this industry.”
Congratulations Rory from everyone at the Corrodere Academy!
Corrodere Academy Registered Companies and Affiliate Providers
We are excited to announce that this year’s PDA Europe Conference will take place at member Graco's premises in Maasmechelen, Belgium. We extend our sincere thanks to Graco for being our host sponsor this year!
We encourage all of you to seize this moment to connect with industry experts and gain valuable insights into the world of polyurea. Together, we can exchange knowledge, and drive the industry forward.
Check our website for more information : www.pda-europe.org
We look forward to a successful event in Maasmechelen !
