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Contract-Specific QA/QC Management Plan for the industrial & protective coatings industry and other contracting industries
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Rotair powered IBIX's blasting and coating system in the restoration of the Ponte Arena bridge
Viewing corrosion protection as a strategic lever means recognising its direct impact on long-term value: fewer plant shutdowns, longer asset life, and greater operational reliability. In an industrial landscape increasingly focused on sustainability and resource optimisation, ignoring what cannot be seen is no longer an option.
EDITOR FROM THE
By its very nature, corrosion is a silent phenomenon. It does not trigger immediate alarms or interrupt processes the moment it begins. It works beneath the surface, in the least accessible places, in parts that visual inspections fail to detect. This invisibility makes it one of the most underestimated risks in complex industrial systems. Reliance on sporadic checks or on established but unstructured practices means accepting a level of uncertainty that is no longer sustainable. Corrosion protection cannot be managed through a patchwork of isolated precautions: it requires an integrated quality system that combines assurance and control, assigning clear roles and defined responsibilities across the entire value chain. Without this framework, even the most advanced technologies remain incomplete tools. It is not just about measuring ‘better’, but about measuring continuously, consistently, and above all, meaningfully. Digital applications are profoundly transforming quality control, extending it into materials management and project supervision. The advent of artificial intelligence-based models enables a transition from a reactive to a predictive approach: action is no longer taken when damage is evident, but when data suggests it might occur. Replacing obsolete manual systems is a paradigm shift in operations, rather than a mere technological upgrade.
At the same time, materials research continues to open up new possibilities. Graphene, in particular, is the focus of numerous studies because of its potential barrier effect in protective coatings. However, the true value of these innovations lies in their ability to be integrated into controlled, validated industrial processes. Without a robust quality system, even the most promising material is likely to remain a theoretical solution.
Viewing corrosion protection as a strategic lever means recognising its direct impact on long-term value: fewer plant shutdowns, longer asset life, and greater operational reliability. In an industrial landscape increasingly focused on sustainability and resource optimisation, ignoring what cannot be seen is no longer an option.
It is no coincidence that these topics are also gaining prominence in international forums. This April issue of Corrosion Protection will be distributed at the AMPP Italy Conference & Expo in Genoa and at IVS – Industrial Valve Summit 2026 in Bergamo, where the Italian Oil & Gas valve industry will present itself with impressive figures: €3 billion in turnover, around 140 companies, 10,000 employees, and a European market share of 38% of total production. True strength, indeed, is always found in what remains unseen.
NEW WHAT’S
Sparc partner with AIML to develop AI driven corrosion assessment software
Sparc Technologies Limited, in partnership with the Australian Institute of Machine Learning (AIML) at the University of Adelaide, has announced a project to develop AI-driven software for modernizing the assessment of protective coatings performance. The software under development utilises advanced computer vision and machine learning to revolutionise the assessment of protective coatings performance within globally used testing methods. A pilot project has demonstrated a strong proof-ofconcept based on ISO 12944 corrosion boundary assessment with plans to expand into other scribe-based and damage-based protective coatings testing protocols. Sparc is highly encouraged by the commercial value of the software tool based on feedback from the protective coatings industry and letters of support have been received from multiple coatings industry players.
“Sparc Technologies is an innovation-led company at its core and we are always looking for opportunities to build on our deep understanding of, and growing position within, the protective coatings industry,” commented Nick O’Loughlin, Sparc Managing Director. “This collaboration with the Australian Institute of Machine Learning at Adelaide University leverages complementary skills from both teams to develop AI-based software for the protective coatings industry which has the potential to significantly improve and accelerate R&D under testing methods which have been unchanged for >25 years. We are very encouraged regarding the potential marketability of the software based on feedback from the protective coatings industry.”
Professor Simon Lucey, AIML Director, commented: “AIML is very pleased to be working on this innovative project targeting enhanced protective coatings performance assessment alongside Sparc Technologies. The replacement of outdated manual corrosion assessment with computer vision holds great potential to increase efficiencies and improve outcomes for the coatings industry.”
Protective coatings are essential for preventing steel corrosion, which costs an estimated 3.4% of global GDP annually ($3.9 trillion). Industry-standard testing simulates long-term performance, often by deliberately damaging the coating (a “scribe”) to measure corrosion spread, known as scribe creep. Current assessment methods rely on manual, subjective evaluation, making the process labour-intensive, time-consuming, and largely unchanged for over 25 years. Sparc and AIML’s AI driven approach combines highly advanced AI and machine learning capabilities with deep protective coatings assessment expertise to develop a solution which offers, among other benefits:
Higher accuracy: visually trained AI software utilising an extensive database of historical results can more accurately detect the corrosion boundary and coating disbondment.
More consistency: a standardised process for taking panel images using existing lab equipment is designed to deliver repeatable results at a high level of confidence.
Enhanced productivity: the current manual assessment and reporting process takes an experienced coatings technician ~40 minutes per result compared to tens of seconds using the AI software.
Better data: manual assessment produces a single result whereas the AI software is modelling a huge number of data points which can be reported in multiple ways enabling comprehensive statistical analysis.
Sparc and AIML have successfully demonstrated a proof-ofconcept model, showing encouraging alignment between the AI driven corrosion boundary assessment and human evaluation. The software is being developed using ISO 12944 corrosion assessment but is expected to be deployable across a variety of widely used scribe-based and damage-based international testing protocols. Multiple coatings industry players are supporting the development of the software with the goal of beta testing in thirdparty coatings laboratories within 12 months.
Sparc’s commercialisation pathway will focus on industry codevelopment and future software licensing to established testing laboratories and coating companies, enabling rapid global deployment. The estimated target addressable market of ~850 global testing facilities provides a significant commercial opportunity, with strong interest from leading protective coatings industry players and testing houses already established.
www.sparctechnologies.com.au
Phosphate-free corrosion inhibitor protects hydrotested drinking water systems
Drinking water storage tanks and the piping behind walls are components that are generally out of sight and typically fall under the responsibility of plumbers and construction contractors. However, the fact that they are not visible does not mean corrosion will ignore them: it can in fact compromise pipes and tanks even before they are put into service. For this reason, Cortec® is encouraging contractors and plumbers to raise awareness of VpCI®-649 HP, a phosphate-free corrosion inhibitor designed to provide protection during and after hydrotesting.
Hydrotesting of drinking water piping, fittings, and vessels is a standard practice after installation and before initial commissioning, as well as after repairs and idle periods. This critical step helps plumbers and contractors identify potential leaks and confirm that the system will withstand operating pressure. Unfortunately, the same water that confirms integrity also leaves behind residual moisture that can cause corrosion problems before tenants ever move into the structure and turn on the water. For years, Cortec® and other manufacturers have offered corrosion inhibitors for hydrotesting oil and gas pipelines, as well as all types of pressure vessels.
The protection of drinking water systems presented another challenge, requiring the corrosion inhibitor to meet ANSI/NSF Standard 61 for drinking water system components. Cortec® met this challenge in 2023 with VpCI®-649 HP, a corrosion inhibitor that, when added as a surface treatment to hydrotesting water at concentrations up to 3% and drained, is certified to meet ANSI/NSF Standard 61. This exciting breakthrough now allows contractors and plumbers to hydrotest potable water pipes and tanks without leaving them prone to corrosion during construction waiting periods.
VpCI®-649 HP protects steel, copper, galvanized steel, and aluminum above and below the water level, covering a broad range of drinking water systems. It does not contain nitrite, phosphate, molybdenum, or chromate. Application can be confirmed with a PTSA tracer. We all need drinking water. Drinking water systems need hydrotesting. Help contractors and plumbers avoid corrosion problems by introducing them to a simple corrosion solution that protects during and after this critical phase.
www.cortecwatertreatment.com
PPG introduces PPG STEELGUARD 652 coating for interior structural
PPG has launched PPG STEELGUARD® 652, a high-performance, water-based intumescent coating designed specifically for interior general-purpose structural steelwork. Available in North America, the coating combines long-lasting protection with aesthetic appeal, delivering up to two hours of fire resistance as a cellulosic passive fire protection (PFP) solution.
Its United Laboratories (UL) 263 certification gives architects, engineers and building owners confidence in the coating’s performance and compliance with industry standards. The low volatile organic compounds (VOC) waterborne formulation supports more sustainable construction practices.
Key features of PPG Steelguard 652 coating include:
Long-lasting protection, offering up to 20 years of performance
Proven for up to two hours of fire protection
UL 263 certified
Low VOC emissions allow efficient trade stacking at complex construction sites
steel
Easy on-site application with standard PFP airless spray equipment ensures smooth, consistent coverage.
“PPG Steelguard 652 coating expands our range of certified solutions for North American projects and reflects our ongoing commitment to fire protection innovation,” said Richard Mann, PPG global product development director, fire protection, Protective and Marine Coatings. “It stands out for its innovative fire performance and physical properties, including low certified thickness, high bond strength and high impact resistance, providing lasting durability for up to 20 years.”
PPG’s Protective and Marine Coatings business offers technical support and additional product options to meet diverse project demands.
www.ppgpmc.com
GMA expands sales channels across Australia’s east coast
GMA Garnet Group, a global leader in garnet abrasives, announced a significant enhancement to its blast abrasives strategy, introducing strengthened sales channels across Australia’s East Coast. Customers in Queensland, New South Wales, Victoria, South Australia, ACT, and Tasmania will now benefit from improved access to GMA’s blast products, technical expertise and tailored project support. This strategic evolution reflects direct feedback from customers and builds on GMA’s long-standing presence in Australia, where the company has supported surface preparation projects for more than 40 years. Increasing GMA’s sales channels extends a model successfully established in Western Australia and the Northern Territory, providing greater opportunities for customers to access GMA’s products and expertise.
“Drawing on over 40 years of experience, we are expanding a proven model that strengthens how we support customers across Australia —through increased access to GMA’s technical expertise and product supply,” said Flynn Cowan, General Manager, International Sales and Marketing, GMA Garnet Group. The introduction of new sales channels enhances accessibility and
provides greater choice across GMA’s abrasive blasting portfolio, while closer engagement with GMA’s technical teams enables more practical, project-specific guidance aligned to performance requirements. This supports GMA’s solutions-focused offerings, improving outcomes for customers across a range of applications and project scales. As a vertically integrated garnet company, GMA manages its operations from mining and processing through to distribution and customer support. This integrated approach underpins consistent product quality, reliable logistics and dependable supply, while enabling GMA to respond effectively to evolving industry requirements.
“GMA will continue to expand our supply chain capability to support businesses across Australia. We are grateful for the trust our customers place in us, and we remain committed to delivering even greater value, service and reliability in the years ahead,” said Flynn.
The expansion across the East Coast began in April 2026.
www.gmagarnet.com/en/
Sherwin-Williams expands its world-class range of solvent-based intumescent coatings
Sherwin-Williams Protective & Marine has expanded its worldclass FIRETEX range of solvent-based intumescent coatings with two new additions. FIRETEX FX1008 and FX2008 deliver superior performance and provide up to 120 minutes of fire protection, certified according to BS 476 testing. Compared to conventional 1-pack solvent-based material, they provide faster drying times and lower film thickness for more efficient, more cost-effective protection of assets such as stadiums, high-rise buildings and transportation hubs, factories, warehouses and data centres. While FX2008 has a more specialised solvent blend with a lower flash point temperature and is suitable for use during application in shop, FX1008, employs a high-flash point solvent blend to optimise application characteristics and improved safety for use on site. Both ensure consistent film build, excellent durability, and a smooth architectural finish, even under demanding site conditions.
Part of the organisation’s one-pack solvent-based intumescent fire protection range, the products enable faster build time and higher throughput, with no compromise on quality, safety, or performance.
Combined with support from Sherwin-Williams’ Fire Engineering and Estimation Team (FEET), FIRETEX helps provide costeffective, code-compliant, sustainable fire protection solutions. FEET, which includes qualified engineers and members of recognised professional institutions, offers an estimation service based on customer drawings and 3D BIM models to evaluate the necessary thickness of FX in each steel section. The team implements the industry-leading Firetex Design Estimator (FDE) software, which offers advanced engineering analysis features, to further optimise fire protection material requirements, and offers a comprehensive CO2 report for each project.
“FX2008 for controlled in-shop coating and FX1008 for dynamic on-site work were engineered to boost efficiency on projects ranging from high-value infrastructure to manufacturing and processing facilities. Their superior performance provide 90 to 120 minutes of passive fire protection. And their faster drying and lower thickness requirements keep schedules moving, reduce material usage, and, ultimately, save contractors valuable time and money,” said Alex Tsiolas, Senior Portfolio Manager Fire Protection EMEAI at Sherwin-Williams.
Key features and benefits:
Greater application efficiency: Faster drying enables quicker recoating and reduced waiting times, helping projects stay on schedule, both in-shop and on-site;
Lower material consumption: reduced film build means less product is needed per project, leads to cost savings and more competitive bids;
Versatile use across environments: FX2008 supports controlled in-shop production workflows, while FX1008 withstands variable on-site conditions without compromising finish;
Improved productivity for contractors: Faster project turnaround and reduced labour hours, making it ideal for complex, large-scale or time-sensitive builds;
High-quality final appearance: Smooth, consistent finish with coloured and tintable topcoats suitable for exposed architectural steel;
Enhanced performance for high fire-resistance requirements: Reliable protection for 90–120-minute ratings, addressing increasing safety demands in modern infrastructure.
https://protectiveemea.sherwin-williams.com
Genoa, Italy, 9-12 June 2026
Gain insights into current and emerging challenges in corrosion management Register here: https://www.studiobc.it/AMPP2026_iscrizio ne1.asp?IDCongresso=62
50+ exhibitors
160+ presentations
For info and details, visit https://www.amppitaly.org 4thConference &
Marco Ormellese receives Elaine Bowman Distinguished Service Award from AMPP
Marco Ormellese, Editorial Director of our Corrosion Protection Magazine, has been awarded the prestigious Elaine Bowman Distinguished Service Award during the AMPP Annual Conference and EXPO 2026, held in Houston, TX, from March 15 to 19, 2026. This accolade recognizes individuals whose notable and cumulative contributions - through assigned or voluntary duties, responsibilities, or achievements - have significantly advanced the mission and work of the Association. The AMPP Awards program honours both individuals and teams that propel the corrosion protection industry forward through innovation, leadership, and impactful contributions. These awards cover a wide spectrum of achievements, ranging from technical excellence and research to education, mentoring, and fieldwork.
Curated by the AMPP Awards Program Committee, they exemplify the Association’s commitment to celebrating those shaping the future of materials protection and performance. By highlighting the dedication, expertise, and passion of awardees, the program underscores the individuals whose work drives meaningful progress in the global corrosion protection community.
Recipients of the Elaine Bowman Distinguished Service Award are recognized not only for their professional accomplishments but also for their ability to inspire peers and elevate industry standards. Their contributions address complex challenges, enhance best practices, and foster a culture of continuous improvement. Receiving this award is a testament to sustained commitment, professional excellence, and enduring impact in the field of corrosion and materials protection.
The award is named in honour of Elaine Bowman, a distinguished leader in the corrosion and materials protection community.
Bowman, a Past President of NACE International - the organization that, following its 2021 merger with SSPC, became part of AMPP - is widely recognized for her long-term contributions to advancing corrosion management and professional service within the industry.
Marco Ormellese’s receipt of this award reflects both his outstanding service to the professional community and his distinguished academic career in corrosion science. Since 2019, he has been Full Professor of Materials Science and Technology
at the Department of Chemistry, Materials and Chemical Engineering “Giulio Natta” at Politecnico di Milano, where his research focuses on corrosion and materials protection in both natural and industrial environments, combining fundamental and applied studies. Alongside his academic role, Ormellese has been actively involved in professional associations, serving as Secretary of the NACE Italia Milano Section since 2019, then as Secretary of the AMPP Italy Chapter from 2021, and Vice Chairman since 2025. His research activity includes 202 publications indexed in Scopus (since 2004), an H-index of 32, and over 3,000 citations, contributing significantly to the understanding of corrosion mechanisms, surface treatments, and protection strategies. Since 2022, he has also been Editorial Director of Corrosion Protection Magazine, supporting the dissemination of technical knowledge within the global corrosion protection community.
The Elaine Bowman Distinguished Service Award thus celebrates both Marco Ormellese’s individual achievements and his broader impact on the field. It highlights his sustained commitment, innovation, and mentorship, which contribute significantly to the advancement of the global corrosion protection industry. ‹
Marco Ormellese (fourth from the left) with the other AMPP award recipients during the 2026 edition.
Nick Karakasch, Total Corrosion Consultants – Victoria, Australia nkarakasch@gmail.com
In this article, Nick Karakasch, a recognised expert in protective coatings and corrosion control and contributor to several previous editions of our magazine, shares his practical guidance on developing a Contract-Specific Quality Assurance and Quality Control (QA/QC) Management Plan for the industrial and protective coatings sector. The article presents proven best practices for surface preparation, coating application, inspection, and safety procedures.
This document provides an example of a “Contract-Specific Quality Management Plan” for abrasive blast cleaning and the application of protective coatings. It outlines the components of the protective system and the reporting methods required to ensure that the installation meets the highest achievable standards of quality for its intended function. This document relates to Australian conditions; however, the principles and guidance it provides, with suitable modifications, are applicable to similar industrial operations in other jurisdictions.
Scope of Quality Assurance and Quality Control (QA/QC)
The scope of the Management Plan outlined in this document shall be limited to site preparation, application, and finishing topcoats of the specified protective coating system (e.g. zinc phosphate epoxy primer and epoxy mastic topcoat).
The procedures shall pertain to:
a. Surface preparation: abrasive blast cleaning of the nominated steelwork;
b. Prime coating: application of the specified primer for the protective system;
c. Finish coating: application of the specified topcoats for the overall protective system.
Essential quality control features shall be addressed as outlined in the following sections of this Work Method Statement.
Quality Control Management Structure
The Project Manager shall have the responsibility and authority to assist in all matters contained within this QA/QC Plan.
The operations and quality control management structure is shown in Figure 1
1. The Quality Control Officer has a direct interface with operations on matters relating to training, standards, and workmanship; however, he reports to the relevant Project Manager, who in turn is responsible to the Managing Director.
2. Supervisors and foremen are responsible for the quality of workmanship produced.
3. The Quality Control Officer is also responsible to the Project Manager for the quality assurance of procured materials, including quality audits at the supplier’s factory, where necessary.
Project Manager
The Project Manager is responsible for organising the project to ensure that the completed work meets the specified contract requirements. He is responsible for ensuring that customer requirements are met by implementing the established inspection and testing activities and verifying their satisfactory results. He shall, through the Quality Control Officer, oversee verification activities carried out by the customer or the testing authority, as required. The Quality Control Officer may, on some sites, also act as the Project Manager.
Figure 1 - Operations and quality control management structure.
Quality Control Officer
The Quality Control Officer, where specifically appointed, reports to the Project Manager on all quality-related matters. He is responsible for the effective operation of the quality system and for maintaining quality system documents to meet contract requirements. The Quality Control Officer is authorised to require all employees to comply with the provisions of the quality system and may issue instructions to that effect. He has delegated authority from the Project Manager to restrict further work until a satisfactory solution has been obtained and implemented.
Foreman
The Foreman is responsible for coordinating and implementing activities at the project site involving direct labour and, where applicable, subcontractors. He is also responsible for completing and detailing inspection and test documents.
Leading Hands
Where appointed, Leading Hands have effective control over all site labour under their supervision.
Trade Operators
Each Operator is responsible for the satisfactory performance of their assigned duties under the direction of the Foreman or Leading Hand, as appropriate.
