• Login
    • Join
  • FOLLOW:
  • Subscribe Free
    • Magazine
    • eNewsletter
    Checkout
    • Magazine
    • News
    • Research
    • Markets & Technologies
    • Raw Materials
    • Top Companies
    • Directories
    • Jobs
    • Events
    • Microsites
    • More
  • Magazine
  • News
  • Research
  • Markets & Technologies
  • Raw Materials
  • Top Companies
  • Directories
  • Jobs
  • Events
  • Microsites
  • Current / Back Issues
    Features
    Business Corner
    Editorial
    Digital Edition
    eNewsletter Archive
    Our Team
    Editorial Guidelines
    Subscribe Now
    Advertise Now
    World Reports
    eBook
    Top Features
    CPMA Celebrates 100 Years of Leadership for the Color Pigments Industry

    Aerospace Coatings Market

    Energy Curing and Coil Coatings

    Lab/Testing Equipment Update

    High Performance and Special Effect Pigments
    Breaking News
    Online Exclusives
    Distributor News
    Financial News
    Paint & Coatings Manufacturer News
    People In the News
    Price Increases
    Product News
    Raw Materials & Equipment
    Video Bites
    Suppliers News
    Live From Shows
    Top News
    RPM to Announce Fiscal 2025 Fourth-Quarter and Year-End Results on July 24, 2025

    Nouryon Earns Awards from Texas Chemical Council and the Texas Chemistry Alliance

    Śnieżka Group Earns Higher Position in ESG Ranking

    SONGWON Appoints New Leader Business Unit Tin Intermediates / PVC

    Cabot Corporation Achieves Platinum Rating from EcoVadis
    Top Companies report
    Market Research
    White Papers / Tech Papers
    Technical Papers
    Product Spec Sheets
    World Reports
    Adhesives and Sealants
    Aerospace Coatings
    Architectural Coatings
    Automotive Coatings
    Automotive Refinish
    Business Operation
    Color Trends & Forecast
    Construction Chemicals
    Corrosion Control
    Industrial Coatings
    Laboratory Equipment
    Marine Coatings
    Market Trends & Forecast
    Powder Coatings
    Production Equipment
    Radcure Coatings
    Special Purpose Coatings
    Wood Coatings
    "Green" Coatings

    ROSS Introduces Custom Coaxial Mixer for Complex Formulations

    AkzoNobel Vehicle Refinishes, Solera to Enable Data-Driven Sustainability

    PPG Revitalizes School in France as Part of COLORFUL COMMUNITIES 10-year Celebration

    Jotun Joins RightShip’s Zero Harm Innovation Partners Program

    Tnemec Launches New Waterborne Epoxy Products
    Additives
    Binders
    Pigments
    Solvents

    Safic Alcan to Distribute Evonik Functional Silanes in Central Eastern Europe

    CPMA Celebrates 100 Years of Leadership for the Color Pigments Industry

    Orion S.A. Earns 10 Safety Awards from ICBA

    OXERRA Expands Augusta Facility to Enhance U.S. Distribution Capabilities

    Münzing Expands U.S. Operations with New Production Facility in South Carolina
    Company Capabilities
    Buyers Guide
    Distributor Guide
    Add New Company
    International Buyers Guide Companies
    Siltech Corporation

    Vibrantz Technologies

    Patcham USA

    WAB US Corp

    Shepherd Color Company, The
    Industry Events
    Webinars
    Live From Show Event
    Top Events
    ABRAFATI SHOW 2025

    Paint Bangladesh 2025

    Paint Expo Eurasia

    CEPE Annual Conference

    Western Coatings Show
    Companies
    White Papers/Tech Papers
    Product Spec Sheets
    Equipment
    Literature/Brochures
    Videos
    International Buyers Guide Companies
    Siltech Corporation

