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Corrosion protection of steel

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.

 

 

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 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.