Tender and contract evaluation
Prior to mobilisation, tender documents and work parameters shall be examined to ensure compliance with the tender enquiry documents. Selection and recommendation for the project shall be based on an evaluation of all tendered factors, including price, quality, time, method, and proven ability to perform the work.
Site Production Procedures
Project Plan Meeting
A meeting shall take place at the project site prior to the commencement of work. Attendees will include the Project Manager, Quality Control Officer, and Foreman, as required. The purpose of the meeting is to:
Establish the production procedures to be implemented on site;
Ensure that all personnel are aware of the specifications to be applied;
Define the Quality Control measures to be imposed on operations and the required safety standards. The Project Manager shall be responsible for ensuring that
all attendees understand and are familiar with the contract requirements. He shall also be responsible for the provision and site establishment of all production, quality control, and safety equipment.
Mobilisation
The Project Manager is responsible for ordering the correct quantity of materials, and for organising the site establishment and the appropriate equipment in accordance with the Specification Requirements.
Operation and surface preparation equipment
Operation equipment: before the commencement of work, the daily maintenance checklist shall be carried out to ensure that all machinery is in good working condition. Daily maintenance of machinery is the responsibility of the Foreman or Trade Operator. The Foreman is responsible for ensuring that fuels, abrasives, water, and inhibitors, where necessary, are available to maintain continuity of work.
Equipment servicing: equipment servicing shall be the responsibility of the Project Manager and Foreman to ensure that all servicing of machines, compressors, spray equipment, blast hoses, and sundry items is carried out on a regular basis. Servicing shall conform with the standard procedures laid down by the manufacturer and the company’s service policy. Regular servicing will prevent equipment breakdowns, production losses, and potential injury to personnel on site or nearby.
Prior to mobilisation, tender documents and work parameters shall be examined to ensure compliance with the tender enquiry documents. Selection and recommendation for the project shall be based on an evaluation of all tendered factors, including price, quality, time, method, and proven ability to perform the work.
Operation of spray equipment
The application of all paint shall generally be carried out using airless or conventional spray, roller, or brush. The Foreman shall ensure that the equipment is suitable for its intended purpose, capable of properly atomising the paint to be applied, and equipped with appropriate water traps, pressure regulators, agitators, and gauges. The air caps, tips, nozzles, and needles shall be those recommended by the equipment manufacturer and the paint manufacturer for the products being used. When operators commence daily paint application, they shall check their techniques with a wet film thickness gauge to verify that the coating thickness will achieve the specified dry film thickness. All paint mixing and agitation, where specified by the paint manufacturer, shall be carried out using continuous paddletype power agitators.
Weather considerations
It is the responsibility of the Foreman to ensure that work is not commenced or undertaken during periods of inclement weather. Painting shall not be carried out in unsuitable conditions, such as high winds, rain, or excessive temperatures or humidity.
Workmanship
The Foreman shall ensure that all work is carried out in a neat and orderly manner. Work shall be performed using best trade practices and to the satisfaction of the Project Manager, within the scope of the Specification. The Foreman shall also ensure that all operators are provided with the required clothing and safety equipment for the work to be performed. Upon completion of the work, the Foreman shall ensure that all debris and waste materials generated during the contract are removed.
Scope of the work (general)
This section outlines the general scope of work to be undertaken under the contract.
Surface preparation
Surface preparation shall be carried out as defined by the relevant specification or contract document, e.g., abrasive blast cleaning in accordance with ISO or Australian Standard 1627 Part 4.
Coating materials (Thickness Control)
Coating materials shall be supplied and applied in accordance with the manufacturer’s specifications. All coatings shall be applied to the recommended wet film thickness to achieve the minimum dry film thickness specified.
All trade operators involved in the application of coatings shall possess wet film thickness gauges for determining film thickness. Coatings shall be checked by applicators immediately following application to ensure that the specified wet film thicknesses are achieved. Where additional film build-up is required, it shall be applied while the coating is still wet, prior to any initial cure taking place.
The risk of overspray onto surrounding or adjacent coatings shall always be considered when determining the method of application.
Topcoats shall generally be applied using airless or conventional spray equipment, or by other approved methods, e.g., brushing or roller application. All topcoats shall be applied in a single coat unless otherwise specified, and to the recommended wet film thickness to achieve the specified dry film thickness. Where adjacent steelwork requires shrouding to prevent overspray, suitable shrouding materials such as plastic sheeting or drop sheets shall be used. Responsibility for assessing risks associated with overspray shall lie with the Project Manager.
Handling, storage and transportation of steelwork
It is the responsibility of the Project Manager, through the Foreman, to ensure that all treated and painted steelwork is handled and moved by crane and/or sling in a manner that minimises damage. The slinging operations and protective measures shall be carried out using best trade practices and techniques at all times.
Site quality control procedures
General
It is the responsibility of the Project Manager and Foreman to familiarise themselves with this Manual and ensure that all instructions are strictly adhered to.
Site preparation
The Project Manager is responsible for quality control via the Quality Control Officer, who shall instruct the trade operators, through the Foreman, on all masking of equipment required prior to commencement. The masking shall be inspected and approved for abrasive blasting, with approval indicated on the quality control report. Such comments may be recorded and initialled in the remarks section of the appropriate report by the inspecting officer.
Raw materials – Incoming Inspection
It is the responsibility of the Project Manager to ensure that the coatings supplier has applied quality control to the raw materials
Surface preparation shall be carried out as defined by the relevant specification or contract document, e.g., abrasive blast cleaning in accordance with ISO or Australian Standard 1627 Part 4.
supplied for the project, and that such reports are available on request prior to the commencement of coating procedures.
The Quality Control Officer shall undertake offsite quality assurance of the supplier’s products by random or regular inspection—at the manufacturer’s premises if necessary— of the supplier’s quality control programme and batch performance. Authorising conformance certificates may be required by clients, and it is the responsibility of the Quality Control Officer to ensure that these are provided by the relevant manufacturer or supplier.
All incoming coatings and materials shall be recorded on the appropriate job card, including the following information:
Manufacturer’s name
Product name
Batch numbers
Authorisation numbers and certificates.
Inspection procedures: general statement
The Foreman shall ensure that the four main hold points for inspection are observed. These are designated as:
a. Prior to surface preparation;
b. After surface preparation;
c. After priming, prior to intermediate or top coating;
d. After top coating.
The condition of prepared surfaces shall be inspected routinely by the Quality Control Officer to ensure conformity with the specification and pictorial standards where appropriate. Inspection for missed areas in the primer shall be carried out by the Quality Control Officer prior to the application of topcoats. Any missed areas or pinholes shall be rectified.
The dry film thickness of the coating system shall be checked by the Quality Control Officer using the appropriate paint film thickness instruments. These checks shall be carried out on a routine basis on the day following application of topcoats, or after the specified drying period.
Ambient temperature and humidity shall be measured by the Quality Control Officer using a whirling hygrometer or other approved alternative units.
The Quality Control Officer shall be responsible for ensuring that the correct specification is applied to the various parts of the steelwork. In particular, they shall record the relevant information on standard quality control forms. This information shall be recorded daily for the various items of steelwork.
Surface preparation standard
Visual examination of the entire surface shall be carried out
daily. The acceptance criteria app lied shall be those detailed in AS1627.4, or the relevant ISO standard for dry-blasted surfaces.
Measurement of dry film thickness
Dry film thickness shall be measured using approved magnetic or electronic gauges. The equipment shall be calibrated regularly (e.g., Elcometer Model 246 or equivalent).
The frequency of dry film thickness measurements shall be in accordance with the relevant standard specified in the contract documents.
Analysis of results
Humidity, dew point and steel temperature measurements shall be used to make the following determinations:
For humidity above 35 %;
For steel temperature less than 4 °C above the dew point;
Figure 2 - Non-Conformance Report.
For steel temperatures above 4 °C;
To proceed with priming of prepared steel or the application of subsequent coats on a daily basis.
Non-conformities and correction
Surface preparation: if the surface preparation does not meet the required standard, it shall be reworked in accordance with the specification and further inspected until it conforms.
Low film build: an additional coat of coating shall be applied to a recleaned surface, and the Quality Officer shall verify that the nonconformity has been rectified.
Coating breakdown/rusting: should coating breakdown or rusting occur within the scope of the warranty, the coating shall be restored in accordance with the relevant specification (Figure 2).
Inspection
Inspection or verification of conformance shall be conducted at each hold point on the following basis:
- Foreman – 100 % of all surfaces.
- Quality Officer – minimum 75 % of all surfaces.
Documentation of inspection: manufacturer, product name, batch number, surface temperature, humidity, film thickness, time (AM/PM), and dew point (Figures 3, 4, 5 and 6).
Final inspection: the final inspection of painted steelwork shall, at a minimum, include:
1. Dry film thickness;
2. Continuity of the film;
3.Verification that the coating exhibits good adhesion to the substrate.
Reporting verification procedure
The Daily Report sheet shall be completed each day, signed by the Quality Officer or Foreman, and submitted to the Project Manager together with the ITP (Inspection and Test Plan) upon completion of the contracted work.
Figure 3 - Inspection and Test Plan (ITP).
Figure 4 – Painting Guide.
Rectification, stop work, and corrective action
If, during their duties, the Quality Officer identifies that work is not being carried out in accordance with the specification or recognised good trade practice, the following actions shall be taken. In the first instance, defects may be resolved through direct discussion between the Quality Officer and the trade operator concerned. Provided that these discussions do not alter the basic work patterns, workload, or output of the operative, they should result in the immediate rectification of the defect. Where specification procedures are not being met and cannot be resolved by direct discussion with the Quality Officer, the Foreman shall be consulted. Resolution of any issue should be approached in the spirit of teamwork rather than by authority or mere conformance. The Quality Officer shall seek to resolve defects for the benefit of both the client and the team concurrently. Where resolution cannot be reached between the Quality Officer and team leaders, and a basis for dispute exists, the matter shall be referred to the Project Manager for resolution.
General disputes procedures
If a dispute arises between the Quality Officer, operatives, and/or the client, and the dispute cannot be resolved, requiring work to be stopped, the following actions shall be taken:
The Foreman shall be informed immediately.
The trade operators shall be relocated as soon as possible to an alternative work area.
The Foreman and Quality Officer shall confer to resolve the dispute.
If resolution cannot be achieved through consultation between the Quality Officer and Foreman, the matter shall, where necessary, be referred to the Project Manager.
Disputes shall be resolved as promptly as possible in the interest of the client and ongoing production.
Where work subject to dispute in relation to quality control requires records, a rectification plan shall be agreed between the Foreman and the Quality Officer.
Figure 5 – Wet/Dry Film Thickness Chart.
Figure 6 – Wet/Dry Table.
The rectification work shall then be carried out as soon as possible.
All corrective actions shall be executed on the understanding that all rework must comply with the contract specification.
Safety practices for surface preparation and spray painting
General
The following sets out instructions and information regarding safety on site.
Production
The Project Manager shall be responsible for all safety aspects of surface preparation and spray-painting operations. All personnel engaged on site shall comply at all times with the appropriate dress standards. Personnel under the influence of alcohol, narcotics, or similar substances shall not be permitted entry to the site. No intoxicating liquor, narcotics, or similar substances shall be brought onto the site. Gambling and fighting are prohibited on site. Personnel shall not interfere with or modify vehicles, plant, or equipment without proper authority, including compressors, machinery, and airless or conventional spray equipment. Personnel using portable electric power tools shall ensure that an approved residual current device (RCD) is connected and that all cords are in a serviceable condition. All personnel engaged in abrasive blasting and spray-painting operations shall be familiar with industry terminology.
Work performed at heights
When major operations are to be undertaken, such as blasting and painting of tankage, galleries, or similar structures, scaffolding in the form of fixed or suspended platforms shall be provided in accordance with the relevant regulations. All personnel shall ensure that these scaffolds are adequately maintained, kept clean, and free from obstructions. No personnel shall make any alterations to scaffolding or staging at any time. Any alterations to scaffolds or staging shall be carried out only by licensed personnel under the direct supervision of the Project Manager or Foreman.
Accidents and incidents
All accidents and incidents, regardless of severity, shall be reported immediately to the Foreman or Leading Hand in accordance with standard safety practices. The Project Manager shall complete the appropriate report forms on the same day that the accident or incident occurs1 ‹
When major operations are to be undertaken, such as blasting and painting of tankage, galleries, or similar structures, scaffolding in the form of fixed or suspended platforms shall be provided in accordance with the relevant regulations.
1 This section shall be read in conjunction with the accompanying “Work Safety” handbook.
Anne Trafton, MIT News1
Massachusetts Institute of Technology Cambridge (MA), United States
MIT researchers have developed a lightweight polymer film that is nearly impenetrable to gas molecules, raising the possibility that it could be used as a protective coating to prevent solar cells and other infrastructure from corrosion, and to slow the aging of packaged food and medicines.
The polymer, which can be applied as a film mere nanometres thick, completely repels nitrogen and other gases, as far as can be detected by laboratory equipment, the researchers found. That degree of impermeability has never been seen before in any polymer, and rivals the impermeability of molecularly-thin crystalline materials such as graphene.
“Our polymer is quite unusual. It is obviously produced from a solution-phase polymerization reaction, but the product behaves like graphene, which is gas-impermeable because it is a perfect crystal. However, when you examine this material, one would never confuse it with a perfect crystal,” says Michael Strano, the Carbon P. Dubbs Professor of Chemical Engineering at MIT.
The polymer film, described by the researchers in Nature1, is made using a process that can be scaled up to large quantities and
Because it is nearly impermeable to gases, the polymer coating developed by MIT engineers could be used to protect solar panels, machinery, infrastructure, and more.
applied to surfaces much more easily than graphene. Strano and Scott Bunch, an associate professor of mechanical engineering at Boston University, are the senior authors of the new study. The paper’s lead authors are Cody Ritt, a former MIT postdoc who is now an assistant professor at the University of Colorado at Boulder; Michelle Quien, an MIT graduate student; and Zitang Wei, an MIT research scientist.
Bubbles that do not collapse
Strano’s lab first reported the novel material — a two-dimensional polymer2 called a 2D polyaramid that self-assembles into molecular sheets using hydrogen bonds — in 2022. To create such 2D polymer sheets, which had never been done before, the researchers used a building block called melamine, which contains a ring of carbon and nitrogen atoms. Under the right conditions, these monomers can expand in two dimensions, forming nanometre-sized disks.
These disks stack on top of each other, held together by hydrogen bonds between the layers, which make the structure very stable and strong (Fig. 1).
That polymer, which the researchers call 2DPA-1, is stronger than steel but has only one-sixth the density of steel.
In their 2022 study, the researchers focused on testing the material’s strength, but they also did some preliminary studies of its gas permeability. For those studies, they created “bubbles” out of the films and filled them with gas. With most polymers, such as plastics, gas that is trapped inside will seep out through the material, causing the bubble to deflate quickly.
However, the researchers found that bubbles made of 2DPA-1 did not collapse — in fact, bubbles that they made in 2021 are still inflated. “I was quite surprised initially,” Ritt says. “The behaviour of the bubbles did not follow what one would expect for a typical permeable polymer. This required us to rethink how to properly study and understand molecular transport across this new material.”
“We set up a series of careful experiments to first prove that the material is molecularly impermeable to nitrogen,” Strano says. “It could be considered tedious work. We had to make microbubbles of the polymer and fill them with a pure gas like nitrogen, and then wait. We had to repeatedly check over an exceedingly long period of time that they were not collapsed, in order to report the record impermeability value (Fig. 2).”
Traditional polymers allow gases through because they consist of a tangle of spaghetti-like molecules that are loosely joined together. This leaves tiny gaps between the strands. Gas molecules can seep through these gaps, which is why polymers always have at least some degree of gas permeability. However, the new 2D polymer is essentially impermeable because of the way that the layers of disks stick to each other.
“The fact that they can pack flat means there is no volume between the two-dimensional disks, and that is unusual. With other polymers, there is still space between the one-dimensional chains, so most polymer films allow at least a little gas to get through,” Strano says.
George Schatz, a professor of chemistry and chemical and biological engineering at Northwestern University, described the results as “remarkable.” “Normally polymers are reasonably permeable to gases, but the polyaramids reported in this paper are orders of magnitude less permeable to most gases under conditions with industrial relevance,” says Schatz, who was not involved in the study.
A protective coating
In addition to nitrogen, the researchers also exposed the polymer to helium, argon, oxygen, methane, and sulphur hexafluoride. They found that 2DPA-1’s permeability to those gases was at least 1/10,000 that of any other existing polymer. That makes it nearly
Figure 1 – The novel material developed in 2022 is a two-dimensional polymer that self-assembles into sheets and could serve as a lightweight, durable coating for car parts or cell phones, or as a construction material for bridges and other structures.
as impermeable as graphene, which is completely impermeable to gases because of its defect-free crystalline structure. Scientists have been working on developing graphene coatings as a barrier to prevent corrosion in solar cells and other devices. However, scaling up the creation of graphene films is difficult, in large part because they cannot be simply painted onto surfaces.
“We can only make crystal graphene in very small patches,” Strano says. “A little patch of graphene is molecularly impermeable, but it does not scale. People have tried to paint it on, but graphene does not stick to itself but slides when sheared. Graphene sheets moving past each other are considered almost frictionless.”
On the other hand, the 2DPA-1 polymer sticks easily because of the strong hydrogen bonds between the layered disks. In this paper, the researchers showed that a layer just 60 nanometres thick could extend the lifetime of a perovskite crystal by weeks. Perovskites are materials that hold promise as cheap and lightweight solar cells, but they tend to break down much faster than the silicon solar panels that are now widely used.
A 60-nanometer coating extended the perovskite’s lifetime to about three weeks, but a thicker coating would offer longer protection, the researchers say. The films could also be applied to a variety of other structures.
“Using an impermeable coating such as this one, you could protect infrastructure such as bridges, buildings, rail lines — basically anything outside exposed to the elements. Automotive vehicles,
aircraft and ocean vessels could also benefit. Anything that needs to be sheltered from corrosion. The shelf life of food and medications can also be extended using such materials,” Strano says.
The other application demonstrated in this paper is a nanoscale resonator — essentially a tiny drum that vibrates at a particular frequency. Larger resonators, with sizes around 1 millimetre or less, are found in cell phones, where they allow the phone to pick up the frequency bands it uses to transmit and receive signals.
“In this paper, we made the first polymer 2D resonator, which you can do with our material because it’s impermeable and quite strong, like graphene,” Strano says. “Right now, the resonators in your phone and other communications devices are large, but there is an effort to shrink them using nanotechnology. To make them less than a micron in size would be revolutionary. Cell phones and other devices could be smaller and reduce the power expenditures needed for signal processing.” Resonators can also be used as sensors to detect very tiny molecules, including gas molecules.
The research was funded, in part, by the Center for Enhanced Nanofluidic Transport-Phase 2, an Energy Frontier Research Center funded by the U.S. Department of Energy Office of Science, as well as the National Science Foundation. This research was carried out, in part, using MIT.nano’s facilities.
This article was reprinted with permission of MIT News3 ‹
3 http://news.mit.edu/
Normally polymers are reasonably permeable to gases, but the polyaramids reported in this paper are orders of magnitude less permeable to most gases under conditions with industrial relevance.
Figure 2 - MIT researchers tested the gas permeability of their new polymer films by suspending them over microwells to form bubbles. Some bubbles from 2021 experiments are still inflated. This optical micrograph shows how the films form very colourful spots when suspended over microwells.