    Vibrantz Technologies

    Patcham USA

    WAB US Corp

    Shepherd Color Company, The
    • Magazine
      • Current / Back Issues
      • Features
      • Editorial
      • Business Corner
      • Digital Edition
      • eNewsletter Archive
      • Editorial Guidelines
      • Subscribe Now
      • Advertise Now
    • Breaking News
    • Directories
      • Buyers Guide
      • Distributor Guide
      • Corporate Capabilities
      • Trade Associations
      • Add Your Company
    • Markets & Technologies
      • Adhesives and Sealants
      • Aerospace Coatings
      • Architectural Coatings
      • Automotive Coatings
      • Automotive Refinish
      • Business Operation
      • Color Trends & Forecast
      • Construction Chemicals
      • Corrosion Control
      • Industrial Coatings
      • Laboratory Equipment
      • Marine Coatings
      • Market Trends & Forecast
      • Powder Coatings
      • Production Equipment
      • Radcure Coatings
      • Special Purpose Coatings
      • Wood Coatings
      • "Green" Coatings
    • Raw Materials
      • Additives
      • Binders
      • Pigments
      • Solvents
    • World Reports
      • Africa Report
      • China Report
      • India/Asia Pacific Report
      • Europe Report
      • Latin America Report
      • Market Research
      • Russian Report
    • Top Companies
    • Online Exclusives
    • Glossary
    • Slideshows
    • Experts Opinions
    • Blog
    • eBook
    • Infographics
    • Videos
    • Podcasts
    • Whitepapers
    • Jobs
    • Microsites
      • Companies
      • White Papers/Tech Papers
      • Product Spec Sheets
      • Equipment
      • Literature/Brochures
      • Videos
    • Events
      • Industry Events
      • Live From Show Event
      • Webinars
    • About Us
      • About Us
      • Contact Us
      • Advertise With Us
      • Privacy Policy
      • Terms of Use
    Features

    Protecting Your Assets in Challenging Environments

    A focus on enhancing operational efficiencies galvanizes change for protective coatings.

    Protecting Your Assets in Challenging Environments
    Protecting Your Assets in Challenging Environments
    Klaus Moeller, Group Vice President and Stefan Olsen, Fouling Release Systems Manager, R&D, Hempel A/S11.09.16
    Klaus Moeller, Group Vice President and Stefan Olsen, Fouling Release Systems Manager, R&D, Hempel A/S
    Global seaborne trade continues to grow despite the current economic difficulties facing many trading nations. But it has been the shipping industry that has felt the pinch most significantly. Thin margins are forcing vessel operators to search for efficiencies at every turn, which has encouraged owners and operators alike to carefully scrutinize every aspect of their operations.  Using innovative hull coatings to save on fuel costs has been a major focus in recent years; the result is that owners and operators now look more strategically at the coatings they use as a tool to increase operational efficiency.

    Like shipping, the offshore sector is not faring well in light of continuing low oil prices. Therefore, operators of complex steel structures in the offshore environment, such as oil and gas installations, must carefully consider their choice of protective coating as a tool to manage operating and maintenance costs and, therefore, enhance profitability.  

    Developing highly complex and technologically advanced protective coatings that deliver the required efficiencies to these specialized market segments raises a number of technical challenges for coatings providers.

    Above the Waterline

    Offshore structures are permanently exposed to highly saline and corrosive conditions along with extremes of temperature and physical stress; these factors present a unique set of challenges for the coatings industry. Traditionally, inorganic zinc-rich coatings (IOZs) such as zinc silicates have been the preferred primers for these environments because of their enhanced anti-corrosive properties, with zinc epoxy coatings taking a back seat. However, while IOZs exhibit superior anti-corrosion properties, they tend to suffer from low mechanical strength and require specific conditions for application. Because of this, an increasing number of offshore installation operators are choosing a zinc epoxy instead. But the problem here is that zinc epoxies require a more regular re-coat which usually means taking the asset out of service. Each system, therefore, has its limitations. 

