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Corrosion protection of steel and metal

Corrosion protection of steel and metal as an economic factor

Corrosion causes millions of Euros of damage every year. To protect metallic materials from the effects of the environment and thus from corrosion, it is normally necessary to carry out coating using suitable corrosion protection material (passive corrosion protection). By comparison with the costs resulting from loss of value and operational downtimes, dismantling, etc. that corrosion causes, the costs are very, very low. Anybody who economises on corrosion protection will find out afterwards that this was an expensive false economy; in particular, in the case of structures that are no longer accessible after assembly, like offshore wind turbines.

But it is not just the economic argument that pleads for corrosion protection – safety is also a major issue. Particularly in the case of large steel structures on which people move around, like drilling rigs or bridges, for example, you must ensure that the corrosion protection coating complies with appropriate standards.

Protection from corrosion with the right coating system

Effective corrosion protection of steel and other metals is based on appropriate preparation of the components, e.g. eliminating surface defects like pores in weld seams or rolling faults. It is only possible for modern coatings to protect the metal from corrosion if the surface quality is good.

The coating systems for corrosion protection on offer today often consist of two or more components. To guarantee long-term protection from corrosion, you must pay close attention to careful processing of the corrosion protection material. In addition to correct surface treatment, this includes, for example, observing the correct mixing ratio and potlife and applying the necessary layer thickness.


WIWA coating systems for corrosion protection

The requirements made of corrosion protection coating functions are becoming more and more demanding. People are demanding surfaces that are highly resistant to the environmental, chemical and mechanical effects. Due to the demands of manufacture and space, the shortest possible drying times are expected. Moreover, people expect the coating to be applied in an environmentally friendly way using as little solvent as possible.

Dual- and three-component coating materials and appropriate system technology are the solution to these many and varied requirements. In close cooperation with leading paint manufacturers, WIWA has developed and optimized dual- and three-component application systems.

 

When deciding on the system you want, the most important thing is practical references. WIWA's robust and powerful coating systems for heavy-duty corrosion protection have been used successfully for more than 50 years in shipyards and naval and offshore applications under some of the hardest conditions imaginable. A large number of metal processing firms also use WIWA airless units and dual-component systems for corrosion protection coatings.


WIWA DUOMIX 230 dual-component system for corrosion protection coatings

The WIWA DUOMIX 230 is compact and can be deployed on a versatile basis; it is based on the proven, reliable concept of the DUOMIX 300/333 high-performance dual-component coating plants that are used above all in heavy-duty corrosion protection all over the world. The modular structure yields individual solutions for virtually all areas of application in corrosion protection with industrial painting, structural steel and facility engineering, building protection and naval and offshore applications. 
The DUOMIX concept is economical and environmentally friendly and offers a wide performance range for virtually all low-, medium- and high-viscosity corrosion protection materials.


WIWA DUOMIX 300 and 333 – rational large-surface coating in heavy-duty corrosion protection

The WIWA DUOMIX 300/333 is part of the WIWA dual-component Series for large-surface coatings with corrosion protection material that is tried and tested all over the world. The reliable system concept for dual- and three-component corrosion protection coating materials. The dual-component system combines the flexibility of a variably adjustable dual-component system and the security of a fixed mixing ratio; moreover, it can also be used as a three-component system. The WIWA DUOMIX 300/333 is used all over the word in heavy-duty corrosion protection. Above all, highly viscose, solvent-free dual- or three component materials are processed. The WIWA DUOMIX 300/333 system shows its particular strength with materials that have extremely short potlives. The wide range of accessories that are available, makes possible numerous different equipment options for innovative areas of application within corrosion protection.

The areas of application are pipe and pipeline coating, naval and offshore applications, tank and container engineering, building refurbishing, coating rolling stock and other high-capacity vehicles, building protection and other large-surface coatings like silos, cooling towers and sewage treatment plants, for example.


Corrosion protection in container engineering

75 % of a container's journey is made by ship. On the way, they are subjected to extreme effects and stress due, in particular, to salt water. In the case of damage due to corrosion, the large-scale containers must be ready for use again as quickly as possible. Companies like our customer C. Groenenboom from Holland, take care of this corrosion protection job quickly and exactly. Their 25 staff members carry out steel and metal work including painting. Four WIWA PROFESSIONAL pumps with material flow heaters are used to process single- and dual-component paints and corrosion protection material.