AN ADSORBENT COATING FOR HIGH PERFORMANCE AND PROTECTION OF THERMAL ENERGY STORAGE SYSTEMS
DAVIDE PALAMARA*, LUIGI CALABRESE, and EDOARDO PROVERBIO
Department of Engineering, University of Messina – Messina, Italy
TREES-MAT Technology and Research on Energy, Environment, and Safety Materials davide.palamara@unime.it
* Corresponding author
Energy storage is a fundamental technology for facilitating the global transition towards a more sustainable energy system [1]. In this context, Thermal Energy Storage (TES) systems enable the accumulation of thermal energy for later use. These technologies are crucial for increasing the flexibility of energy systems, bridging the temporal mismatch between energy availability and demand, and enabling “peak shaving”, the reduction of peak energy demand, thereby optimising resource utilisation.
TES systems are categorised based on the mechanism used for heat storage (Figure 1a and 1b):
sensible heat storage: simply utilises the temperature change of a material without a phase change (e.g., water, molten salts, rock beds).
latent heat storage: exploits heat stored or released during a phase change (e.g., solid-liquid transition) at a nearly constant temperature, using phase change materials (PCMs).
thermochemical energy storage (TCES): employs reversible chemical reactions that capture (endothermic) and release (exothermic) heat1.
TCES systems offer high-density, long-term thermal energy storage, surpassing the performance of the first two methods [2]. These systems demonstrate remarkable versatility across a wide thermal spectrum, ranging from residential climate control (5 – 90 °C) and industrial process heating (40 – 250 °C) to hightemperature solar thermal applications reaching up to 600 °C [3]. Consequently, they are well-suited for applications such as waste heat recovery, solar thermal energy utilisation, and industrial heat management. In particular, low-temperature TCES (<90 °C) allow the use of water as a refrigerant, significantly reducing environmental hazards, corrosion, and maintenance issues [4].
The search for durable materials for low-temperature TCES
The selection of appropriate materials is crucial to the effectiveness of TCES systems. These materials must exhibit high energy storage capacity, thermal stability, and mechanical durability. Among the most promising materials are hydrated salts and solid adsorbents such as zeolites and silica gel. While hydrated salts are often more efficient in terms of energy density, they frequently present significant challenges, including corrosion, volume variation, and deliquescence (the tendency to dissolve in adsorbed moisture). Consequently, solid adsorbents are often preferred for their superior stability.
Zeolites are widely utilised solid adsorbents characterised by their unique porous crystalline structure. This structure allows them to effectively adsorb water vapour, releasing heat, and when
and
Figure 3 - Concept of zeolite-based coatings for TES: a visual comparison between an uncoated and a coated heat exchanger (left), and a schematic representation of integration within a TES cycle.
4 - Schematic illustration of the zeolite-based composite coating preparation process.
heated, to release the stored water vapour, storing thermal energy, thereby functioning as a stable thermal battery. A schematic representation of the zeolite adsorption/desorption process is shown in Figure 2
An approach to integrating zeolites into TES systems is to apply a zeolite-based polymeric coating to heat exchanger surfaces (a visual example is illustrated in Figure 3). This technique offers the potential for improved performance and stability compared to other types of adsorbent units, enabling enhanced heat and mass transfer [5, 6]. A successful adsorbent coating must possess three important characteristics:
Vapour permeability: the polymer matrix used in the coating must allow water vapour to permeate easily to reach the zeolite’s active sites without hindering the adsorption and desorption processes. This ensures efficient thermal cycling.
Figure 1a and b - The innovative sustainable energy storage plant inaugurated in Tuscany (Italy) and a graphical representation of the three fundamental mechanisms for storing thermal energy.
Figure 2 - Schematic representation of the reversible adsorption
desorption process within the SAPO-34 unit cell.
Figure
Mechanical stability and durability: the coating must exhibit sufficient mechanical strength and adhesion to prevent material loss or detachment during handling and operation, ensuring long-term system integrity and durability.
Corrosion protection: in the oxygen-depleted environments required to preserve dehydrated zeolite, the aluminium substrate is unable to form its natural protective oxide layer. Simultaneously, condensation during operational cycles can trigger degradation of the heat exchanger. Therefore, the coating must serve as a physical barrier, shielding the metal surface from corrosive phenomena [7] and thereby extending the service life of the heat exchanger unit. Adsorbent materials are subject to hygrothermal stress throughout their operational life due to repeated adsorption/desorption cycles and subsequent temperature variations. These cyclic stresses can lead to the degradation of both mechanical and adsorption properties, potentially compromising the long-term reliability of the entire TCES system. Consequently, maintaining the structural and chemical stability of the polymer matrix is essential, as it must withstand these fluctuations without cracking or losing adhesion to ensure consistent performance over time. To ensure consistent performance and accurately predict durability in real-world applications, targeted ageing tests designed to simulate operational conditions are essential. Guaranteeing the long-term performance of both the coatings and the adsorbent unit is paramount. An effective reduction in the environmental impact of any energy system is intrinsically linked to the lifespan of its components [4].
Therefore, material stability is a key factor in achieving sustainable energy targets.
Developing and testing the novel composite coating
This research introduces a novel composite coating based on SAPO-34 zeolite (average particle size of ~5 µm) embedded in a sulfonated styrenic pentablock copolymer matrix.
SAPO-34 exhibits promising adsorption capacity across a temperature range suitable for low-temperature TCES applications, while the sulfonated copolymer ensures excellent vapour permeability [8] and favourable mechanical properties. A schematic illustration of the coating preparation process is shown in Figure 4
The following procedure was used to prepare the coatings:
Polymer dissolution: the sulfonated copolymer was initially dissolved in dimethylformamide (DMF) at 60 °C.
Zeolite incorporation: pre-dried SAPO-34 zeolite was subsequently added to the mixture.
Deposition: the resulting solution was applied to pre-treated aluminium sheets by drop-casting.
Curing: the coated sheets were dried for 6 hours at ambient temperature, followed by a final curing step in an oven at 60 °C for 12 hours.
Multiple batches of coatings were prepared with varying zeolite filler contents, ranging from 80 wt% to 95 wt%, yielding thicknesses between 500 and 700 µm.
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Climatic chamber testing
To assess the long-term reliability of the prepared coatings, an accelerated climatic chamber prototype (illustrated in Figure 5) was engineered to simulate repeated dry/wet cycles.
The chamber is thermally insulated and connected to an external steam generator. Inside the chamber, a heating element coupled with a fan maintains the set temperature. A second fan, which vents to the exterior, evacuates internal humidity. A humidity and temperature sensor is positioned inside for continuous environmental monitoring.
The temperature and relative humidity values selected for the accelerated ageing study were:
“Dry” condition: 40 °C and 10% relative humidity.
“Wet” condition: 30 °C and 90% relative humidity.
Four distinct batches of coatings were placed inside the chamber. Each batch, containing samples from all filler percentages, was extracted after a specific number of ageing cycles to evaluate degradation: 10, 30, 70, and 130 cycles.
Post-ageing characterisation methodology
After each batch was removed from the climatic chamber, all coatings were dried overnight at ambient temperature and subsequently subjected to characterisation to assess the impact of accelerated ageing. The results obtained from the aged batches were systematically compared with those from the unaged samples.
Two primary mechanical tests were performed to evaluate the coating’s durability. The scratch test indirectly measures the
coating’s scratch resistance. This involves drawing an indenter across the coating surface, with performance then determined by measuring the resulting groove width. The applied force on the coating was systematically varied by changing the load, specifically ranging between 100 g and 1300 g. Conversely, the pull-off test provides a direct measurement of the adhesive strength of the coating to the aluminium substrate. This method requires glueing a standardised “dolly” onto the coated surface and then measuring the force required to cause coating detachment.
A fundamental aspect of an adsorbent coating is its ability to maintain effective vapour exchange with the external environment, and that this characteristic is preserved over time during use.
A dynamic vapour sorption system utilising a microbalance was employed to measure the amount of vapour adsorbed and desorbed as a function of temperature under specific vapour pressure conditions. By plotting the sample mass values measured at the plateau of each temperature step, adsorption and desorption isobars are obtained. The analysis of these isobars provides critical information regarding the effectiveness and performance retention of the coating.
To investigate any potential effect of the ageing process on the thermal stability of the composite material, the aged samples were also subjected to thermogravimetric analysis (TGA).
This analysis helps to identify changes in the decomposition temperature or mass loss profiles, indicating material degradation. Furthermore, to evaluate the corrosion protection and barrier effectiveness provided by the composite coatings to the underlying aluminium substrate, electrochemical impedance
Figure 5a and b - Experimental setup for accelerated hygrothermal ageing: a) Representative temperature and relative humidity profiles over multiple dry/wet cycles; b) Schematic representation of the custom-engineered climatic chamber prototype.
spectroscopy (EIS) tests were performed using a conventional three-electrode cell: the coated sample acted as the working electrode, a titanium grid was used as the counter electrode, and a saturated Ag/AgCl electrode was the reference electrode. All tests were performed in a 3.5 wt% NaCl solution at room temperature and under open-to-air conditions. The testing area was about 0.785 cm2
Results: degradation mechanisms and performance stability
Mechanical stability under accelerated ageing
The trend in pull-off strength as a function of both zeolite content and the number of cycles (as shown in Figure 6a) reveals high initial resistance followed by subsequent degradation. No significant changes in coating-substrate adhesion were observed during the initial ageing cycles (0 - 30 cycles). This suggests that the exposure duration was insufficient for water vapour to fully permeate to the coating-metal interface, thus causing no substantial alteration in adhesive and cohesive properties. A more substantial variation in adhesion was noted after 70 cycles, followed by a sharp reduction upon reaching 130 cycles, with the pull-off value stabilising around 0.8 MPa. This stabilised value remains superior to those typically reported for conventional coatings [9]. The degradation mechanism is attributed to water vapour action, which, upon reaching 70 cycles, begins to propagate to the interface, leading to a progressive reduction in adhesive properties. This effect was found to be most pronounced at both low and high zeolite contents. In the former case (low zeolite content), the larger quantity of the permeable polymer matrix allows greater water vapour ingress towards the interface. Conversely, with the highest zeolite content, the reduced polymer matrix (which acts as the binder) leads to greater intrinsic mechanical instability of the coating layer. The 90% zeolite formulation represents the optimal condition, achieving an effective balance between the amount of functional filler and mechanical stability.
The analysis of the pull-off fracture surfaces (shown in Figure 6b) corroborates these observations. For up to 30 cycles, the failure mode is predominantly cohesive across all formulations, indicating that the interfacial bonding strength remains higher than the composite’s internal strength. However, at 70 cycles, adhesive failure becomes evident, signalling a reduction in bonding strength at the substrate interface. Notably, the intermediate compositions maintain a fully cohesive failure mode at this stage, demonstrating more persistent interfacial integrity. It is also noteworthy that, for the 95 wt% zeolite formulation, a mixed failure mode is already detectable at 30 cycles, highlighting
characterisation of the composite coatings:
adhesion strength as a function of zeolite filler content and the number of ageing cycles; b) Visual analysis of fracture surfaces after pull-off testing, illustrating the transition from cohesive to adhesive failure.
Figure 6 - Adhesion
a) Pull-off
how extreme filler content triggers a premature reduction in adhesive strength.
Finally, at 130 cycles, adhesive properties are further compromised across all samples; the increased adhesive contribution to the fracture process leads to a prevalent mixed failure mode even for intermediate zeolite contents.
Figure 7 illustrates the evolution of groove width measured after the Scratch Test; wider grooves indicate lower scratch resistance. A progressive increase in groove width was observed with increasing cycle number. This deterioration was marginal during the initial ageing phases but became more pronounced after a greater number of cycles. This behaviour is particularly evident in coatings with a low zeolite content, which displayed an average increase in scratch width of 25% after 130 cycles. In contrast, samples with a higher filler content showed a smaller increase, averaging 10%, suggesting that the higher amount of filler confers better resistance to water permeation at the interface even after ageing.
Adsorption performance and thermal stability
The final phase of the study analysed how the accelerated ageing process affects the adsorption capacity and thermal stability of the composite coatings. Adsorption isobars were measured at a constant water vapour pressure of 11 mbar, representative of typical operating conditions in adsorption-based technologies [10]. As illustrated in Figure 8a, the results are reported for all coatings (aged and unaged) and for the pure SAPO-34 zeolite powder. The maximum adsorption capacity values for the unaged samples align with the actual quantities of zeolite within the coating. This is a key finding, as it confirms that the presence of the polymeric matrix does not significantly hinder the effective exchange of water vapour with the internal zeolite particles, thereby validating the coating design. Comparison of the isobars of the aged and unaged samples shows a slight reduction in the maximum adsorption capacity at 30 °C. After exposure to 130 hygrothermal cycles, the coatings exhibited a drop in maximum capacity ranging from 2.9% to 3.5%. This negligible performance decline is potentially due to limited degradation within the polymer matrix. Crucially, however, this reduction is not substantial enough to compromise the long-term functionality or operational effectiveness of the coatings in a TCES system.
Using water uptake values derived from the adsorption isobars, the heating capacity of the coatings was calculated. Specifically, considering a thermodynamic cycle operating between a maximum temperature of 60 °C and a minimum temperature of 30 °C, with an evaporation temperature of 7 °C (corresponding to a constant pressure of 11 mbar), the heat of adsorption was
determined. For these calculations, an average specific heat of adsorption of 2800 kJ/kg was assumed [11]. Under these conditions, the heating capacity values obtained per square metre of coating (with a 0.6 mm thickness) range from 207.5 kJ/m2 (460.9 kJ/kg) to 270.5 kJ/m2 (600.9 kJ/kg), depending on the zeolite content. This result further emphasises the high energy density achievable by these composite layers, confirming their suitability for compact heat exchanger integration in TCES systems.
To further assess the composite’s durability, the thermal stability of the aged coatings was evaluated by thermogravimetric analysis. Figure 8b shows the thermogravimetric curves for the coating containing 80 wt% zeolite, both aged and unaged. Analysis of the derivative weight curve reveals an advancement (shift to lower temperatures) of the two main decomposition peaks. The first peak, associated with the decomposition of the sulfonic groups, shifted by 3.6 °C. The second peak, related to the main degradation of the polymer backbone, shifted by 8.0 °C. While these shifts confirm limited deterioration of the polymer structure as a consequence of the ageing process, the overall thermal integrity of the composite is largely maintained, consistent with the negligible drop in adsorption performance.
To complement these findings and evaluate the coating’s barrier efficiency and corrosion protection, EIS analysis was employed. As illustrated in Figure 9a, all coated samples exhibited higher impedance magnitudes across the entire frequency spectrum than the bare aluminium substrate, with the 90 wt% and 95 wt% formulations yielding optimal results.
The impedance spectra of the coated samples revealed two distinct time constants, clearly evident in the phase angle plot (Figure 9b). The high-frequency response (~105 Hz) is attributed to the capacitance of the composite coating [12]. In contrast, the lower-frequency response (~101−102 Hz) corresponds to the electrochemical behaviour of the aluminium oxide layer [13], mirroring the response observed in the uncoated aluminium reference. Furthermore, the resistive behaviour was characterised by two impedance plateaus. The high-frequency plateau (~104 − 105 Hz) represents the pore resistance (Rpore) within the coating matrix, while the low-frequency plateau (~10−1 − 100 Hz) represents the coating/aluminium interface. Rpore was found to be slightly dependent on the filler concentration: the 95 wt% batch displayed an Rpore nearly two orders of magnitude greater than that of 80 wt%, indicating a more effective barrier against electrolyte penetration at higher zeolite contents. At low frequencies, coatings with lower filler content exhibited impedance values similar to those of bare aluminium. This convergence suggests a potential loss of interfacial protection, likely due to the adsorption
Figure 7 - Evolution of groove width as a function of applied load for 80 wt% and 90 wt% zeolite coatings at different ageing stages (from 0 to 130 cycles).
Figure 8 - Adsorption and thermal characterisation of the composite coatings: a) Adsorption isobars comparing pure SAPO-34 powder with unaged (0 cycles) and aged (130 cycles) coatings at different zeolite contents; b) TGA derivative weight curves for the 80 wt% zeolite coating before and after ageing.
Figure 9 - Electrochemical impedance spectroscopy (EIS) spectra of the uncoated aluminium substrate and composite coatings with different zeolite contents (80, 85, 90, and 95 wt%): a) Bode impedance plots; b) Bode phase angle plots.
or incorporation of chloride ions at the substrate surface. The results highlight the dual functionality of the coating as a function of filler content: it simultaneously enhances corrosion protection at the metal-coating interface and provides the essential adsorption capacity required for thermal energy storage systems.
Conclusions and future outlook
In conclusion, several batches of composite coatings with varying zeolite contents were produced and characterised both before and after a period of accelerated ageing in a prototype climatic chamber. These comprehensive investigations have yielded significant findings on the durability of these TCES materials. The coatings under examination exhibited measurable degradation in mechanical properties as the number of ageing cycles increased. Crucially, the magnitude of this degradation was found to be highly dependent on the zeolite content: coatings with the lowest and highest zeolite concentrations showed the most significant reductions in mechanical integrity. Conversely, the adsorption isobars showed only a negligible reduction in maximum adsorption capacity. This minimal performance drop suggests limited degradation of the polymer matrix, which was confirmed by thermogravimetric analysis. TGA results showed a shift of the decomposition peaks to lower temperatures, indicating a slight reduction in thermal stability.
Furthermore, EIS analysis elucidated the corrosion protection effectiveness of the composite coatings and the electrochemical processes occurring at the coating/electrolyte and coating/ substrate interfaces. The results indicated that, despite the polymer’s hydrophilic nature, increasing the zeolite content enhanced corrosion resistance. This was evidenced by higher pore and aluminium/coating interface resistances, suggesting an improved barrier effect.
The more modest reduction in mechanical properties observed in the 90 wt% zeolite coating, a composition specifically chosen to balance mechanical integrity with water vapour adsorption capacity, indicates that this formulation is potentially compatible with practical TCES applications.
Future studies will involve fabricating a full-scale heat exchanger coated with the optimal 90 % zeolite composite. This component will then be subjected to real-world TCES operating cycles to investigate the specific degradation phenomena that occur during actual operation. We will also extend the ageing duration in the climatic chamber to further stress the material’s stability. Ensuring the long-term performance and lifespan of the coating in an integrated system is paramount to achieving the sustainable energy goals enabled by TCES technology. ‹
References
[1] A. Guruprasad, L. Yaxue, and F. Guiyin, “An overview of thermal energy storage systems,” Energy, vol. 144, pp. 341– Figure 9. Electrochemical Impedance Spectroscopy (EIS) spectra of the uncoated aluminium substrate and composite coatings with different zeolite contents (80, 85, 90, and 95 wt%): a) Bode impedance plots and b) Bode phase angle plots.378, 2018, doi: 10.1016/j.energy.2017.12.037.
[2] F. Desai, S. Prasad, P. Muthukumar, and M. Mustafizur, “Thermochemical energy storage system for cooling and process heating applications: A review,” Energy Convers. Manag., vol. 229, no. December 2020, p. 113617, 2021, doi: 10.1016/j.enconman.2020.113617.
[3] S. Gamisch, M. Kick, F. Klünder, J. Weiss, E. Laurenz, and T. Haussmann, “Thermal Storage: From Low-to-High-Temperature Systems,” vol. 2300544, 2023, doi: 10.1002/ente. 202300544.
[4] S. Longo, V. Palomba, M. Beccali, M. Cellura, and S. Vasta, “Energy balance and life cycle assessment of small size residential solar heating and cooling systems equipped with adsorption chillers,” Sol. Energy, vol. 158, no. May, pp. 543–558, 2017, doi: 10.1016/j.solener.2017.10.009.