    In both zinc silicates and zinc epoxies, the zinc acts as the sacrificial element and corrodes instead of the iron to leave the steel intact. This process - known as the galvanic effect - only works if the zinc primer is able to transfer galvanic current. In general, a normal zinc coating is around 60-80 microns thick but it is only the first 20-30 microns of a traditional zinc epoxy coating that delivers the galvanic protection. The epoxy resin insulates the zinc particles causing them to lose their galvanic properties. Even at high zinc loads, around 80% of the zinc is too far away from the point of corrosion for it to be of any use.

    Activated Zinc

    As a coatings specialist, our challenge has been to activate more of the zinc to improve the galvanic effect of the coating without increasing the actual zinc content itself. Doing this ensures that the zinc throughout the film is delivering anti-corrosion protection. Our solution was to introduce two new substances into the primer - hollow glass spheres and a proprietary activator. The combination of these new items, together with the optimum mix of binders, pigments, fillers and additives ensures that the zinc is activated throughout the coating.

    In general, traditional zinc coatings are porous and so offer little resistance to water. But with our new coating, as well as significantly enhancing the galvanic effect, we also found that our new activated zinc primer had a lower water permeability. Once the zinc becomes activated, the resistance to water is increased as it forms a layer of insoluble salts on the surface and within the film – the barrier effect. The benefits of such a barrier within the marine environment – where an installation is permanently immersed in water – are significant and can provide additional protection over the lifespan of the installation.

    It’s also important to note that water is not the only destructive force for installations operating offshore. In particularly aggressive saltwater environments, chloride ions will penetrate a protective coating to cause pitting corrosion. Our coating effectively captures these chloride ions by forming chloride-containing salts around the hollow glass spheres. This significantly delays the corrosive process as the chloride ions are trapped within the coating and prevented from reaching the steel surface – the inhibitor effect.

    Avantguard Technology

    These innovations have been captured in a new Hempel coating technology called Avantguard. This has, in our view, redefined anti-corrosion coatings as Avantguard delivers a triple protection. It exhibits greater galvanic activity by increasing the activation of the zinc; it creates an inorganic salt barrier against water and other corrosive species; and it acts as a chloride scavenger by capturing chloride ions.

    Offshore structures are often exposed to severe mechanical stress and fluctuations in temperature which can cause a zinc primer to crack as the steel contracts and expands. The new Avantguard technology compensates for this through its unique self-healing properties. The hollow glass spheres within the primer absorb much of the energy from the cracking process to prevent initial cracks from widening and developing. In addition, the sub products formed by the zinc activation process will occupy the space left by micro-cracks and prevent them from developing into something more serious. This significantly reduces rust creep and ensures that the coating maintains its anti-corrosive performance for much longer. 

    In terms of the application process, an Avantguard coating may be applied at high temperatures and levels of humidity without blistering. And, with a re-coat interval of one hour at 20 °C, it is 50 percent quicker to dry than most zinc-rich epoxy primers at similar temperatures. Its high dry film thickness is not susceptible to cracking which means that operators needn’t be overly concerned when applying to welds or in corners where over-application tends to occur.

    Efficiency Gains

    The advantages of utilizing this innovative technology in aggressive environments are significant. Owners of offshore structures can increase the lifetime of their assets and reduce maintenance requirements and costs. This is particularly relevant for hard-to-access areas that require a shut-down to maintain. For contractors, having confidence in their choice of coating allows them to offer enhanced warranties for the equipment and structures they supply.  Avantguard’s wide tolerance allows contactors to touch-up and repair a coating on site. For fabricators, Avantguard is easier to apply than other similar primers and enjoys a shorter re-coat interval which improves speed and efficiency. All in all, this new technology has redefined anti-corrosion coatings by reducing rust creep, enhancing resistance to corrosion, improving crack resistance and heightening tolerance to varying climatic conditions.

    Below the Waterline

    Ship owners are keen for their vessels to maintain a smooth and foul-free hull. Fouling increases the drag of the hull which, in turn, increases the fuel consumption and associated harmful emission. The right coating keeps the hull smooth thus minimizing the need for cleaning operations or premature docking of the ship.