Steel corrosion protection

Peer Stahlbau uses a fully automated steel processing line on an area of several thousand square metres to produce more than 10,000 tonnes annually for industry, plant engineering as well as for building workshops and multi-storey car parks. It goes without saying that corrosion protection also plays a major role. By using modern, efficient coating equipment, like the WIWA PROFESSIONAL 28064, Peer Stahlbau not only offers appropriate corrosion protection but also numerous component colour design options.


Corrosion protection for bridges

The Hafenbahn bridge in Hamburg Harbour is almost 100 years old. Due to the severe corrosion damage, the Hamburg Port Authority decided in 2010 to rebuild the 56 m structure. Initially the new bridge was manufactured in four sections by Stahl- und Brückenbau Niesky GmbH based in Niesky in Saxony.

The corrosion protection coating was carried out by Krebs Beschichtungssysteme GmbH and managed by Dipl.-Ing. Karl Michael Leser. In only one spray process, a layer of ProCoat® 1010 at least 10,000 μm thick was applied to the 6.25 m wide trackbed. The patented dual-component rubber polyurethane corrosion protection material is made mainly from recycled car tyres; it is the only sprayable rubber in the world and can be sprayed vertically and without joints. However, the requirements of the coating system are very high. In this case, with a 75-metre-long hose, the temperature at the nozzle of 42-44 °C required by the manufacturer had to be kept constant. Following comprehensive testing, the WIWA DUOMIX 333 hot spray unit for ProCoat® applications achieved by far the best results. WIWA developed the corrosion protection system in conjunction with dealer André Maass and the Krebs group of companies. A total of 4760 kg of corrosion protection coating material was applied.


Corrosion protection for pipelines

After extraction, natural gas is very wet and thus highly corrosive. Natural gas plants that are run on an economic and ecological basis demand a high-quality and resistant corrosion protection coating. The Ukraine energy supply company NavtoGAZ decided to use a WIWA DUOMIX 230 system for coating their 56“ gas pipes. Every day, the company coated about 20 pipes of up to 12 metres in length with a corrosion protective polyurethane material layer of 1.5 mm in only one spraying process.


Corrosion protection for shipyards and shipbuilders

Amongst others, a number of WIWA PROFESSIONAL pumps are used for a variety of corrosion protection and painting jobs at the Meyer-Werft, for example. In addition to protective surface coating like heavy-duty corrosion protection under water, decorative surface coating in the design of the sterns of luxury liners is becoming more and more important.

Together with the engineers of Volkswerft Stralsund, our dealer André Maass of Hamburg provided optimum technical conditions for effective corrosion protection in shipbuilding. In the system there, the paint is taken from bulk containers and conveyed using a logical paint guidance system from the tapping point via feed pumps directly to the WIWA DUOMIX 333 dual-component system. In the case of a paint change, it is possible to just open or close the ball valves and reset the system to new material.


Corrosion protection for drilling rigs

The latest generation of drilling rig technology for oil and gas production combines highly specialized systems. In addition to the technical workflows of structures like this, corrosion protection is one of the major challenges. Aker Werft Warnemünde uses high-performance WIWA dual-component systems for this task. Rational application of highly viscose, solvent-free and environmentally friendly dual-component corrosion protection coatings has made WIWA the world market leader in this sector. In addition to the largest and most modern shipyards all over the world, the US Navy also works with our innovative dual-component spray technology.


Corrosion protection for naval and offshore applications

It is only possible to run ships, machinery or structural steel elements on a safe and profitable basis if they are protected from corrosion in an optimum way. Under the hard operating conditions that often apply, steel quickly reaches its load limit. Corrosion can above all lead to rust damage, cracks and leaks, which – in a worst case situation – can result in massive environmental damage and financial losses for the operator.

Compromises in corrosion protection negatively affect safety, operability and value retention!

 

WIWA has been supplying national and international shipyards with innovative coating systems which are specially optimized for corrosion protection in shipbuilding and the offshore industry for almost 60 years. To be able to operate complex steel structures like ships or drilling rigs economically and above all safely in the long term, using the right corrosion protection coating before commissioning as well as at refurbishment is of crucial importance.