[5] B. Dawoud, “Water vapour adsorption kinetics on small and full-scale zeolite-coated adsorbers: A comparison,” Appl. Therm. Eng., vol. 50, no. 2, pp. 1645–1651, 2013, doi: 10.1016/j.applthermaleng.2011.07.013.
[6] G. Engel, “Sorption thermal energy storage: Hybrid coating/granules adsorber design and hybrid TCM / PCM operation,” Energy Convers. Manag., vol. 184, no. January, pp. 466–474, 2019, doi: 10.1016/j.enconman.2019.01.071.
[7] L. Calabrese, L. Bonaccorsi, and A. Caprı, “Electrochemical behavior of hydrophobic silane – zeolite coatings for corrosion protection of aluminum substrate,” vol. 11, no. 6, pp. 883–898, 2014, doi: 10.1007/s11998-014-9597-4.
[8] Y. Yang, R. Tocchetto, K. Nixon, R. Sun, and Y. A. Elabd, “Dehumidification via polymer electrolyte membrane electrolysis with sulfonated pentablock terpolymer,” J. Memb. Sci., vol. 658, no. March, p. 120709, 2022, doi: 10.1016/j. memsci.2022.120709.
[9] A. Freni, B. Dawoud, L. Bonaccorsi, S. Chmielewski, A. Frazzica, and L. Calabrese, Characterization of Zeolite-Based Coatings for Adsorption Heat Pumps. 2015.
[10] M. Gelaw, D. Palamara, A. Freni, S. De Antonellis, E. Proverbio, and L. Calabrese, “Adsorption and mechanical properties of composite coatings based on zeolite 13 × and sulfonated polymer for thermal energy storage in electric vehicles,” vol. 208, no. 109460, 2025, doi: https://doi.org/10.1016/j. porgcoat.2025.109460.
[11] J. Ammann, B. Michel, A. R. Studart, and P. W. Ruch, “Sorption rate enhancement in SAPO-34 zeolite by directed mass transfer channels,” Int. J. Heat Mass Transf., vol. 130, pp. 25–32, 2019, doi: 10.1016/j. ijheatmasstransfer.2018.10.065.
[12] S. Matysik, “Impedance spectroscopic investigations of zeolite Á polydimethylsiloxane electrodes,” vol. 48, pp. 297–301, 2002.
[13] Y. Huang, H. Shih, J. Daugherty, and F. Mansfeld, “Evaluation of the properties of anodized aluminum 6061 subjected to thermal cycling treatment using electrochemical impedance spectroscopy ( EIS ),” Corros. Sci., vol. 51, no. 10, pp. 2493–2501, 2009, doi: 10.1016/j.corsci.2009.06.031.
THE BREAKDOWN
Internal FBE coatings for valves: expected durability, real system impermeability, and proper management of post-application machining
trisolino@donelli.it
Alessio Trisolino,
Donelli Alexo Srl – Cuggiono (Milan), Italy
In the field of industrial valves intended for the most demanding services, internal coating can no longer be considered as a simple execution step or as a secondary stage of manufacturing. In oil and gas, water, desalination, fire water, seawater and other critical services, internal FBE coating is an essential part of the component’s final performance. The issue is not merely protecting a metal surface, but ensuring over time an effective, continuous and reliable barrier between the substrate and the process fluid.
This is especially true in the most demanding technical environments, including those associated with ARAMCO, SWCC and other major operators requiring high levels of integrity, service continuity and component durability. In such applications, internal protection is not regarded as a simple finish, but as a technical function that must retain its characteristics in the valve’s final configuration, after all manufacturing, assembly, fitting and machining operations have been completed before commissioning.
For this reason, one of the most important yet least understood topics in the market concerns the management of machining operations carried out after coating application. This is where the most dangerous misunderstanding often arises. There is a tendency to assume that a good application automatically means good final performance. But that is not the case. Excellent application is an essential condition, but not a sufficient one. The actual behavior of the system also depends on what happens afterwards.
An intervention that extends beyond the application phase
An internal FBE coating may be applied flawlessly. The surface may be properly prepared, the profile may be suitable, cleanliness may be excellent, and the film may be uniform, continuous, properly cured and checked against all required parameters. From an application standpoint, the work may be carried out to the highest standard.
A correct FBE application is not sufficient to ensure the final performance of a valve. It is the understanding of the component’s behaviour in its real operating context that determines the success of the system. The article explores the correct approach to FBE application, highlighting the critical role of consistency between the coating, component design, and subsequent machining stages.
THE BREAKDOWN
And this is, of course, the foundation of any serious activity. However, once application has been completed, the system does not exist in a theoretical vacuum. It exists within a valve that, in many cases, must still undergo further manufacturing or finishing stages. If those stages involve internal machining, then the issue is no longer application quality alone. It becomes the compatibility between the coating already applied and the subsequent machining operation.
This is exactly where the difference lies between a merely execution-based approach and a genuinely technical one.
When performance diverges from expectations
The end user does not purchase a good application in the abstract. The end user purchases a valve expected to provide durability, impermeability, reliability and continuity of service over time. What is expected is real performance, not partial compliance with only one stage of the process. If the coating is correctly applied but then subsequently machined in a way that is not consistent with the nature of the system, the final result may no longer correspond to what the customer expected. And this is not because the coating was poorly applied, but because the overall production sequence was not managed with the necessary technical awareness.
The key point is that internal FBE coating performs its function because it acts as a continuous, adherent and impermeable barrier. Its effectiveness depends on its ability to isolate the metal from the fluid in a stable and durable manner. However, when the film is subsequently machined, thinned, interrupted, blended or locally reworked in certain areas, that original continuity changes. At that point it is no longer enough to say that the system was applied properly. One must ask whether, after machining, it still retains the same impermeability, sealing capability and resistance expected in the component’s final configuration.
The complexity of valves
This issue is particularly delicate in valves because many internal surfaces are not merely passive areas to be protected. They are often functional surfaces: seats, sealing areas, coupling areas, guides, pocket areas, and surfaces affected by contact with other parts or by the dimensional tolerances necessary for correct operation. In these areas the coating is not only an anticorrosion barrier; it is directly related to the component’s mechanical function. For this reason, subsequent machining cannot be considered neutral. It alters the system not only in terms of residual thickness, but also in terms of its ability to remain a truly impermeable barrier consistent with the functional role of the surface.
The issue of an incompatible production sequence
It is precisely at this point that the market still shows a certain degree of superficiality. Those selling valves often rely on applicators who, even correctly, limit themselves to the straightforward and proper execution of the coating. From the application standpoint there is nothing to object to. The problem begins when such good application is then followed by machining operations that are not assessed in relation to the system’s behaviour after application. At that moment the risk no longer lies with the applicator who correctly performed the assigned task, but with the party that sold the valve, managed the component’s manufacturing sequence, or decided to perform subsequent machining without first verifying whether that choice was truly compatible with the selected coating.
This point must be stated very clearly. If a system is approved, qualified or technically valid within its application field, that does not automatically mean that it will retain the same characteristics after subsequent machining. The issue is not to question the overall validity of a material. On the contrary. The point is to respect its proper field of use, understand the application limits declared by manufacturers, and avoid expecting performance beyond what the system was designed to deliver.
Every evaluation of the coating system should begin with a very simple question: is the selected system truly suitable not only for the fluid, but also for the valve’s complete production cycle, including any post-application machining?
If, after coating, the component is processed in a manner that is not consistent with the nature of the system, then one is not dealing with an application defect. One is dealing with a production sequence that is incompatible with the durability promised to the end user.
The responsibility of those managing the production sequence
This is where the notion of expected durability becomes the true guiding criterion.
Anyone purchasing a valve for severe services, especially in environments associated with ARAMCO, SWCC and other high-level operators, does not merely expect that the coating has been applied well. The expectation is that the component will maintain impermeability, protection, resistance and reliability over time in its real service configuration. That expectation must be the starting point of every technical choice. Every evaluation of the coating system should begin with a very simple question: is the selected system truly suitable not only for the fluid, but also for the valve’s complete production cycle, including any post-application machining? If this question is not asked in advance, the risk becomes substantial. One may obtain a surface that is initially perfect but later loses part of its effectiveness because the final component configuration is no longer consistent with the one for which the system was selected. In such cases, responsibility cannot simply be assigned to the FBE applicator, especially where the coating has been correctly applied. Responsibility must instead be traced to whoever designed, sold or managed a subsequent production sequence that is incompatible with the behaviour of the system once modified.
Proper handling
This is why technicians need to gather the relevant information in advance. They must ask which surfaces will be coated and which will later be machined. They must distinguish between surfaces that are simply protected and surfaces that are functionally critical. They must understand whether the system retains or does not retain the same characteristics after machining. They must ask whether, once machining has been performed, the expected impermeability truly remains the same or is instead altered. In short, the coating must not be viewed as an isolated product, but as an integral part of the valve’s final configuration. This is exactly the level at which Donelli Alexo positions its approach.
Donelli Alexo’s approach
Donelli Alexo addresses these applications starting from a very clear principle: ensuring that the end customer receives what is actually expected. Not simply a well-executed coating, but anticorrosion protection consistent with the valve’s final performance.
This means not stopping at the good application of the system, essential as that is, but always asking in advance the technical questions needed to verify the compatibility between the coating, the component geometry, any subsequent machining and the level of durability required. The goal is not simply to deliver a coated valve. The goal is to help deliver a valve that, once all manufacturing stages have been completed, is truly consistent with the performance expected by the customer in terms of anticorrosion protection, system impermeability and long-term reliability.
For this reason, at Donelli Alexo, the question of whether any machining is planned after application is not a formality. It is an essential technical verification. It serves to select the truly suitable system. It helps prevent a good application from later being made incompatible by inconsistent production choices. Above all, it helps protect the end customer from the risk of receiving a valve that appears correct at the outset but is not actually durable in service.
The coating as an integral part of component performance
This approach becomes even more important in the most severe and highly qualified contexts, such as those associated with ARAMCO, SWCC and other major operators in the oil and gas, water, desalination, fire water and critical industrial services sectors. In such environments, internal coating is not considered a simple finish, but an integral part of the component’s performance. Anyone operating seriously in these markets knows well that the end customer does not expect merely a well-applied film. The expectation is that the system will retain continuity, sealing performance and resistance over time in the valve’s real configuration, that is, after all operations required to manufacture the finished product have been completed. And this is precisely where the value of a specialized and, above all, qualified applicator for these applications becomes evident.
The importance of real-world system understanding
In such a delicate field, the end customer must clearly know who is being trusted. It is not enough to turn to someone who is simply capable of applying a coating.
One must rely on an organization that truly understands what anticorrosion protection means, can correctly interpret application conditions, understand system limitations, assess the impact of subsequent machining and guide the selection toward the most suitable solution.
When dealing with internally coated valves for severe services, experience is not an accessory. It is a substantial guarantee of technical reliability.
The end customer must understand that there is a concrete difference between improvisation and competence built over time. It must be understood that anticorrosion protection is not merely the application of a material, but a full understanding of the system’s behaviour in the real context in which it must operate. It must also be understood that the most serious problems do not always arise from poor application; they often arise from a poor assessment of the subsequent stages or from superficial handling of the component after coating.
In the oil and gas, water, desalination, fire water and critical industrial services sectors, internal coating is not considered a simple finish, but an integral part of the component’s performance.
Key technical considerations for successful application
This is why the value of Donelli Alexo, a company present on the market for more than one hundred years, has a very concrete meaning. It means experience built in the field. It means the ability to distinguish between apparently good application and a genuinely durable solution. It means understanding what industrial anticorrosion protection truly involves rather than approaching it in an improvised manner. It means asking the right questions before they turn into problems in service. In a market where simplified or improvised approaches are still too common, the difference lies with those who truly know the work and understand that the result is not measured when the coating is applied, but over the time during which the component continues to perform as the customer expected.
In the end, the technical message is very clear. Excellent application is essential, but it is not enough. The valve’s real durability depends on the consistency between the selected system and the component’s entire production cycle. If post-coating machining is carried out in a way that is incompatible with the system’s behaviour, responsibility cannot be shifted onto the party that correctly applied the coating. Responsibility instead lies with the party that sold, designed or managed a production sequence incompatible with the promised performance.
Full technical responsibility
For this reason, anyone operating seriously in the field of internally coated valves must move beyond a purely executionbased logic and adopt a logic of full technical responsibility. It is not enough to ask whether the coating was applied well. One must ask whether the finished valve, as it will actually be delivered and used, will retain over time the impermeability, protection and reliability the customer expects.
And it is precisely in this ability to ensure that the customer receives what is actually expected, to assess anticorrosion protection as a complete technical responsibility, and to select the correct system also in view of subsequent machining, that the value of Donelli Alexo is recognized as that of a specialized, qualified applicator supported by a solid industrial history. ‹
ADVANCED AIR HANDLING IN MIXED-USE BOOTHS FOR SHOT BLASTING, COATING,
AND
PICKLING: A CHALLENGE MET BY ALBIZZATI WITHIN OIL
AND GAS APPLICATIONS
Monica Fumagalli ipcm®
Active for over fifty years in the design and manufacture of metal components for the oil and gas sector, the Albizzati Group has developed an integrated system combining shot blasting, coating, and pickling in collaboration with plant engineering firm Eurotherm. The layout also includes advanced air extraction, filtration, and handling units designed to ensure production continuity and compliance with the sector’s regulatory requirements.
In the oil and gas sector, requirements placed on suppliers have historically been characterised by a high degree of complexity and fragmentation. Each operator defines its own technical specifications, which complement and sometimes overlap with international reference standards. This results in a layered regulatory and documentation framework that forces suppliers to constantly adapt to requirements that change not only from contract to contract but also across different projects for the same client.
The role of equipment suppliers has therefore had to evolve from mere executors to qualified technical partners, responsible for compliance with both international standards and individual project specifications. Additionally, leading companies in the sector require product and process certifications relating to quality management and the qualification of production cycles, as well as the availability to undergo periodic audits. The checks also cover the environmental and operational conditions in which production processes are carried out, a particularly critical aspect during the surface preparation and protective coating application phases; emissions control thus becomes crucial for environmental protection and operator safety, as well as for final product quality, since the presence of particulate matter in the atmosphere can compromise coating performance.
For companies such as Albizzati S.p.A., it is essential to have systems in place that serve this purpose: belonging to a Group that has specialised in the design and manufacture of equipment and metal structures for gas turbine, petrochemical, and power generation plants for almost sixty years, it regards regulatory compliance and the validation of processes and products as the cornerstones of its development. “Anti-corrosion and fire-retardant surface treatments for large-scale products such as those we manufacture,” confirms Stefano Albizzati, Executive Director of the company headquartered in Magenta (Milan, Italy), “must be carried out using shot blasting and coating booths equipped with extraction systems specifically designed for the filtration and extraction of dust, aerosols, fumes, and vapours in accordance with regulations. For the surface treatment plant we have installed at our new Magenta factory, which has been operational since February 2025, we chose to rely on the expertise of Eurotherm Spa (Volpiano, Turin, Italy) not only for the company’s solid reputation and the quality of its lines but also for its technical team’s ability to customise solutions and its diverse operational capabilities,
which enable it to meet the specific needs of every client, from small businesses to major companies, both nationally and internationally. This reflects our own approach to the market, which translates into our ability to design, build, and integrate solutions and systems for various fields of application, including industrial, airport, military, and aerospace sectors.”
Production insourcing: a winning strategy
The Albizzati Group’s forerunner specialised in metalworking. It was founded in 1969 as Alex Sistemi in Ossona (Milan) as an initiative of Giuseppe Albizzati, the father of the current owners, Cristian, Stefano, and Luca: “Our business began with the manufacture of oil-filled electrical transformers,” says Account Executive Luca Albizzati. “It has since expanded by incorporating a division specialising in plant engineering for the electrical integration of systems and equipment, now enabling us to offer complete turnkey solutions. We design and manufacture prefabricated, pre-tested modular solutions to facilitate the installation of these complex systems at sites and in plants all over the world.”
This strategy has proved to be Albizzati’s winning move: “Since 2015, we have adopted a counter-trend approach, unlike many other operators in the sector, who have progressively outsourced production activities to focus on plant engineering. We have chosen to insource the entire production cycle, from metalworking to surface treatments – which, incidentally, are among the most critical process phases in terms of both lead times and execution quality.” The new production site in Magenta, acquired in 2021 and covering 125,000 m², reflects this approach. Home to one of the Group’s companies, Albizzati International Project, it specialises in design and engineering, alongside various production departments dedicated to machining, assembly, and surface treatments, each housed in its own building.
A bird’s eye view of the factory housing the machining department at the Albizzati Group’s site in Magenta (Milan), and the outside of the area devoted to surface treatments.
The
Albizzati
Group: five factories and four centres of excellence
Today, what was once a small family business has grown into an industrial Group with five production sites across northern and central Italy, covering a total area of 320,000 m² and employing 270 people. It has completed over 120 projects in the past four years and operates in more than twenty-five countries, which account for 90% of its turnover.
In addition to Albizzati International Project, already mentioned, the Group, founded in 2006, comprises three other companies: Alex Sistemi, specialising in turnkey solutions for integrating mechanical, electrical, and electronic systems, including passive-cooling shelters, enclosures, fully equipped shelter systems, forward medical posts, and containers for transporting modules for the orbiting space station, satellites, and mechanical ground support equipment (MGSE); Albizzati S.p.A., founded in 1996 and active in the design, manufacture, integration, and qualification of components for power stations, waste treatment and waste-to-energy plants, hyperbaric units for naval applications, and systems for the petrochemical sector, including hyperbaric chambers, pressure vessels, storage tanks, piping, separation and cooling towers, and cyclone filters; and Eudosia Sistemi, acquired in 2005 and specialising in the design and manufacture of systems for housing and protecting equipment intended to operate in harsh environmental conditions, as well as industrial mechanical systems for telecommunications and oil and gas applications.
The five sites are interchangeable, each equipped with its own shot blasting and coating departments. The site handling each order is selected based on workloads and the dimensional and construction characteristics of products. “We handle components such as shelters, ranging in
The first booth, carrying out shot blasting and liquid coating operations.
An extraction wall in Zone 1.
size from 6 × 2.5 m to 60 × 15 × 9 m,” notes Luca Albizzati, “made from carbon steel, stainless steel, aluminium, and special alloys. We do not have a standard catalogue: every product is developed to customer-specific requirements.”
Complex, long-lasting systems and components
The chemical and petrochemical sector places severe demands on the efficiency and durability of plant equipment, and numerous factors must be considered when designing these systems. “Our products must guarantee high levels of reliability even under extreme pressures, temperatures, and humidity in highly aggressive atmospheres, and maintain structural integrity even in emergencies, such as prolonged exposure to fire.” That is why they are developed in accordance with the main international regulations and undergo rigorous design checks to ensure they meet the highest safety and quality standards imposed by the market. “To meet these requirements, we have been operating in accordance with the ISO 9001 quality management standard since 1996, and we are currently finalising the accreditation process with the Italian Ministry of Defence for NATO AQAP 2110 certification. We also hold sector-specific certifications, such as ISO 3834-2 for the manufacture of components for turbines and petrochemical plants, metal structures, and pressure vessels, and CSA Standard W47.1 for the manufacture of steel products for the oil and gas sector.”
The Group maintains a fleet of state-of-the-art equipment, including CNC-controlled laser and plasma cutting systems,
press brakes, roll forming machines, and submerged arc welding systems, as well as in-house departments dedicated to surface treatments such as shot blasting, pickling, and coating. This gives it full control over its entire production cycle and ensures the correct application of anti-corrosion and fire-protection measures, a key factor in guaranteeing the durability of the solutions it manufactures and the suitability of its work environment. “Our clients specify the coating cycles: in most cases, these fall within the highest corrosion classes (C5-M and above) and must comply with REI regulations, which require the application of intumescent paint for fire protection: in this case, we use, among others, products from the International® range.”