    The antifouling market is dominated by conventional antifouling coatings that rely on biocides to control hull fouling. This is traditionally achieved by the addition of cuprous oxide as a pigment, combined with organic co-biocides, in order to deliver the required biocide activity to fight off the entire span of marine-based biofouling organisms. Conversely, fouling release systems are generally biocide-free. They are based on polydimethylsiloxane, known as PDMS or silicone, that minimizes the strength of adhesion of the fouling organism, allowing for release during the operation of the vessel. The problem here is that PDMS coatings have limited effect at low operating speeds. This is particularly relevant in today’s market where ships can be idle for longer periods or are steaming more slowly to save on fuel costs.  

    Resistance to Fouling

    The way around this is to combine a PDMS coating with a hydrogel to deliver improved resistance at slower speeds or when the vessel is idle. A hydrogel is a layer of water trapped in or around a network of hydrophilic polymers. An organism wanting to attach to a hydrogel-covered hull will first need to recognize if the surface is suitable for settlement. As the hull is covered in bound water, most organisms will simply not recognize it as a suitable surface and find a home elsewhere. A water bound surface will also require the organism to expel the water before it can apply its own adhesive direct to the hull, and most organisms don’t have the energy to do this.

    Actiguard Technology

    Moving the concept on, we are now combining the hydrogel layer with biocide to form a biocide-activated hydrogel layer – a technology called Actiguard®. Here, the hydrogel traps the biocide during its diffusion out of the film and this increases the surface concentration of biocide. It thereby prolongs the retention of biocide on the surface enabling Actiguard to remain extremely effective with lower amounts of biocide. Because of this, an Actiguard coating is able to release biocide in a stable and controlled manner for vessel speeds (or currents) exceeding 0.1 knot and upwards. This is significant for a ship owner as it means the hull remains protected even when the vessel is idle, or is slow steaming. From an environmental perspective, the stable release of biocide irrespective of speed means that less biocide is released into the oceans when travelling at higher speeds.

    The efficient use of biocides allows for a very low pigment and filler volume concentration; they also enjoy a low VOC content. 

    Low biocide content also ensures the coating is smooth after application, which is important for a vessel to maximize its fuel efficiency and, therefore, reduce operating costs. Even if the hull suffers scratching, Actiguard offers a window of defense and tests have shown that Actiguard coatings will retain their protection levels for at least 22 months when scratched.

    Performance Consistency

    Efficiency is paramount in the current shipping markets and tests of Actiguard technology show that its fouling defense properties remain effective for vessels that switch from slow to fast steaming and that remain idle for periods up to 120 days. This is particularly interesting for larger container vessels and tankers that, for example, may wish to increase speed on one route to meet schedules and slow steam on the other to achieve extra fuel savings. It also means an operator can lay up a vessel for up to four months without having to clean the hull.  Additionally, fuel savings of 6 percent on average, across the entire docking interval, have been achieved which is significantly higher than conventional self-polishing technologies. Further efficiencies are gained due to the extended re-coating interval which reduces the time a vessel spends in dry-dock.