Corrosion protection of steel at Volkswerft Stralsund

 

"What are the optimum technical conditions for effective corrosion protection in shipbuilding?" Our dealer, André Maass of Hamburg, took a close look and listened carefully to draw up a number of detailed solutions for effective corrosion protection coating of steel together with the Volkswerft engineers. The material chosen for corrosion protection is taken from bulk containers and conveyed using a logical paint guidance system from the tapping point via feed pumps directly to the WIWA DUOMIX 333 dual-component system. In the case of a paint change, it is possible to just open or close the ball valves and reset the system to a new corrosion protection material. Material is heated in each case after after paint distribution so that only two paint heaters are needed (parent and hardener). The complete system is flushed using the centrally operated PROFESSIONAL flushing pump.



Steel corrosion protection using WIWA dual-component technology at the Aker shipyard

 

The latest generation of offshore technology for oil and gas production combines highly specialized systems. In addition to the technical workflows on a gigantic facility like this, steel corrosion protection is one of the major challenges. For this reason, the Aker shipyard of Warnemünde, Germany, uses WIWA high-performance dual-component systems for corrosion protection. Rational application of highly viscose, solvent-free and environmentally friendly dual-component coatings have made WIWA the world market leader in the "heavy-duty corrosion protection" sector and in steel corrosion protection. In addition to the largest and most modern shipyards all over the world, the US Navy also works with our innovative dual-component corrosion protection technology.


Corrosion protection for pipes and pipelines

Supplying energy and water on an uninterrupted basis is a crucial factor in being competitive on the global market. For efficient transportation of oil or gas across long distances in particular, pipelines are the only economically viable solution. However, under the hard operating conditions that often apply, steel quickly reaches its load limit. Inadequate corrosion protection of the steel structure can lead to cracks and leaks, which – in a worst case situation – can result in massive environmental damage and financial losses for the operator. To be able to operate a pipe system like this on an economic basis in the long term, using the right corrosion protection coating before commissioning as well as at refurbishment is of crucial importance.

 

 

Corrosion protection of a 75 km-long steel drinking water pipeline in Nigeria

 

In Nigeria, drinking water was intended to be transported via a pipeline from a reservoir to the capital 75km away. The idea of using prefabricated steel pipes was quickly rejected. It is not possible to transport pipes measuring 3.10 metres in diameter and 12-18 metres long on an economical basis on the rough roads in the bush. For this reason, the government decided to build a factory to manufacture spindle pipes. To provide permanent corrosion protection of the steel and coat the internal pipes, they were first sand-blasted and then coated with an epoxy material in the factory using a WIWA DUOMIX dual-component internal pipe coating system to provide steel corrosion protection. After the pipes were laid, the second step was to carry out corrosion protection coating of the weld seams on-site using a transportable WIWA DUOMIX system. The Nigerian government's confidence in a project of this enormous magnitude is based, amongst other things, on the decades of experience of our engineers and our global references in the field of corrosion protection of steel.

 

 

30,000 m² of coating for corrosion protection of steel pipes

 

Avoiding corrosion and the consequent damage amounting to billions, the efficiency of corrosion protection is only guaranteed by deploying qualified staff members and using the most up-to-date application technologies", according to Axel Kulmer, Project Manager of Tiefenbach Oberflächenschutz based in Duisburg, Germany. In conjunction with his competent and innovative team, he places his trust in the tried and tested WIWA DUOMIX series when it's a question of corrosion protection. For a major contract with Salzgitter Mannesmann Rohrbiegewerke in Mülheim, Germany, the company coats about 30,000 m² of pipe bends for oil and gas pipelines using about 150 t of material. The company processes a solvent-free epoxy material that has a potlife of 120 sec. and a mixing ratio of 1.75: 1 for corrosion protection coating to coat the pipes. A second polyurethane material (with a mixing ratio of 3.5:1) and a potlife of 100 sec. is used for other coating jobs. The two WIWA Duomix 333 systems that are primarily used for heavy-duty corrosion protection and structural steel work, suck the spraying agent out of 200-l barrels and heat it to 70 °C using material flow heaters, drum heating belts and heatable hoses. In one process, a layer thickness of about 1,500 μ is applied using several WIWA 500 spray guns. WIWA systems are ideal for corrosion protection in structural steel work.