THE CHEMICAL AND PETROCHEMICAL SECTOR PLACES SEVERE DEMANDS ON THE EFFICIENCY AND DURABILITY OF PLANT EQUIPMENT, AND NUMEROUS FACTORS MUST BE CONSIDERED WHEN DESIGNING THESE SYSTEMS.
The display for paint application management: the entire line is designed in accordance with Industry 4.0 parameters.
The technical area located between Zone 1 and Zone 2.
A bespoke manual coating line
Unlike the Group’s other production sites, the layout of the new Magenta factory was designed from the outset to separate machining from surface treatments. This decision stemmed from a clear assessment: the coating phase is a major production constraint because of its rigid cycle times and the need for strict flow management. “In this new facility, we kept the processes separate because coating is the actual bottleneck of our entire production flow,” explains Luca Albizzati. “The large space available enabled us, together with Eurotherm, to create a dedicated line within a 30 × 30 × 7.5 m building, organised into two independent areas for liquid coating that can operate simultaneously on multiple workpieces. The project also made it possible to integrate shot blasting (Zone 1) and pickling (Zone 2) within the same areas.”
The plant consists of two mixed-use booths, designed and built by Eurotherm, each equipped with extraction and filtration systems sized for the specific processes involved. “One system is configured to remove dust generated by the shot blasting operations, which use red-brown corundum, and aerosols produced during liquid coating,” explains Davide Quartana, Project Manager at Eurotherm. “The other extracts fumes and vapours from the pickling station.”
Accommodating processes with such different characteristics within the same booth was one of the most critical design considerations. In particular, pickling involves the use of acidic solutions and the generation of corrosive vapours, which called for precise design choices. “We adopted bespoke solutions to ensure the plant’s chemical resistance and durability, including lining the booth with AISI 304 stainless steel, installing filter walls, designing special ductwork, installing ceiling filters, and choosing a resin floor coating to protect surfaces from the effects of acid vapours.” The two treatment areas are separated by a central corridor housing the technical area serving both zones, facilitating operational control and maintenance.
Zone 1: shot blasting and liquid coating
“Two separate extraction systems have been developed for the different processes involved here,” explains Quartana.
“During shot blasting, corundum dust is captured by extraction hoods positioned along the sides of the booth and conveyed to a suitable dust abatement system, while during the coating process the side extraction panels are activated to capture the aerosol.”
The shot blasting plant’s extraction system
The extraction system for the shot blasting plant comprises 12 extraction hoods, each connected to a group of 3 to 4 external dust collectors fitted with 32 filter cartridges and an exhaust
THE PLANT CONSISTS OF TWO MIXED-USE BOOTHS, DESIGNED AND BUILT BY EUROTHERM, EACH EQUIPPED WITH EXTRACTION AND FILTRATION SYSTEMS SIZED FOR THE SPECIFIC PROCESSES INVOLVED.
chimney, with a flow rate of 40,000 m³/h. The 4 independent extraction units can operate simultaneously or in pairs, depending on production requirements.
“Through the extraction hoods,” indicates Quartana, “a vacuum is created to force the airflow towards the external filter units, without any dispersion into the environment. The filtered air is then expelled through the chimneys via extractor fans, sized to ensure extraction speeds comply with current regulations. Air is replenished in the booth via ceiling-mounted diffuser ducts fitted with filter grilles.”
The plant operates without recirculation: all extracted air is expelled. The extraction flow is therefore maintained at full capacity. For safety reasons, the solenoid valves feeding the shot blasting guns operate only when the extraction plant is active.
The abrasives recovery system
Corundum is recovered through a mechanised system installed beneath the booth’s ground floor, consisting of 8 scrapers fitted with self-propelled blades that move in an alternating, oscillating motion, driven by gear motor units. Via a connecting arm, each gear motor system enables the frames placed inside dedicated compartments to make a forward and a return stroke: this ensures complete recovery of the abrasives, which are conveyed to the transverse screw conveyors and from there to bucket elevators. The separation stage is carried out by 2 abrasives separators installed at the top of the elevators, which separate the coarser particles from the finer ones. The former are retained by a screening plant equipped with a perforated mesh tray, followed by a pneumatic vibrating screen, and are subsequently recovered; the latter are separated by an air stream, then conveyed to the ground floor and partly redirected to the external filter systems. The system is completed by 2 abrasives storage silos, each with a capacity of approximately 8,000 kg and equipped with an overflow discharge device to manage peak build-ups. As with the extraction
solution, the abrasives recovery system is also configured flexibly, with the option to operate by individual zone or simultaneously, depending on operational requirements.
The liquid coating plant’s extraction system
During the liquid coating phase, the 6 extraction walls are activated simultaneously; each is equipped with an extractor fan and an independent exhaust chimney with a flow rate of 18,000 m³/h. The plant operates under controlled negative pressure, with air replenishment provided by ceiling diffusers, similar to the solution used for the shot blasting phase.
From a safety perspective, 2 solenoid valves prevent the supply of paint to the spray guns when active extraction is not in operation. The operating principle is based on capturing the overspray generated during paint application: the air flow is channelled through the extraction walls towards the filtration units, where the air is purified before being expelled via the chimneys. The booth’s inner walls, including the protective doors of the extraction walls, are lined with 3 mm-thick abrasion-resistant rubber.
Zone 2: picking, liquid coating, and drying
“Two independent extraction systems have been installed in the second zone, alongside a system devoted to the supply of hot air for the drying stages, which is fed by a central heating plant,”
The second booth, carrying out pickling and liquid coating operations.
A painting phase of a large component in the second booth.
illustrates Quartana. “This configuration allows for the separate management of incoming air flows, which can be drawn from the outside environment or, when required, heated by a heat generation unit.”
The extraction system for the pickling and cleaning booth is designed to capture fumes and vapours released by the chemicals and the high-pressure cleaning operations; at the latter stage, it also removes the water molecules mixed with air produced by the high-pressure spray. On the other hand, the second system handles the aerosol generated during liquid coating, following the same collection and filtration principle as in Zone 1. Finally, the drying station integrates a controlled supply of heated air, used to accelerate the drying of paint.
The cleaning and pickling plant’s extraction system
The 6 stainless steel extraction walls, each fitted with a dedicated extractor fan and an independent exhaust chimney with a flow rate of 10,000 m³/h, can be switched
Top left: The drying phase can also be carried out in the same booth thanks to two air handling units (AHUs), one for filtered air and the other for heated air.
Top right: A finished shelter ready for shipment to its final destination: the coating applied is a three-layer system comprising a primer, intumescent paint, and a top coat.
Stefano and Luca Albizzati (centre) with Davide Quartana (first from left) and Gianpaolo Candelero from Eurotherm.
on or off individually as required, or activated simultaneously. In this operating mode, the solenoid valves feeding compressed air to the liquid coating spray guns remain closed (safety position). Inside the extraction walls, droplet separators are fitted to remove water molecules from the air. Air can thus be released through the extraction chimneys while the liquid drips inside the extraction walls.
The air intake system and the management of the drying phase
2 external air handling units (AHUs) connected to the ceiling diffusers via dedicated ductwork are designed to supply filtered and heated air to the work environment.
The system adjusts the process temperature by balancing the inlet and outlet airflows under controlled negative pressure. During the drying phase, the 6 extraction walls and the 2 AHUs operate in an integrated mode with a heating function, using air-stream gas burners. Simultaneous activation allows for the supply of forced, temperature-controlled air to accelerate the paint drying process. Air replenishment is primarily provided by the AHUs, while the extraction flow rate is reduced and regulated via an inverter to run at low speed.
Motorised dampers close the partial air replenishment ducts to optimise thermal control of the treated volume. The system allows a controlled temperature increase of up to ΔT = +20 °C relative to the outside temperature, ensuring uniform drying conditions and process stability.
Co-engineering applied to plant design
“The active collaboration of Albizzati’s team was crucial,” concludes Quartana. “Projects of this kind, featuring two mixeduse booths, are rare: ongoing communication with the client enabled us to develop a solution that truly met its operational needs, in line with the concept of co-engineering.” Layout design benefited from the availability of ample production space, which allowed the areas allocated to surface treatments to be physically separated from those used for other processes. This approach, which is not always feasible in existing industrial settings, has resulted in optimised process flows and streamlined work cycles. “The experience gained at our Group’s other sites was a key factor in developing this project,” says Luca Albizzati. “In particular, the abrasives management issue was addressed and resolved systematically, whereas it had been a major problem on other lines due to the sub-optimal design of the recovery plant.” That is why Albizzati’s team drew up a detailed project plan, which Eurotherm translated into a bespoke plant engineering solution, with particular attention to customising the corundum recovery unit and positioning the extraction systems in accordance with the regulatory requirements for certification and periodic audits. The resulting line incorporates advanced air filtration and management systems, with continuous monitoring of operating parameters and environmental emissions in line with Industry 4.0 standards. “Remote monitoring of consumption and emissions,” states Albizzati, “enables constant supervision of operating conditions, helping to meet environmental certification requirements and facilitating audits by clients and regulatory bodies. The set of solutions adopted also guarantees controlled working conditions for our staff and external operators involved in coating activities, ensuring high standards of safety and comfort during the application stages.” ‹
THE EXTRACTION SYSTEM FOR THE PICKLING AND CLEANING BOOTH IS DESIGNED TO CAPTURE FUMES AND VAPOURS RELEASED BY THE CHEMICALS AND THE HIGH-PRESSURE CLEANING OPERATIONS.
Protecting the future of renewable energy from the foundations up
Dennis Macht, Key Account Manager - Wind Energy
Matthias Winkler, Senior Key Account Manager - Wind Energy
Sherwin-Williams Protective & Marine, Bolton – United Kingdom
The He Dreiht offshore wind farm, Germany’s largest, relies on steel monopiles exposed to extreme marine conditions that demand long-term corrosion protection. Using Sherwin-Williams’ 100% solvent-free Dura-Plate SW-501 coating, Steelwind Nordenham ensured durable, high-quality foundations, safeguarding both turbine performance and Germany’s renewable energy future.
Offshore wind is playing a vital role in delivering clean, reliable power at scale. And with the foundations of these mammoth structures being exposed to some of the harshest environments imaginable, protecting them from corrosion is tantamount to protecting our energy security. Given positive experiences on previous projects in collaboration with EnBW, Steelwind Nordenham steel fabricators turned to Sherwin-Williams when working on He Dreiht, Germany’s largest wind farm and a showcase for modern, sustainable infrastructure.
Our renewable future
The EnBW offshore wind farm “He Dreiht” comprises 64 turbines with a total capacity of 960 megawatts, and is one of the first wind farms in Germany to be built without government subsidies. Covering an area of around 90 kilometres near the island of Borkum in the North Sea, it is one of Europe’s largest energy transition projects. By spring 2026, it will be able to supply 1.1 million households with renewable energy. It plays an integral part in the country’s future energy plans, making its protection from the elements a crucial consideration.
Protecting monopiles from corrosion is not just a technical necessity. It is a matter of safety, sustainability, and energy reliability. Corrosion protection coatings act as a barrier between the metal and its environment, preventing corrosive elements like water, oxygen, and salts from reaching the surface.
“Off-shore wind monopiles are exposed to aggressive environmental conditions every day. Rising from the seabed, these steel structures encounter saltwater immersion, strong currents, wave impacts, and fluctuating splash zones, all of which leaves them highly vulnerable to corrosion,” said Matthias Winkler, Senior Key Account Manager Wind Energy at Sherwin-Williams. Off-shore wind facilities are expected to run with minimal maintenance for more than 30 years. A small failure in a coating system, then, can often go unnoticed until it is too late, leading to increased repair costs and expensive extended downtimes. “The monopiles are the backbone of the entire wind farm. If they fail, the turbines fail.”
Coatings and challenges
Protecting monopiles from corrosion, then, is not just a technical necessity. It is a matter of safety, sustainability, and energy reliability. Corrosion protection coatings act as a barrier between the metal and its environment, preventing corrosive elements like water, oxygen, and salts from reaching the surface. SherwinWilliams’ Dura-Plate SW-501 Series is a 100% solvent-free and benzyl alcohol-free high-build epoxy coating that forms a dense, impermeable layer over the steel surface. With outstanding structural integrity, these coatings offer long-term protection
for turbine investment while delivering safety and reliability well beyond their expected service life. Choosing the right coating, however, can be challenging. Traditional options are not designed to withstand the decades of light-touch maintenance that is central to the wind farm business model. Rather, they are based on the very different needs of manned oil and gas platforms. Many contain volatile organic compounds (VOCs) and harmful solvents that can evaporate into the air, threatening applicator safety. VOCs can also contaminate water, necessitating time- and resourcesapping post-application treatment before installation. Some coatings can be difficult or slow to apply, reducing build efficiency. Others do not meet relevant standards and regulations, such as VGBE-S-021-02-2023, NORSOK M-501 or ISO 12944-9 2018.
Industry leading
Due to their extensive experience working with Sherwin-Williams on a range of projects, Steelwind Nordenham and EnBW were well aware of the coating system that best met their needs.
“For Steelwind Nordenham, reliability and quality are nonnegotiable. Our reputation depends on delivering foundations that will stand the test of time. By choosing the Sherwin-Williams Dura-Plate SW-501 coating system, we’re not only ensuring 25 to 30 years of corrosion resistance in one of the toughest marine
environments, but also helping safeguard Germany’s energy security and the end user’s investment,” says Dr. Andreas Liessem of Steelwind Nordenham.
“Together with our partners, we pursue sustainable solutions that create long-term value”, he continues.
Application of the 100% solvent-free coating system took place at Steelwind Nordenham’s advanced fabrication facility in northern Germany, where the massive steel monopiles, each measuring up to 71 metres in length and weighing approximately 1,350 tons, were produced.
Steelwind’s applicator partner, Robert Krebs GmbH from Hamburg, used manual airless spraying to ensure consistent film build and surface coverage across the vast steel structures.
Matthias Winkler notes: “Despite the scale and complexity of the task, the project was completed smoothly and without any application issues. This is testament to both the product’s ease of use, and the professionalism of the project partners.”
Close collaboration between all three partner companies ensured the system met all regulatory and client requirements. As part of
the He Dreiht offshore wind project, Steelwind Nordenham once again relied on the proven protective coating Dura-Plate SW-501 this time on a foundation of exceptional size. The application process went smoothly and impressed with outstanding surface quality.
Dura-Plate SW-501 exceeded expectations in two key areas: excellent handling during application and superior surface finish after curing. This confirmed the coating as a reliable solution for demanding offshore structures and highlighted its role in a longterm corrosion protection strategy.
Secure energy future
Coating technology is fundamental to building a sustainable energy future, helping to ensure steel monopiles will stand strong beneath the waves for decades to come.
By protecting the very structures that anchor our clean energy infrastructure, the industry is helping to secure not just the longevity of wind farms, but the reliability of renewable power for generations to come. ‹
IBIX SURFACE PREPARATION AND FLAME SPRAY TECHNOLOGY
Temperature resistance from -40°C to +70°C approx
Resistance to extreme weathering, UV and salt
spray protection
Immediate use of coated items
Easy to repair
From Genoa to America: Donelli was honoured by AMPP for the repainting of the Bigo
Fumagalli ipcm®
Genoa’s Bigo has been restored to its original glory thanks to the cleaning and repainting work carried out by Donelli using Jotun coatings, for which the company received an international award from AMPP in recognition of aesthetic excellence.
Monica
The Bigo, the panoramic lift whose eight arms rise above the Gulf of Genoa, built as part of the 1992 redevelopment of the Port of Genoa – planned by Renzo Piano for the Expo ‘92, the International Exposition organised to mark the 500th anniversary of Christopher Columbus’s first voyage – has certainly made the city’s harbour area even more picturesque. Immediately become a symbol of Geona, it is now defined as a sculpture-infrastructure, combining strong aesthetic and symbolic value – it recalls the ancient bighi, the metal cranes once used for handling goods in the port – with a technical function as the supporting element of the tensile structure covering the Piazza delle Feste below.
Having undergone various maintenance works over the years to counteract the effects of the weather and the marine environment, the Bigo has recently been the subject of a major restoration and repainting project, which began in 2025 and was carried out by company Donelli (Legnano, Milan, Italy) with the aim of preserving its integrity and original appearance.
The architecture of one of Genoa’s landmarks
One of the main tourist attractions in the capital of the Liguria region, the Bigo is a complex steel cable-stayed structure consisting of two independent arm systems extending from a small artificial island within the port basin. It comprises a central inclined mast and seven cigar-shaped arms of varying lengths and functions, arranged in a fan-like pattern. The main arm, about 70 m long and 2.3 m in diameter, supports a panoramic lift that reaches a height of 40 m and rotates 360°, offering visitors a complete view of the city. From an engineering perspective, the structure has a hybrid design, incorporating several architectural elements: a guyed mast structure, a suspended system of arches
and cables, and a cable-stayed roof supporting a tensioned membrane. The central mast plays a fundamental role in distributing stresses and is equipped with jack-based adjustment mechanisms to maintain the structure’s static balance. The Bigo and its arms are anchored to the artificial island by tie rods connected to submerged foundations at the bottom of the harbour.
The main structural components, namely the masts, arches, and supports, are made of Fe510 C steel, while high-performance materials have been used for elements subject to particularly high stresses, such as the Ferralium alloy for the anchor rods. From the top of each arm supporting the roof, 16 cables fan out, supporting slender arches that suspend a membrane made of fibreglass coated in PTFE, a material highly resistant to atmospheric agents. The roof consists of five panels, connected by glass joints. The structure was erected using a combination of ground-based and floating lifting equipment.
The project’s complexity
The repainting of the Bigo was commissioned by Porto Antico di Genova S.p.A., the company that manages and promotes the Old Port area, which allocated a total budget of €1,870,000. Following a tender process, it awarded the contract to Donelli, active since 1911 in the field of protective coatings, in partnership with IMC Engineering Srl, which had previously been involved in maintenance work on the structure. The project sought to restore the structure’s original colour scheme designed by Renzo Piano Building Workshop, aiming to achieve uniformity and aesthetic continuity across the entire structure. Unlike previous maintenance works, which were limited to localised repairs of deteriorated areas and had, over time, resulted in obvious colour inconsistencies, the project included the complete repainting of the Bigo.
One of its most complex aspects was planning the application work, taking into account both the structure’s complexity and the need to prevent any contamination of the surrounding marine environment1. To this end, protective systems consisting of tarpaulins mounted on floating pontoons were installed to contain process residues, and surface preparation operations, including sanding, were carried out using equipment with integrated extraction systems to limit the dispersion of dust and particulates.
During the design phase, the initial plan had been to use aerial work platforms or rely exclusively on rope access technicians; however, Donelli’s technical team deemed this solution suboptimal and recommended installing a scaffolding system capable of providing access to over 80% of the surfaces to be treated.
The repainting work
Launched in February 2025, the project was divided into two phases. The first focused on the parts of the structure accessible from the scaffolding, namely the central mast, the four side arms, and the three additional masts supporting the panoramic lift and the tensile structure in Piazza delle Feste.
After general cleaning of the entire structure to remove flaking sections of the existing paintwork and thorough blasting, a new multi-layer coating system was applied, using paint products supplied by Jotun. The Norwegian multinational provided a two-component epoxy primer and a two-component polyurethane top coat through its Italian subsidiary.
The project sought to restore the structure’s original colour scheme designed by Renzo Piano Building Workshop, aiming to achieve uniformity and aesthetic continuity across the entire structure.