    Galvanizing Change

    Tough markets and challenging physical conditions are encouraging those who operate in such environments to demand more from their coatings provider. This provides an opportunity to push harder and develop ever more sophisticated coatings solutions for the benefit of our customers, and the environments in which they operate. Contemporary coatings must offer the highest levels of protection as well as opportunities to enhance efficiencies and control costs. In turn, as coatings providers, we can play a significant role in helping our customers develop their operational capabilities. A heavy investment in continued R&D will pay dividends in both quarters, and we will all benefit from the ripples of change.
    Suggested For You
    Protective Coatings Leader Hempel Brings Expertise to the Wind Industry Protective Coatings Leader Hempel Brings Expertise to the Wind Industry
    PPG Introduces New SIGMA SAILADVANCE NX Marine Coating PPG Introduces New SIGMA SAILADVANCE NX Marine Coating
    European Anti-corrosion Coatings Market to Grow to $4.5 Billion by 2027: Graphical Research European Anti-corrosion Coatings Market to Grow to $4.5 Billion by 2027: Graphical Research
    PPG Launches AUE-20 OEM 2.1 VOC Clearcoat for Heavy-duty Applications PPG Launches AUE-20 OEM 2.1 VOC Clearcoat for Heavy-duty Applications
    Coatings World CEO Forum Part 2 Coatings World CEO Forum Part 2
    Automotive OEM Coatings Automotive OEM Coatings
    Hempel Announces Global Price Increase Hempel Announces Global Price Increase
    Vink Chemicals Offers parmetol PSG Vink Chemicals Offers parmetol PSG
    Pigment Supplier Directory Pigment Supplier Directory
    Hempel Launches Re-formulated Antifouling Technology Hempel Launches Re-formulated Antifouling Technology
    Sherwin-Williams Announces 2020 Water, Wastewater Impact Award Winners Sherwin-Williams Announces 2020 Water, Wastewater Impact Award Winners
    PPG Seeks EPA Approval for Antiviral Paint Containing Corning Technology PPG Seeks EPA Approval for Antiviral Paint Containing Corning Technology
    Allegiant Stadium Kicks off with PPG Coatings Allegiant Stadium Kicks off with PPG Coatings
    Pigment Supplier Directory Pigment Supplier Directory
    Duralar Announces Ultra-Hard, Permanent Dry-Lubricant Coating for Metal Parts: ArmorLube Duralar Announces Ultra-Hard, Permanent Dry-Lubricant Coating for Metal Parts: ArmorLube

    Related Online Exclusives

    • Industrial Coatings | Paint & Coatings Manufacturer News
      Protective Coatings Leader Hempel Brings Expertise to the Wind Industry

      Protective Coatings Leader Hempel Brings Expertise to the Wind Industry

      Protective coatings provide the durability needed to ensure that wind turbines play their part in a sustainable future.
      09.22.21

    • Breaking News | Marine Coatings | Product news
      PPG Introduces New SIGMA SAILADVANCE NX Marine Coating

      PPG Introduces New SIGMA SAILADVANCE NX Marine Coating

      SIGMA SAILADVANCE NX coating delivers significant antifouling technology breakthrough.
      09.07.21

    • Breaking News | Market Reports
      European Anti-corrosion Coatings Market to Grow to $4.5 Billion by 2027: Graphical Research

      European Anti-corrosion Coatings Market to Grow to $4.5 Billion by 2027: Graphical Research

      Epoxy coatings emerged as a dominant segment, with more than 42% of the industry share during 2020.
      08.06.21


    • Breaking News | Industrial Coatings | Product news | Special Purpose Coatings
      PPG Launches AUE-20 OEM 2.1 VOC Clearcoat for Heavy-duty Applications

      PPG Launches AUE-20 OEM 2.1 VOC Clearcoat for Heavy-duty Applications

      The addition of PPG AUE-20 OEM 2.1 Clearcoat enables PPG to offer a complete low-VOC system for targeted customers.
      06.17.21

    • Breaking News
      Coatings World CEO Forum Part 2

      Coatings World CEO Forum Part 2

      Coatings World’s 2021 CEO Forum features executives from nine coatings companies offering their insights on the state of the industry.
      Kerry Pianoforte, Editor 04.05.21

    Loading, Please Wait..
    Breaking News
    • RPM to Announce Fiscal 2025 Fourth-Quarter and Year-End Results on July 24, 2025
    • Nouryon Earns Awards from Texas Chemical Council and the Texas Chemistry Alliance
    • Śnieżka Group Earns Higher Position in ESG Ranking
    • SONGWON Appoints New Leader Business Unit Tin Intermediates / PVC
    • Cabot Corporation Achieves Platinum Rating from EcoVadis
    View Breaking News >
    CURRENT ISSUE

    May/June 2025

    • Aerospace Coatings Market
    • Energy Curing and Coil Coatings
    • Lab/Testing Equipment Update
    • High Performance and Special Effect Pigments
    • View More >

    Cookies help us to provide you with an excellent service. By using our website, you declare yourself in agreement with our use of cookies.
    You can obtain detailed information about the use of cookies on our website by clicking on "More information”.