“The primer applied is a high-build two-component epoxy product from our Jotamastic Smart Pack HB range,” explains Angelo Susani, Sales ManagerInfra & Energy at Jotun. “It is designed to deliver high levels of corrosion protection even under less-than-ideal application conditions and stands out for its ‘surface-tolerant’ technology, which allows application on mechanically or manually prepared surfaces where shot blasting is not possible, while maintaining excellent adhesion and protection. This feature makes it particularly suitable for maintenance and restoration work in industrial settings.” This primer has a 1:1 mixing ratio, which simplifies mixing and reduces waste during application. “It is also specifically formulated for application by roller and brush, ensuring ease of application, excellent edge coverage, and adequate film spreading, even without the use of spray equipment. Key features include a high solids content, which implies a reduced presence of solvents in the formulation and, consequently, low emissions of volatile compounds into the atmosphere, good chemical and mechanical resistance, and the ability to build up a significant thickness in a single coat, helping to increase the durability of the protective coating.”
A high-performance aliphatic twocomponent polyurethane top coat, Hardtop XP, renowned for its excellent colour and gloss retention, was chosen as the finish. “It offers superior resistance to weathering, UV rays, and harsh environments, making it particularly
suitable for outdoor applications and in demanding industrial settings”. It also guarantees excellent resistance to abrasion and chemicals, combined with good aesthetics and ease of cleaning. “Hardtop XP,” Susani says, “also stands out for its application versatility, offering good film spreading and uniformity and helping to achieve homogeneous surfaces with high cosmetic quality. When used as part of a system with an epoxy primer such as Jotamastic Smart Pack HB, it enables the creation of highly reliable, durable protective systems that meet the industry’s most demanding standards”. The second phase, launched at the start of 2026, focused on areas inaccessible by traditional methods, particularly the masts’ uppermost sections, and was carried out using rope access techniques.
The award presented by AMPP Impresa Donelli, together with IMC Engineering and Porto Antico di Genova, was honoured by AMPP-Association for Materials Protection and Performance during the Honoree Night at the AMPP Annual Conference and Expo in Houston
(Texas, USA) on 18 March for its restoration work on the Bigo. The project received the prestigious Recognition of Excellence in Aesthetic Merit in a Coatings Project award, presented in acknowledgement of excellence in the execution of works characterised by quality, innovation, and impact on historical heritage.
“We are very proud to have been part of this project,” the company states. “Today, this symbol of Genoa and its Old Port has been restored to its former glory, thanks to the removal of salt, smog, and other pollutants and to repainting in its original colour. This international recognition makes us even prouder, as it rewards the dedication, innovation, and passion our team brings to every project. This one, in particular, presented a complex challenge, combining advanced protection, aesthetic enhancement, and high durability. The key message is clear: executing a complex project requires effective collaboration among all parties involved, from the client to the designers, right through to the contractors and subcontractors.” ‹
Scan the QR code to watch the first stage of the repainting work on the Bigo
Aluminium and its alloys rely on a thin native oxide film for corrosion resistance; however, in chloride-containing environments this passive layer is prone to localized breakdown and pitting corrosion. Reduced graphene oxide (rGO) has emerged as a promising material for aluminium corrosion protection due to its high aspect ratio, excellent impermeability, chemical and mechanical stability. When used as a coating component or nanofiller in paints rGO significantly enhances barrier properties. In this work rGO was obtained by simple reduction with L-ascorbic acid from GO solution and its direct application on commercial aluminium alloys, commonly used for structural applications, is investigated as an anti-corrosion and anti-wear coating by means of electrochemical techniques and tribology. The results support the effectiveness and suitability of such simple, inexpensive, and environmentally friendly treatment, capable to enhance the stability of the surface passive layer.
Aluminium alloys are indispensable structural materials in modern engineering due to their low density, high specific strength, and good formability. They are widely applied in aerospace, marine and transportation sectors, and emerging energy technologies. The corrosion resistance of aluminium originates from the rapid formation of a thin, adherent oxide film (Al₂O₃) that passivates the surface under neutral and mildly alkaline conditions [1, 2]. Despite this natural passivity, aluminium alloys are highly susceptible to localized corrosion in the presence of aggressive anions, particularly chloride ions [3]. Pitting corrosion represents the most critical degradation mechanism, as it can initiate at microscopic defects, intermetallic particles, or inclusions and propagate rapidly with limited macroscopic warning. Once the passive film breaks down, localized dissolution is sustained by autocatalytic mechanisms involving local acidification and chloride enrichment. Historically, chromate-based conversion coatings have provided excellent corrosion protection for aluminium alloys.
However, due to the toxicity and carcinogenicity of hexavalent chromium compounds, increasingly stringent environmental regulations have driven intense research into chromate-free alternatives. In this context, nanomaterial-enabled coatings— especially those based on graphene derivatives—have attracted significant attention [4-6]. Among graphene-based materials, reduced graphene oxide (rGO) offers a unique combination of properties: high impermeability comparable to graphene, residual functional groups that improve dispersion and adhesion, and scalable synthesis routes [7]. Generally, the conversion from GO to r-GO requires a reducing agents [8-9] or thermal treatment [1014], or even bacterial methods [15]. However, in order to propose a simple and easily scalable process for industrial applications, several aspects need to be accurately taken into consideration, the most relevant of which are the use of water-based treatments and the use of inexpensive and benign reducing agents. Based on these concerns many commonly used chemical reductants, such as hydrazine, hydrazine hydrate, and NaBH4 need to be avoided. Green reductants, such as L-ascorbic acid (L-aa) [16-18], L-cysteine [19] and even various plant extracts [20-22], have been proposed. Despite inherent limitations—such as reduced deposition efficiency arising from the formation of graphene agglomerates that do not participate in film growth, and the requirement for moderately elevated processing temperatures (>60 °C), which restrict applicability to thermally sensitive substrates—this method remains the most viable and scalable approach for the deposition of rGO coatings on metallic substrates [23], including in industrial and artisanal manufacturing contexts.
Experimental procedures
Samples preparation
Metallic substrates were prepared from commercially available bars of AA5754 and AA6068 aluminium alloys [their chemical composition, as determined by XRF-WDS (Rigaku ZSX Primus II), are depicted in Table 1] as 1 mm thick and 50 mm diameter tokens. The samples were than grinded with emery paper down to 1200 grit, rinsed in distilled water, acetone and then air dried letting the spontaneous oxidation film to be formed on the sample surface.
Table 1: Designation, chemical composition (Wt%) and of the aluminium alloys tested.
Reduced graphene oxide (rGO) coatings were deposited on the sample surface by immersing the metallic tokens in an aqueous solution prepared by diluting a commercial graphene oxide (GO) dispersion (0.4 wt%, Goodfellow) with Milli-Q water to a final GO concentration of 0.1 mg/mL-¹. L-ascorbic acid (99%, Merck) was added as a reducing agent in the amount of 4 g/L-¹. Solution containing the immersed samples was then heated at 80 °C under continuous stirring (≈600 rpm) for 2 h. During the process, the solution colour changed from grey to brownish and a rGO film is deposited on the solid surfaces in owe to the reduced solubility of rGO respect to the GO. As side by-products some colloidal graphene agglomerates appeared. Following the treatment, the samples were retrieved from the solution, gently rinsed with Milli-Q water, air-dried, and then subjected to subsequent testing and characterization. Visual investigation of the samples so produced was obtained by means of digital magnifier (OCULUX Macro Zoom, Microconsult).
Electrochemical tests
The potential effect of rGO as an anticorrosive coating was assessed by electrochemical techniques. A computer controlled potentiostat (Autolab, Metrohm) controlled via Intello electrochemical software (vers. 2.1) and a threeelectrode corrosion cell (EG&G Parr Flat cell) constituted the electrochemical set-up. 1 cm2 is the exposed area of the working electrode while a platinum grid and a saturated calomel electrode (SCE) constituted counter and reference electrodes, respectively. Electrochemical tests were carried out in aerated 5 % NaCl solution at room temperature. Prior to each measurement, opencircuit potential (OCP) was recorded until a stable potential was reached (about 1 hour), then EIS and potentiodynamic polarization (PDP) measurements were performed. EIS measurements were carried out with an AC amplitude of 10 mV at open circuit potential in the frequency range 100 kHz to 1000 mHz while, successively to the EIS measurement PDP curves were registered at scanning rate of 0.1667mV/s from -0.9V to -0.2V vs SCE in the anodic direction. The inhibition efficiency (IE) of the rGO coating was calculated accordingly to the following equation (1)
IE% = 100 x
Where:
IE = inhibition efficiency; icorr, ref= corrosion current of the untreated aluminium sample; icorr, rGO = corrosion current of the rGO treated sample.
Among graphene-based materials, reduced graphene oxide (rGO) offers a unique combination of properties: high impermeability comparable to graphene, residual functional groups that improve dispersion and adhesion, and scalable synthesis routes.
Tribological tests
The coefficient of friction (COF) was determined using a ball-ondisk tribometer (POD 4.0, Ducom Instruments, India), in which a stationary spherical ball (10 mm diameter, in our case) was brought into sliding contact with a rotating disk specimen under controlled conditions applying a constant normal load throughout the test. During testing, that was carried at room temperature, the friction force generated at the ball–disk interface was continuously measured, and the COF was calculated as the ratio of the measured friction force to the applied normal load (4 N) as function of the sliding distance. Figure 1 depicts a scheme of test. Three replicate tests were carried out for each specimen, and at the end of the test, the worn samples were observed by SEM microscopy (Hitachi, SU3800, filament electron source) operating at 15keV and 16.3mm working distance.
1 - Sketch of the ball-on-disk principle. The wear test was performed with a 10 mm diameter ball applying a normal load of 4 N.
Figure
Results
Sample preparation
The detailed physical characterization of the rGO layer obtained via GO reduction with L-ascorbic acid is reported in literature [23-25], in our case the successfully formation of rGO film was cheked by FTIR measurements (not reported here) and visual investigation. Representative images of the sample surface before and after the deposition of rGO are depicted in Figure 2 (AA5754 alloy) and Figure 3 (AA6068 alloy). For both aluminium alloys, no detectable changes in surface morphology were observed after the treatment; however, the treated samples exhibited a slight, but clearly visible, shift in colour towards a more brownish hue.
Electrochemical corrosion tests
PDP curves are shown in Figure 4, and values of Ecorr and icorr obtained by the tangent extrapolation method are displayed in Table 2. Despite the Ecorr values remain almost unaffected by the rGO treatment the icorr values showed a clear decrease pointing out a corrosion reduction with inhibition efficiency (IE %) values respectively of 82% for AA6068 and 84 % for AA5754.
The corrosion protection performance of the rGO coating on Al alloys was investigated by electrochemical impedance spectroscopy (EIS). The Nyquist plots, and the corresponding equivalent electrical circuit, are presented in Figure 5
Figure 2 - Digital macro images of the sample AA5754 before (a) and after (b) the deposition of rGO coating (field of view 3mm x2mm).
Figure 3 - Digital macro images of the sample AA6068 before (a) and after (b) the treatment with rGO (field of view 3mm x2mm).
4 -
of uncoated (dashed curves) and rGO-coated (solid curves) Al samples recorded in aerated 5% NaCl. Coated samples show a clear decrease in icorr values, compatible with an inhibition of the corrosion process.
5 -
plots for uncoated and coated Al samples. The inset displays the proposed circuit equivalent.
The equivalent circuit consists of the solution resistance (Rs), the charge transfer resistance (Rct), and a constant phase element (CPE). The Nyquist plots of both coated and uncoated samples exhibit a typical depressed semicircular shape in the high-frequency region. Notably, the diameter of the semicircle for the rGOcoated samples is significantly larger than that of the uncoated sample. This increase indicates a higher charge transfer resistance (Rct), which is associated with enhanced corrosion resistance of the coated aluminium samples.
Wear tests
To better elucidate the role of rGO, the wear behaviour of treated and untreated samples was investigated using ballon-disk tribometry. Figure 6 depicts the coefficient of friction (COF) as a function of sliding distance (m). The red curves correspond the untreated samples, whereas the blue curves represent the rGO-treated samples. After rGO treatment, both alloys exhibit a significant stabilization and reduction of COF values. Figures 7 and 8 display the SEM images of the wear surfaces for the treated and untreated samples. The wear scars on both the untreated alloys are characterized by their extensive width and roughness, accompanied by a plethora of debris. Additionally, the friction ball associated with the untreated sample displays a considerable amount of wear debris (not displayed here), showing the presence of severe adhesion wear and justifying the high variability of COF. Nevertheless, the samples treated with rGO exhibited much smaller wear track, consistent with reduced COF and almost none wear debris.
Table 2: Electrochemical corrosion values obtained from PDP curves.
Figure
PDP curves
Figure
Nyquist
Discussions
It is well known that rGO obtained by partial reduction of GO via chemical reduction in aqueous environment, retains residual oxygen-containing functional groups that enhance adhesion capability towards the oxide layer present on the surface of airexposed aluminium items. [26]. After deposition of rGO layer the colour of the samples turns towards a more brownish hue but, from the electrochemical point of view no significative change in the OCP and Ecorr, respect to the untreated samples were observed (Figure 4). Such electrochemical data asses that the rGO layer is not in direct contact with metallic surfaces, avoiding the potential galvanic coupling which could increase the corrosion rate. [27,28]. That is probably due to the partial surface coverage by rGO layer and the absence of direct contact of the rGO layer with metal parts.
The electrochemical data asses that the rGO layer is not in direct contact with metallic surfaces, avoiding the potential galvanic coupling which could increase the corrosion rate. That is probably due to the partial surface coverage by rGO layer and the absence of direct contact of the rGO layer with metal parts.
Figure 6 - The coefficient of friction (COF) as a function of sliding dis tance (m) for untreated (a) and rGO – treated (b) samples.
Figure 7 - SEM micrographs of wear traces on AA5754: (a) Untreated sample, (b) rGO treated sample. Same magnification for the two samples, scale bar in the picture.
Figure 8 - SEM micrographs of wear traces on AA6068: (a) Untreated sample, (b) rGO treated sample. Same magnification for the two samples, scale bar in the picture.
Nevertheless, the presence of such film effectively reduces the corrosion rate in mild NaCl bearing environments, limiting the icorr of about 1 order of magnitude (table 2) with respect to the untreated samples. The inhibition effect player by rGO layer is reasonably attributable to the increased charge transfer resistance (Rct) as highlighted by EIS measurements (Figure 5). That is consistent with a reducing permeation of water, oxygen, and chloride ions as proposed in previous works [29, 30] and is attributed to the near-impermeability to gases and liquids of graphene-like materials. Furthermore, the increased hydrophobicity and the lubricating effect played by the rGO layer, as demonstrated by the wear tests (Figure 6), may further inhibit the retention of aqueous solution at the surface or within the pores of the oxide layer, effectively enhancing the barrier effect, which is widely recognized as the predominant corrosion protection mechanism of rGO-based coatings.
Conclusions
A reduced graphene oxide (rGO) layer was successfully deposited onto commercial grade aluminium alloys by the simple reduction of GO aqueous solutions using L-ascorbic acid. The capability of the film, so generated, to improve the anticorrosion characteristics of two different aluminium alloys (namely AA5754 and AA6068) widely used for structural applications was successfully tested in aerated NaCl aqueous solution via electrochemical test. Potentiodynamic polarization measurements demonstrate that rGO coatings does not significatively affects the corrosion potential (Ecorr) but indeed reduce the corrosion rate of about 84% and 82% for AA5754 and AA6068, respectively. EIS measurement confirms this behaviour indicating a strong increment of the polarization resistance respect to the untreated
References
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This study presents a relatively simple and cost-effective approach to improving the corrosion and wear resistance of bare aluminium alloys for practical applications in mild ambient environments, while preserving their aesthetic appearance. Although the enhancement in corrosion resistance is lower than that provided by conventional chromate-based conversion coating or anodizing treatments, the simplicity of the process and the low cost and low toxicity of the reagents make this environmentally benign method well suited for large-scale industrial implementation.
Acknowledgements
The authors acknowledge financial support from the Italian Ministry for enterprise and made in Italy (MIMIT) for partially supporting this research through the project: “Studio di applicazioni industriali innovative del graphene” (Acronim: GRAFENEX) funded within the call:“Accordi per l’Innovazione” (D.M. MiSE 31/12/2021). ‹
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Protection of steel from corrosion
Thermal stability – reliable performance across a wide temperature range
Mechanical strength – excellent resistance to abrasion and impact
THE WATERPROOFING OF FLAT ROOFS ON BUNGALOWS IN SARAJEVO WAS SUCCESSFULLY COMPLETED USING POLYUREA SPRAY SYSTEMS, WITH ON-SITE TRAINING AND EQUIPMENT PROVIDED BY B & M GMBH. THIS PROJECT DEMONSTRATES THE EFFICIENCY AND
TECHNICAL PERFORMANCE OF MODERN HIGH-PRESSURE SPRAY TECHNOLOGY.
Extreme durability – retains waterproofing and protective properties under various environmental stresses
Elastic and flexible – accommodates substrate movements without cracking or delamination
Chemical resistance – withstands various chemicals, including acids and oils.
Case study:
a challenging construction site in Sarajevo
The project involves the waterproofing of several flat roofs on bungalows in Sarajevo, Bosnia. Local applicators were trained on the correct use of materials and the appropriate spray equipment. Using professional two-component high-pressure airless pumps, transfer pumps, heated hose assemblies, and a two-component mixing and atomizing spray gun, a coverage rate of 100–150 m² per hour is achieved.
The team from b & m GmbH, headquartered in Oberteuringen, Germany, and the supplier of this type of professional spray equipment, travelled to Sarajevo to provide hands-on training under real on-site conditions.
The spray unit was installed at ground level. Material supply (components A and B) is provided via two pneumatic transfer pumps drawing directly from 200-liter drums. The pumps feed the material to the pneumatically driven high-pressure pumps of the polyurea spray system.
Transfer pumps are pre-assembled on the drum lids. When a drum is empty, a new drum is opened, and the complete lid, including the transfer pump, is placed on top. This setup minimizes changeover time and prevents unnecessary ventilation of the material circuit.
Spray equipment installed at ground level.
The high-pressure pumps pressurize components A and B, delivering them through separate hoses. From there, the material is conveyed via heated hose assemblies (up to 90 meters) to the spray gun for application. The extended hose length allows the material to be pumped vertically across several floors, while the spray equipment remains safely positioned at ground level. At the application area, the operator easily sprays the polyurea using the heated hose assembly and spray gun. This setup optimizes space requirements and significantly reduces time and logistical effort on site. Components A and B are delivered through separate heated hoses to a dedicated two-component spray gun equipped with an internal mixing chamber. Inside the gun, the components mix and discharge at high pressure through the spray nozzle. The mixed material is then applied to the surface in a fine, atomized spray pattern. Since the reaction time after exiting the spray gun is limited to only a few seconds, the applied coating is ready for subsequent layers or overcoating within minutes.
Electronic control and operating parameters
A key feature of the two-component spray system is its intelligent electronic control unit, equipped with a user-friendly display that provides all relevant operating parameters. The system monitors and displays critical data such as flow rate, material temperature, and mixing ratio tolerances. In the event of a malfunction, the system automatically issues a warning signal. The recommended ambient air temperature for polyurea application ranges from 5 °C to 40 °C. Relative humidity levels of up to 85% are permissible, making the material suitable even for use in tropical climates. As an alternative to polyurea, PU foam insulation materials can also be processed using the same equipment. However, this technology is not a do-it-yourself solution. Proper training is essential.
Operators must be instructed by the equipment supplier on correct handling, commissioning, shutdown procedures, and thorough cleaning of all system components.
Proper training and safety
For appropriate material selection and correct application procedures, additional training provided by the material supplier is strongly recommended. Ideally, both the material and equipment suppliers should be present during the initial on-site training session to ensure optimal system setup and user qualification. Last but not least, the use of appropriate personal protective equipment (PPE) is mandatory.
The roofing project in Sarajevo was successfully completed within a remarkably short timeframe. All stakeholders expressed great satisfaction with both the technical results achieved and the longterm value of this forward-looking investment. ‹
A KEY FEATURE OF THE TWO-COMPONENT SPRAY SYSTEM IS ITS INTELLIGENT ELECTRONIC CONTROL UNIT, EQUIPPED WITH A USER-FRIENDLY DISPLAY THAT PROVIDES ALL RELEVANT OPERATING PARAMETERS.
From left to right: Spray unit with dual pumps and integrated control panel; User-friendly control display; High-pressure application: the material is mixed inside the spray gun and atomized by airless high pressure, eliminating the need for additional atomizing air.
THE BREAKDOWN
SMARTER CORROSION PROTECTION FOR TOUGHER ENVIRONMENTS
Yidong Meng,
Global Key Account Management and New Business Development Manager at AkzoNobel Powder Coatings
Corrosion costs global industry around US$3 trillion annually, but up to 35% is preventable.
For manufacturers producing components used in tough environments and requiring coatings with specific functional properties, where busbars, rotors, pipes, rebars, valves and fittings must be safeguarded, corrosion protection is no longer a background engineering decision, but a strategic lever for performance, sustainability and customer trust. The impact of corrosion is felt far beyond the rust and product damage it causes, and for manufacturers, it quietly but steadily eats into profits, damages reputations, and undermines sustainability ambitions.
To understand how businesses are responding, 'AkzoNobel Powder Coatings' Interpon team commissioned a global survey of 1,000 manufacturers across diverse industry sectors including architecture, automotive, electric vehicles (EV), industrial, functional, and ACE, revealing how leaders are navigating the challenge. This article focuses on manufacturers producing components used in challenging operating conditions, such as underground water systems, gas networks or high-voltage power infrastructure and technologies. It will highlight the importance of corrosion resilience in some of the most demanding applications, and a growing trend among manufacturers to transform corrosion protection from a necessary cost into a strategic lever for long-term value.
The cost of corrosion
Corrosion is costly, both visibly and invisibly. According to the Association of Materials Protection and Performance (AMPP), the global cost of corrosion exceeds US$3 trillion each year – nearly 3% of worldwide GDP. Yet up to 35% of this is preventable, representing US$875 billion in potential savings if the right strategies are applied. These figures are not just attracting attention, but inspiring action from manufacturers.
The knock-on effects are wide-ranging. In the US water and infrastructure sector alone, corrosion contributes to 260,000 pipe failures every year, adding $2.6 billion in repair costs to an already hefty annual bill. And around 40% of all new steel production is simply to replace corroded products and systems, contributing to around 3.2% of global CO2 emissions. For manufacturers, the pain points are clear. Almost a third (32%) of surveyed manufacturers say that lost customers and product returns are their biggest corrosion-related expense, while 28% highlight the environmental cost of increased equipment replacement. These findings are broadly consistent across all sectors: corrosion is a universal challenge that shortens product lifespans, damages trust and consumes resources that could otherwise fuel innovation and sustainable growth.
Corrosion protection is evolving from a maintenance cost to a strategic driver: increasingly used powder coatings in the fight against corrosion, such as Resicoat, enable manufacturers to safeguard the most critical infrastructure while ensuring long-term durability, environmental sustainability, and high performance.
THE BREAKDOWN
Shifting strategies
To support sustainability, safeguard reputations, and achieve the AMPP’s estimated 35% cost savings, forward-thinking manufacturers are no longer treating corrosion protection merely as a cost or a ‘factory-fix’ but are reframing it as a strategic investment. This is reflected in two key trends:
Selecting technologies for efficiency as well as durability: advances in single-coat powder coating technologies now deliver robust corrosion resistance and enhanced UV durability, with lower material and energy inputs, improving efficiency and supporting sustainability goals simultaneously.
Quantifying sustainability gains: companies are measuring the benefits of reduced replacements, lower energy consumption and minimized waste as part of their ESG and procurement reporting. It is in support of this shift in mindset that we are redefining the role of sustainability in powder coatings to one that empowers businesses to own their impact, and turns sustainability into a catalyst for performance, innovation and measurable results.
High-performance applications: where corrosion protection works hardest
A common theme for manufacturers producing components used in critical infrastructure is the harsh conditions in which these products must perform. For example, many pipes and valves are buried underground, where they must withstand constant exposure to moisture, temperature fluctuations and chemical contaminants, making conditions especially challenging. Robust protection is essential to prevent failures that can disrupt water
supplies, energy systems or transport networks. Some 43% of manufacturers use electroplating to protect steel parts exposed to soil, water, cement and potentially corrosive chemicals. Liquid coatings, including e-coat, also retain a significant share, with 45% of manufacturers opting for this method of corrosion protection. Powder coatings are used by nearly half (48%) of these applications, combining durability with multi-purpose functionality. They are increasingly valued not only for corrosion protection, but also for electrical insulation and thermal management, helping to safeguard electric vehicles and energy storage systems against electrical breakdown and temperature fluctuations.
To meet these requirements, purpose-developed powder coating systems are engineered for long-term reliability. Resicoat powder coatings, for example, have been developed for such applications, delivering high levels of protection to the products our world relies on. For these critical uses, testing and proof of capability are essential and demonstrated in real-world settings.
One such example is a Resicoat powder coating that became one of the first products of its kind to complete a 25-year realworld study, demonstrating its ability to protect valves and fittings used in potable water infrastructure from the damaging effects of corrosion. The independent study, conducted in Bad Bentheim, Germany, found that when the valves were unearthed, they showed no significant signs of corrosion, confirming the integrity of the system had been preserved. By delivering proven long-term protection, these solutions help make water supply systems more reliable while reducing maintenance costs.
Rising importance of sustainability
Across the board, coatings choices are changing. Durability and corrosion protection remain core requirements (54% overall), but sustainability is ascending the priority list.
Some 37% of manufacturers – rising to 42% among manufacturers producing components for these demanding environments –expect environmental performance to be their leading buying criterion in the future, up from 24% today. There is growing demand for coatings that combine robustness with proven sustainability credentials, helping equipment manufacturers own their impact in the eyes of regulators and customers alike.
Modern powders have evolved to meet these demands, by supporting faster production speeds, and lowering material and energy use. Also important is for manufacturers to source coatings that are free from Volatile Organic Compounds (VOCs), and that comply with global drinking water approvals. Within these hardworking industries, extending product lifespans not only serves to protect revenues, reputation and critical infrastructure, but also reduces landfill and the environmental burden associated with increased maintenance cycles.
Alongside these performance benefits, regulatory compliance is becoming an increasingly important part of the sustainability equation. Powder coatings, including advanced solutions such as Resicoat R8, are not only designed to meet current legislation but also to anticipate future regulatory developments, including the European Green Deal. Resicoat R8 is BPA (Bisphenol A) labelling-free, supporting compliance with evolving requirements on substances of concern. This includes REACH Regulation No. 1907/2006, as well as ongoing initiatives from the European Chemicals Agency (ECHA) to reduce migration limits into drinking water.
Powder coatings’ role in hard-working industries
Across all survey respondents, 76% say powder coatings extend product lifespans, while 74% believe they directly reduce environmental impact – figures echoed among manufacturers producing components used in these demanding applications. The benefits are clear:
Outstanding corrosion with proven, long-term performance to support critical gas, water and electricity supplies;
Multi-functional properties offering electrical insulation, thermal management and resistance to extreme environments;
Faster, more efficient application processes;
Documented reductions in energy use and waste, directly supporting sustainability goals;
Free from VOCs, helping to ensure the free flow of clean, safe drinking water.
A common theme for manufacturers producing components used in critical infrastructure is the harsh conditions in which these products must perform. For example, many pipes and valves are buried underground, where they must withstand constant exposure to moisture, temperature fluctuations and chemical contaminants, making conditions especially challenging.
In short, powder coatings now underpin both the practical and strategic needs of manufacturers, helping them outperform competitors and safeguard reputations.
Corrosion protection as a value driver
Corrosion protection is no longer a maintenance issue; it is a strategic business lever that directly affects financial results, customer trust, sustainability performance and credentials. Manufacturers can find new value through improved efficiency, reduced lifecycle emissions, longer equipment lifespans, and greater customer loyalty. Manufacturers can move beyond treating corrosion as a cost to be managed and instead consider protection as a source of long-term value. With innovations such as those found within Resicoat ranges, corrosion protection is evolving from a necessity to a measurable source of competitive advantage and sustainability gains. These technologies help manufacturers truly own their impact.
For deeper insight into how corrosion protection is driving efficiency, resilience, and sustainability, the full AkzoNobel Cost of Corrosion report is available1 ‹
1 interpon.com/insights/cost-of-corrosion-report
THE BREAKDOWN
Digital applications in coating industry
Awadh Al-Gahtani, Nasser Hutilah, Meshari Al-Otaibi, Abdullah Al-Wayel, and Abdulla Al-Issa
Saudi Aramco, Dhahran – Saudi Arabia
Digital applications in the coating industry are reshaping quality control and material management processes, enhancing efficiency, traceability, and compliance with industry standards. This article examines the adoption of digital solutions in oil and gas projects, with a particular focus on environmental data loggers and digital surface cleanliness assessment systems.
Managing quality system during execution of the oil and gas projects is associated with several major challenges like performing inspection and testing activities through a conventional (manual) method. Such practice can’t assure fully compliance and meeting requirements. To overcome and mitigate these challenges, it has been observed that projects are increasingly adopting digital solutions to enhance efficiency, reduce costs, and improve the overall quality of projects.
Digital applications in the coating industry are revolutionizing the field in terms of data-driven solutions, user-friendly usage, and sustainable practices. To be valuable during project execution, the applications shall provide precise measurement, ensuring compliance with industry standards. This article is focusing on two digital solutions which have been successfully deployed in Saudi Aramco projects; environmental data logger and digital surface cleanliness.
Environmental monitoring system of coating materials preservation
Environmental monitoring systems play an important role in controlling the storage conditions of critical project materials, including protective coatings. Such monitoring enables datadriven decision-making, supports regulatory compliance, and improves operational sustainability across industrial sectors [1]. Environmental factors such as temperature, humidity, and exposure conditions are known to significantly influence the physical properties, durability, and degradation behaviour of coating materials and other industrial products [2][3]. Monitoring these variables ensure materials remain within acceptable storage limits, thereby reducing the risk of deterioration and maintaining performance integrity. Furthermore, real-time environmental tracking allows early detection of deviations and enables timely corrective actions, which is essential for preserving material quality throughout storage and handling processes [4].
Conventional environmental monitoring system
The conventional method of environmental monitoring device, shown in Figure 1, provides real-time data at a single point in time. The conventional technology consists of two main components as follows:
Sensors: measure various environmental parameters such as temperature and humidity. They are strategically placed to collect data.
Displayer: environmental monitoring devices are integrated with a built-in displayer, which depicts the real-time data at a single point in a time.
The process of data monitoring in projects utilizing the conventional method of environmental monitoring device is shown in Figure 2. This process starts with measuring required data, such as temperature and relative humidity, as per company standards and manufacturer recommendations. The measured data is then recorded on a paper log, shown in Figure 3, by contractors’ store keeper on a regular basis. The logs are then scanned for record-keeping purposes before finally sharing them with company.
This environmental monitoring technology often faces several challenges. Firstly, it can be time-consuming and labour-intensive. Collecting data manually requires dedicated personnel to monitor regularly. Additionally, human error is a significant concern, such that mistakes can occur during data collection, transcription, and analysis, leading to inaccurate or unreliable results. Manual recording and lack of digital records make it easy to falsify or lose data. Moreover, the conventional method may not provide real-time data. Environmental conditions can change rapidly, and relying on periodic inspections may lead to delayed or outdated information, hindering prompt action when necessary.
Furthermore, the conventional indicators do not provide automatic alerts when measured data deviate from acceptable ranges. Critical temperature or relative humidity excursions may go unnoticed until the next manual check, potentially leading to damage or spoilage of sensitive materials. Conventional indicators also do not facilitate easy data extraction or reporting. Generating reports for audits, regulatory compliance, or internal reviews becomes cumbersome, as it relies on manual logs, which may be inconsistent.
Figure 1 (left) - A photo of the conventional method for environmental monitoring systems.
Figure 2 (right) - Conventional technique for data parameters monitoring.
Figure 3 - Log for temperature and relative humidity.
Environmental data logger
To overcome the challenges encountered during capital project, this paper presents the deployment of a pioneering technology, namely Environmental Data Logger, shown in Figure 4. This smart logger is a specialized cutting-edge technology that continuously records data over a period of time, allowing for detailed analysis and monitoring of data variations. This solution monitors temperature and humidity values of stored critical materials, such as welding consumables, coating materials, and other sensitive equipment. It is equipped with additional features:
Data acquisition: collects the data from the sensors. It may be wired or wireless connections, such as Wi-Fi or Bluetooth, to transmit the data to a central monitoring unit.
Central monitoring unit: receives and processes the data from the sensors. It can be a computer or a dedicated monitoring device. The central unit analyses the data and provides real-time monitoring and alerts.
Data storage and analysis: the system stores the collected data in a database for future analysis to identify patterns, trends, and potential issues. Advanced analytics may be employed to gain insights from the collected data.
Reporting and visualization: the system generates reports and visualizations to present the collected data in a user-friendly format. This helps stakeholders understand the environmental conditions and make informed decisions.
Alarms and notifications: the system can be configured to send alerts, notifications alerts and when certain predefined thresholds are exceeded. An immediate action can be taken if there is any deviation from the desired environmental parameters. Utilizing the smart environmental data logger further enhances the process of data monitoring in company projects as shown in Figure 5
This process starts with measuring required data, such as temperature and relative humidity, then digital, which is recorded by using the digital data logger. The data is then extracted remotely via Wi-Fi. The extracted logs then documented and shared with company in a weekly basis.
The Environmental Data Logger is a specialized cutting-edge technology that continuously records data over a period of time, allowing for detailed analysis and monitoring of data variations. This solution monitors temperature and humidity values of stored critical materials, such as welding consumables, coating materials, and other sensitive equipment.
Figure 4 (left) - Smart environmental data logger [5].
Figure 5 (right) - Data parameters monitoring using smart environmental data logger.
Field trial and results
Field trials were conducted to evaluate the performance of the Environmental Data Logger in comparison with the conventional environmental monitoring technique.
The main objective of this field trial was to assess Smart Environmental Data Logger in data recording, remote monitoring, alarming and notification mechanism and the report exporting. The performance of Smart Environmental Data Logger during trials are summarized in Table 1
Conventional Environmental Data Logger
Data Recording Manual recording Automatic recording
Remote Monitoring
Alarm & Notification
Reports Exporting Paper Digital
Table 1: Comparison of conventional monitoring systems with smart environmental data loggers.
The data logger automated the data logging process as the temperature and humidity readings are recorded and stored in the cloud on certain established intervals. Monitoring of recorded and live data for the data logger was attainable anywhere by accessing to a dashboard. The dashboard showed live data for multiple data loggers installed in one premises connected to the same WLAN. In addition, the dashboard of the data logger highlights data measurements that exceeded the set limits by a red highlight and a notification, and allow for report exporting. This technology activated alarm, emails and SMS, which were automatically shared to registered users once the recorded values exceeded set limits. If temperature or humidity was about to reach the limit value, an initial reminder was sent through email and/or SMS to the recipient, showing the measured value, the set limit value, and the device’s serial number.
Multiple data loggers installed in one premises connected to the same WLAN were integrated and connected to cloud in order to generate summary reports in different formats, which are viewed and configured in the dashboard. One format of a generated report
was in the form of graphical report, which illustrated different identification colours assigned for each installed data logger in different location, while the other format was generated in the form of tabulated data. Automatic reports were regularly generated by the system according to the limit value settings, name of the report, measuring points for the report, and frequency of report specified by the user. Reports of each data loggers were shared through email for registered users.
The manhour saving was calculated based on the inspection manhour spent on reviewing and verifying the data log according to the inspection process shown in Figure 2 and 5 that are required for storage inspection records. Upon utilizing the smart environmental data loggers, the data logs are shared with inspectors on a weekly basis to be verified in office instead of weekly site verification. As a result, this practice saved 50% of inspectors’ manhour spent on data log review.
Conventional surface cleanliness techniques
Surface cleanliness assessment after abrasive blasting is conventionally performed through visual comparison methods using reference photographs provided in international surface preparation standards such as ISO 8501-1 and SSPC-VIS 1. Inspectors evaluate the prepared steel surface by visually comparing its appearance with standardized pictorial representations corresponding to defined cleanliness grades, including Sa2, Sa2½, and Sa3 as shown in Figure 6 [6][7].
Upon utilizing the smart environmental data loggers, the data logs are shared with inspectors on a weekly basis to be verified in office instead of weekly site verification. As a result, this practice saved 50% of inspectors’ manhour spent on data log review.
Visual assessment methods are universally accepted and have been successfully utilized for decades. However, these methods are inherently qualitative and rely mostly on inspector judgment, which may be influenced by experience level, lighting conditions, surface geometry, and even the assessor’s eye sight level as shown in Figure 7. Variability in interpretation becomes more noticeable when surfaces are close to cleanliness grade transition limits, like between Sa2 and Sa2½, and between SA2½ and SA3. In addition, visual inspection provides limited capability for quantifying surface condition or demonstrating repeatability across large blasted areas. Documentation is typically limited to manually filled inspection reports, which may not fully capture localized surface variations. As a result, conservative acceptance decisions are often applied, leading to unnecessary re-blasting, increased abrasive consumption, extended preparation time, and higher overall project costs.
While visual assessment remains the primary acceptance method mandated by standards, these limitations have driven interest in complementary techniques that improve consistency and confidence without altering established inspection criteria.
Digital coating surface cleanliness
Surface cleanliness inspection on piping, pipeline and equipment is a critical activity in company capital projects due to the
aggressive internal and external service environments and longterm performance requirements of protective coating systems. Abrasive blasted steel surfaces are required to comply with defined cleanliness grades of ISO 8501-1 in accordance with company requirements, with inspection conducted prior to coating application as a mandatory quality control check point. Company projects are carried out across multiple geographic regions and operational sites, involving parallel activities by different contractors and inspection teams.
Maintaining consistent inspection outcomes across inspectors, shifts, and locations in these conditions is essential for maintaining quality and long-term asset integrity. Visual inspection remains the primary acceptance method; however, practical challenges are frequently encountered when surfaces approach acceptance thresholds.
Borderline cleanliness conditions can result in differing interpretations between inspectors, leading to repeated blasting cycles and avoidable rework. Such variability contributes to surface preparation inefficiencies and inconsistent documentation across large-scale projects.
To support inspection consistency while maintaining full compliance with existing standards, a quantitative Digital Surface Cleanliness Measuring device was evaluated and implemented as an inspection support instrument.
Figure 6 - ISO 8501-1 and SSPC Vis-1 conventional surface cleanliness measurement [6][7].
Figure 7 - Assessing surface cleanliness by comparison with reference Image.