    • About Us
    • Privacy Policy
    • Terms And Conditions
    • Contact Us

    follow us

    Subscribe

    Latest Breaking News From Nutraceuticals World

    Gattefossé Opens New Facilities in Mumbai, India
    TSI Group Unveils myHMB + Vitamin D Logo
    Indena to Showcase Metabolic, Brain Health Solutions at In-Vitality 2024

    Latest Breaking News From Coatings World

    RPM to Announce Fiscal 2025 Fourth-Quarter and Year-End Results on July 24, 2025
    Nouryon Earns Awards from Texas Chemical Council and the Texas Chemistry Alliance
    Śnieżka Group Earns Higher Position in ESG Ranking

    Latest Breaking News From Medical Product Outsourcing

    StimLabs's Umbilical Cord-Derived Wound Care Product Released in U.S.
    New Medical-Grade Bio-Based PVC Compounds Introduced
    Croívalve Reports 1st Tricuspid Coaptation Valve Implant in U.S. Feasibility Study

    Latest Breaking News From Contract Pharma

    Neurocrine Bioscience’s CRENESSITY Becomes Commercially Available in the U.S.
    Roche's Parkinson's Disease Drug Misses Primary Endpoint
    PTC Therapeutics Submits Vantiquinone NDA to FDA

    Latest Breaking News From Beauty Packaging

    Weekly Recap: Coty Sells SKKN, Henkel Recall, Awards, & More
    Rare Beauty to Host Pop-Up Event with Sephora UK
    Cloud Haircare Expands to Walmart Stores Nationwide

    Latest Breaking News From Happi

    Cosmetify Names Nikkie de Jager the World’s Most Powerful Beauty Influencer
    Big Lips in the Small Wonder
    L’Oréal’s Bioprinted Skin & Dove’s Deodorant Launch

    Latest Breaking News From Ink World

    BCF Sponsors Parliamentary Event to Engage with Policymakers
    Weekly Recap: DIC Corporation, BASF, Toyo Printing Inks Top This Week’s Stories
    INX International Launches Innova Plus NCF Nitrocellulose-Free Inks

    Latest Breaking News From Label & Narrow Web

    Mexico's Flexopolis adds second Bobst flexo press
    Paramount Labels installs Rotatek Brava 450
    Esko teams with Bobst for smartGRAVURE System

    Latest Breaking News From Nonwovens Industry

    Harper Hygienics Introduces Microbiome Care Baby Wipes
    Drylock Technologies Offers Packaging Breakthrough
    Premier Care Industries Expands Manufacturing Operations

    Latest Breaking News From Orthopedic Design & Technology

    David Thordarson Takes Charge of American Orthopaedic Foot & Ankle Society
    UPM Biomedicals Launches FibGel Injectable Nanocellulose Hydrogel for Medical Devices
    ONWARD Medical Attracts €50 Million in Capital

    Latest Breaking News From Printed Electronics Now

    Weekly Recap: DuPont, SEMI, Sun Chemical Top This Week’s Stories
    ORNL’s 3D-Printed Metal Molds Poised to Accelerate US Auto Manufacturing
    SRI, NSIC are Catalyzing Corporate Innovation in Japan

    Copyright © 2025 Rodman Media. All rights reserved. Use of this constitutes acceptance of our privacy policy The material on this site may not be reproduced, distributed, transmitted, or otherwise used, except with the prior written permission of Rodman Media.

    AD BLOCKER DETECTED

    Our website is made possible by displaying online advertisements to our visitors.
    Please consider supporting us by disabling your ad blocker.


    FREE SUBSCRIPTION Already a subscriber? Login