This device is used to complement visual inspection by providing objective confirmation of surface condition. The use of this device is consistent with ISO/TR 22770, which recognizes analytical colorimetry as a valid supporting method for the assessment of surface preparation grades (Figure 8). The digital surface cleanliness measuring device operates based on analytical colorimetry principles. The instrument captures reflected light from the blasted steel surface and measures the colour parameters which are correlated with the defined visual cleanliness grades of ISO 8501-1. By converting surface appearance into measurable numerical values, the device reduces subjective interpretation and enables accurate and consistent inspection while maintaining compliance with established acceptance criteria. Importantly, these tools do not replace visual inspection or modify acceptance criteria but enhance inspector confidence, documentation quality, and traceability.
Field trial & results
Field trials were conducted to evaluate the performance of a surface cleanliness measuring device under practical abrasive blasting conditions. Steel pipe sections with initial rust grades A and B were prepared using approved blasting procedures to achieve cleanliness levels of Sa2, Sa2½, and Sa3 in accordance with ISO 8501-1 (Figure 9).
Each prepared surface was first assessed through conventional visual inspection by qualified inspectors. Following visual evaluation, the surface cleanliness measuring device was applied directly to the blasted surface, and measurements were taken at multiple locations to assess uniformity and repeatability. The obtained readings were compared with the corresponding visual cleanliness grades.
The results demonstrated full agreement between the cleanliness levels identified through visual inspection and those indicated by the measuring device. This alignment was consistently observed across all tested rust grades and cleanliness levels, including surfaces near grade transition boundaries (Table 2).
Table 2: Test results during one of the field trials.
SL # RUST Grade
Figure 8 (left) - Digital surface cleanliness measuring device.
Figure 9 (right) - Digital surface cleanliness measurement on CS pipe external.
Repeated measurements taken on the same surface produced stable and repeatable results, supporting the suitability of the device for use as a trusted inspection tool. Similar findings regarding repeatability and objectivity of colorimetric surface cleanliness assessment have been reported in prior studies and industry evaluations.
Conclusion
The implementation of smart environmental data logger and digital surface cleanliness technologies align with Saudi Aramco’s strategic objectives of digitalization, automation, environmental sustainability, and circular economy. For data logger, it offers continuous, automated monitoring of environmental conditions, ensuring the integrity of critical materials like coatings and welding consumables and enabling real-time data collection, remote monitoring, and instant alerts.
In parallel, the transition to digital surface cleanliness measurement complements these advancements by offering objective, consistent, and reliable assessments that align with existing visual standards while reducing subjectivity and strengthening documentation. Together, these technologies support a more efficient, transparent, and sustainable approach to material and quality control in capital projects. ‹
The implementation of smart environmental data logger and digital surface cleanliness technologies align with Saudi Aramco’s strategic objectives of digitalization, automation, environmental sustainability, and circular economy.
References
[1] Al-Amri, A.M. (2025) ‘Printed sensors for environmental monitoring: Advancements, challenges, and future directions’, Chemosensors, 13(8), 285. https://doi.org/10.3390/chemosensors13080285
[2] Zhang, Y. et al. (2025) ‘Prediction of coating degradation based on environmental factors–physical property–corrosion failure two-stage machine learning’, npj Materials Degradation, 9, Article 614. https://doi.org/10.1038/s41529-025-00614-6
[3] Kojnoková, T., Nový, F. and Markovičová, L. (2022) ‘The study of chemical and thermal influences of the environment on the degradation of mechanical properties of carbon composite with epoxy resin’, Polymers, 14(16), 3245. https://doi.org/10.3390/ polym14163245
[4] Gomes, G., Silva, L. and Bauer, E. (2025) ‘Hygrothermal analysis of ceramic coating durability under thermal fluctuations on building facades’, Journal of Infrastructure Preservation and Resilience, 6, 7. https://doi.org/10.1186/s43065-024-00115-x
[5] Anaum SA (n.d.) Testo 162-H2. Available at: https://anaum.sa.com/products/testo-162-h2 (Accessed: 17 February 2026).
[6] ISO 8501-1: Preparation of steel substrates before application of paints and related products — Visual assessment of surface cleanliness. ISO, Geneva.
[7] SSPC-VIS 1: Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning. AMPP, Pittsburgh
ROTAIR POWERED IBIX’S BLASTING AND COATING SYSTEM IN THE RESTORATION OF THE
PONTE ARENA BRIDGE
Edited by Rotair Spa Caraglio (Cuneo), Italy info@rotairspa.com
Utilising the MDVN 83 compressor, the IBIX-ROTAIR setup achieved coating removal rates more than twice as fast as a competitive system, delivering a high-performance, on-site solution.
ROTAIR S.p.A., a leading company in the design, manufacture and distribution of advanced portable air compressors, multi-functional dumpers and hydraulic breakers for more than 60 years and a brand of ELGi Equipments Limited, partnered with IBIX Srl, a provider of portable surface blasting and coating technologies, on a major restoration project for the Ponte Arena Bridge in Mazara del Vallo, Sicily. The collaboration supported essential surface preparation and application of protective coatings on the heavily corroded metal structure, with the ROTAIR MDVN 83 compressor ensuring efficient on-site operations.
Founded in Italy, IBIX is a leading developer and manufacturer of technologies for surface blasting, preparation and specialised cleaning. The company provides advanced sandblasting and micro-air-abrasion systems for restoring architectural and historical structures, as well as for industrial coating removal. IBIX also offers cutting-edge surface protection through its flame-spray technology, delivering long-lasting thermoplastic coatings with anti-corrosive, waterproof and chemical-resistant properties.
One of IBIX’s recent projects focused on the restoration of the Ponte Arena Bridge in Mazara del Vallo, Sicily, where the metal structure had suffered severe corrosion after years of exposure to moisture, salt and atmospheric pollutants. Traditional multi-layer liquid coatings offered limited durability and required long curing times, so the challenge was to apply a robust, solvent-free coating directly on-site. Before the new coating could be applied, the old thick paint system had to be removed, requiring a powerful yet mobile air compressor to operate the IBIX 60 HI PRO blasting system.
For this project, IBIX selected the ROTAIR MDVN 83 portable compressor, a compact, high-performance unit capable of delivering stable, dry compressed air. This consistency was essential for both the sandblasting phase of the surface preparation and the subsequent flame-spray coating process, ensuring optimal application quality and reliable results throughout the workflow.
The restoration work began with surface preparation. IBIX 60 Hi PRO system was used to remove rust, old coatings and contaminants, creating the correct surface profile. Next, the surface was preheated with the IBIX Atlantis 4.0 flame-spray system before applying the PHC-A thermoplastic powder. This produced a uniform, durable and impermeable coating layer in a single 900–1000 µm pass, allowing the treated components to be returned to service once cooled.
“IBIX has been working with ROTAIR for more than twenty years, combining compressed air solutions with portable surface treatment and coating technologies. For this project, we have chosen ROTAIR compressors for their reliability, compact design and ability to deliver dry, consistent compressed air, which is essential for both blasting and coating. Their portability allowed us to carry out the entire process directly on the bridge, without any additional infrastructure. With ROTAIR compressors, fixed coating facilities were no longer required, we reduced the application time and were able to enhance the coating’s performance and durability,” said Susanna Giovannini, CEO & Founder at IBIX. In preliminary comparison tests, the combination of the IBIX 60 HI PRO and the ROTAIR MDVN 83 compressor outperformed a competitive, much larger setup, which included a 12,000-litre air compressor and a 200-litre blasting pot.
The IBIX–ROTAIR system was more than twice as fast, removing a 2 mm multi-layer paint system at a rate of 6.6 m² per hour with a 9 mm nozzle while achieving an SA 3 blasting grade, compared with the other system’s 2.4 m² per hour through a 12 mm nozzle. This increased speed enabled surface preparation and coating to be completed in one continuous workflow. Immediate commissioning after coating was also possible thanks to the intrinsic properties of flame-sprayed thermoplastics, which require no curing time. “This project demonstrates how the combined expertise can deliver durable, sustainable and field-ready solutions for infrastructure maintenance. Sustainability is a core principle for ROTAIR, and this project reflects that commitment. The integrated IBIX–ROTAIR system is entirely eco-friendly, with no solvents or harmful emissions, minimal material waste and low energy consumption. The unit’s long-lasting performance also reduces environmental impact by extending maintenance cycles,” said Jacopo Incrisse, Marketing Manager at Rotair.
The MDVN series features compact, ergonomic and durable design, offers lowest acoustic pressure levels required by current legislation, and emissions that are fully compliant with the latest global environmental standards. Each unit is equipped with an integrated after-cooler and condensate filtration system, ensuring a reliable supply of cool, dry air for a wide variety of applications. Designed for maximum usability, the compressors offer easy maintenance access, a centralised control panel for straightforward monitoring, and an intelligent system that prevents starting load on the engine and enables low-pressure shut-down. The “No Key” one-button start, together with an antirepetitiveness system that protects the starter motor, further enhances operational reliability. ‹
New hull cleaning standard ready to ensure cleaner shipping
Edited by CHI Clean Hull Initiative - Norway
Last March, a new ISO standard was published to help port authorities, shipowners and operators navigate rules on how ships should be cleaned in an environmentally sound way. Hull cleaning is gaining traction among shipowners, while countries are increasingly introducing regulations - but many ports still lack practical guidance on how to manage it.
“Biofouling on ships’ hulls can spread invasive aquatic species and damage ecosystems. It also increases drag, reducing a vessel’s efficiency and leading to higher fuel consumption and increased greenhouse gas emissions,” says Irene, Senior Adviser at Bellona. Tvedten is the project manager for the Clean Hull Initiative (CHI) and has led the work on the new ISO-standard known as ISO 6319, titled “Conducting and documenting inwater cleaning of biofouling on ships”.
One of the key solutions for managing biofouling on ships— hull cleaning—can help prevent the spread of invasive aquatic species and reduce greenhouse gas emissions. ISO 6319 supports these practices by ensuring that hull cleaning is carried out responsibly and does not release organisms or chemicals into the environment.
“On Wednesday, 11 March, the standard was finally published, and I’m delighted to share that it is now available for global stakeholders in shipping and ports,” says Tvedten.
ISO 6319 aims to help ports and regulators request documentation from service providers intending to clean ship hulls, making it easier to assess whether the technology used provides adequate environmental protection.
One of the contributors to ISO 6319 was Port Environment Expert at Port of Antwerp-Bruges, Luc Van Espen. He explains that at the Port of Antwerp-Bruges, hull cleaning is permitted as part of the port’s commitment to sustainable shipping.
“An internationally accepted and applied standard creates a level playing field among seaports worldwide, strongly limiting the transfer of invasive alien species from one port to another,” says Van Espen.
Globally, approval procedures vary widely among ports and authorities, creating challenges for shipowners. Wallenius Wilhelmsen, a leading global RoRo operator, was among the shipowners contributing to ISO 6319 and is working to lower fleet emissions through enhanced hull maintenance.
“When applications follow the same structure and technical specifications, ports and authorities can process them more efficiently. For us as a shipping company, this means fewer operational disruptions and greater predictability,” says Senior Manager Kim-Helge Brynjulfsen at Wallenius Wilhelmsen.
Another contributor to ISO 6319 was Jotun, a global leader in marine coatings to tackle biofouling, which also offers a proactive hull-cleaning robot and compatible coatings.
“At Jotun, we find that many ports and authorities lack detailed knowledge about hull cleaning and are often unnecessarily sceptical of cleaning ships. ISO 6319 can help ports assess permits on a case-by-case basis, depending on whether the hull cleaning technology sufficiently protects the environment. There are significant quality differences between hull cleaning systems,” says Petter Korslund, Regulatory Affairs Manager at Jotun, one of the many contributors to the new standard.
“ISO 6319 helps guide approval authorities as to what the actual risks of cleaning are and how to manage and mitigate those risks to the greatest extent possible while promoting the environmentally-sound cleaning of ships.” says Mark Riggio, one of the contributors to ISO 6319, and technical director at BEMA, an organisation consisting of several hull-cleaning service providers.
“In the group developing this standard, competitors have put commercial interests aside and collaborated to set the terms for hull cleaning. I’m truly impressed by their efforts,” says Tvedten. Originally, the standard was initiated by the Clean Hull Initiative, which consists of a range of stakeholders with a shared interest in proactive hull cleaning—meaning sufficiently frequent cleaning to maintain a thin layer of biofouling on the hull. The group produced the original draft four years ago, under the leadership of Bellona.
“Ports and regulators play a key role in enabling or prohibiting hull cleaning. ISO 6319 will help them make informed decisions,” Tvedten concludes. ‹
From left to right: Irene Tvedten, Senior Adviser at Bellona and Project Manager of the Clean Hull Initiative; Luc Van Espen, Port Environment Expert at the Port of Antwerp-Bruges; Kim-Helge Brynjulfsen, Senior Manager at Wallenius Wilhelmsen; Petter Korslund, Regulatory Affairs Manager at Jotun; Mark Riggio, technical director at BEMA.
THE INDUSTRY MEETING
Asia Pacific Maritime 2026 concludes with strong success, driving momentum ahead with continued focus on next energy and technological innovations
The 19th Asia Pacific Maritime (APM) held its largest-ever edition in Singapore, welcoming 19,431 attendees, alongside more than 819 exhibitors from 41 regions/ countries, including 20 pavilions, and 112 speakers from across the globe. Amid the strong turnout, APM saw a significant number of announcements, covering product launches and the inking of partnerships, signalling strong momentum for advancing the industry and underscoring the industry’s unwavering confidence in Asia’s premier maritime event and conference.
Yeow Hui Leng, Group Project Director of APM, said: “The numerous deals and partnerships announced at the event underscore APM’s role beyond that of a maritime marketplace; it also serves as a platform for showcasing best-in-class innovations and setting the stage for solutions that will shape the future of the industry. We thank our partners for their long-standing support and trust in APM as the premier meeting point for global and regional players—one that fosters meaningful dialogue, bold collaboration, and strategic partnerships that will propel the maritime sector to greater heights.”
This year’s event brought together key decision-makers from across Asia, including shipowners and shipyards. Notably, the Indonesian National Shipowners’ Association (INSA) led a delegation of 60 shipowners representing 20 shipping lines. Carmelita Hartoto, Chairwoman of the Indonesian National Shipowners’ Association (INSA), said, “INSA is delighted to be back at APM. As a long-standing partner of APM, we truly value the opportunity for Indonesian shipowners to engage in productive conversations with global solution providers and industry leaders, forge new partnerships, and connect with industry forerunners. I am confident that the connections and insights gained at APM will shape Indonesia’s growing maritime industry and drive innovation in vessel operations.”
A myriad of deals, showcases, and partnerships that focused on driving zero emissions with next energy innovations were announced, including:
Forming of industry partnerships led by VC Power, including collaboration with Bureau Veritas Marine Singapore on promoting battery technology as a practical and sustainable energy solution; with DNV Singapore for joint development of marine battery training programmes; and with Chengrui Power Technology (Shanghai) and Contemporary Amperex Technology Co., Limited to advance marine battery supply and integration.
A collaboration partnership to advance next-generation hybridelectric fleet technology for offshore wind support vessels was signed between Siemens Energy and Marco Polo Shipyard.
Partnership formalised between Bureau Veritas, Beng Hui Marine Electrical, and Penguin International marked the debut of Bureau Veritas’ Type-Approved PWR+ Power Management and Digital Monitoring System on Penguin International’s new series of compact crewboats for the oil and gas industry.
Next energy in focus, driving net-zero resolutions
Amid the delay in adopting IMO’s net-zero framework and the oil and gas trade disruption caused by current geopolitical conflicts, it has become more crucial to empower decision-makers with a broader range of energy sources and more efficient solutions. The focus on next energy at APM 2026 has become an extremely timely conversation. The conference posited that conversations on alternative fuels need to continue to progress, despite uncertainty in formal regulatory adoption, especially given the concerns over energy sovereignty. One message was clear across the various panels – the industry needs to emphasise fuel optionality, because the direction towards net-zero has not changed.
APM 2028: Powered by next energy and technological innovations
Next energy and technological innovations have become strategic necessities in today’s maritime industry. The conversations at the conference saw technology providers, shipowners and industry experts convene to explore practical pathways to enable cleaner and more efficient operations. As the industry continues to balance tighter emissions rules, greater fuel uncertainty, and pressure to build resilient supply chains, APM will return for its 20th edition from 22-24 March 2028, diving deeper into next-generation innovations that drive the future of vessels, the solutions for tomorrow.
www.apmaritime.com
AMPP Italy Chapter announces the 4th Conference & Expo in Genoa titled “Driving innovation into corrosion management”
The AMPP Italy Chapter is proud to announce that its 4th Conference & Expo will be held again at the prestigious Magazzini del Cotone, located in the heart of Genoa’s historic Porto Antico, from 9 to 12 June 2026. This premier international event, dedicated to materials protection, corrosion control, and industrial performance, will bring together the world’s leading experts and industrial professionals to discuss the latest innovations in asset integrity. As the energy transition and industrial digitalization reshape global infrastructure, the conference serves as a high-level platform for sharing knowledge on metallic materials protection.
The Conference will present a thriving exhibition hub and strategic sponsorships: the Expo floor within the Magazzini del Cotone will host toptier players from across the industrial spectrum, and the conference will feature an extensive technical program with over 160 professional presentations. The event will cover a diverse and exhaustive range of critical industry topics, including:
Applied Research on Corrosion in Academia
Automotive Corrosion Challenges
Cathodic Protection & Corrosion Inhibitors
Carbon Capture and Storage (CCS)
Coatings & Linings, Inspection & Monitoring
Corrosion Resistant Alloys and Welding
Corrosion Under Insulation (CUI)
Durability of Reinforced Concrete
Failure Case Studies
Hydrogen Service and Renewable Energies
Microbiologically Influenced Corrosion (MIC)
Sweet and Sour Service.
Major global supporters, including industry giants such as Eni, Saipem, Shell, BP, Total Energies, Equinor, EFC, Enea, EPRG, APCE, AIM, Centro Inox and Edison, have historically recognized this event as a key venue for demonstrating excellence in material performance.
The conference features a robust technical program covering innovative research in corrosion prevention and infrastructure longevity. A highlight is the Student Poster Session, which showcases the next generation of engineering talent to a global audience of professionals and potential employers.
Registration is now open with various tiers:
Full Delegate Registration: Includes access to all sessions, the expo area, and the gala dinner
Speaker & Student Rates: Discounted fees to encourage academic contributions and One-Day Pass (For targeted visits to specific sessions or the exhibition).
For detailed information regarding Fee & Registration, the Technical Program, and to download the Sponsor & Exhibitors’ Prospectus, please visit the official website.
About AMPP Italy Chapter
The AMPP Italy Chapter is a non-profit association dedicated to promoting research and education in the field of corrosion and materials protection, striving to enhance the safety and reliability of infrastructure through professional development.
Registrazione al Tribunale di Monza N° 4 del 26 Marzo 2012 Eos Mktg&Communication srl è iscritta nel Registro degli Operatori di Comunicazione con il numero 19244
POSTE ITALIANE S.P.A. – SPEDIZIONE IN ABBONAMENTO
POSTALE D.L. 353/2003 (CONV. IN L. 27/02/2004 N.46) ART. 1, COMMA 1 LOM/MI/4352
EDITED BY
Eos Mktg&Communication srl
Via Pietro Mascagni, 8 - 20811 Cesano Maderno (MB) - Italy Tel. +39.0362.503215 www.eosmarketing.it - info@eosmarketing.it | www.myipcm.com - info@ipcm.it
EDITORIAL DIRECTOR
Marco Ormellese, Politecnico of Milan
EDITORIAL BOARD
Annalisa Acquesta, University of Naples
Francesco Andreatta, University of Udine
Mehdi Attarchi, Senior Materials & Corrosion Specialist
Andrea Balbo, University of Ferrara
Hadi Beirami, Cathodic Protection Certified Specialist
