An Offshore Repair Revolution for Corrosion Protection

Using wind in offshore environments to capture renewable energy offers great opportunities but places highest demand on corrosion protection due to the exposed locations and the associated mechanical and climatic conditions.

One of the most important protective methods to prolong asset life is the application of corrosion protection coatings, which must have a service life of more than 25 years for the economic use of such offshore wind structures, a time span, which often stretches beyond the duration of protection for conventional coating systems for steel constructions stated in the appliable technical guidelines.

Mechanical influences or abrasion during installation and service can bring about the need for extensive restoration measures. Maintenance and repair work is a challenge as all work must take place in a maritime offshore climate. The difficulties associated with access and handling of chemicals/application process at inconvenient heights/locations on the structure makes on-site repair very challenging.

A sustainable repair system that can be applied offshore therefore necessitates the consideration of complex interrelations such as system operation, on-site-conditions and the monitoring and evaluation of existing protection systems. In addition, specific environmental and safety requirements need to be considered.

Environmental Factors and Their Impacts

Research Project Results in Repair Solution for Corrosion Protection Systems on Offshore Wind Turbines

In the cooperative research project “RepaKorr”, the project partners drew up the basic material-related, technical, conceptual and organizational principles for an “on-site-repair” concept.

The aim was to simplify maintenance and repair work in terms of technical effort, in order to reduce the currently extremely high costs for maintenance of the offshore protective paint systems and accelerate repair work.

The focal point of this intention was an efficient coating material, modified to the key requirements of the project. The Industrial Coatings division of Sika Deutschland GmbH (acquired by Sherwin-Williams in 2022 and now integrated with the Protective & Marine division) led this part of the project and was the sole research partner for the development of this material.

Finally, a new product, Repacor™ SW-1000, resulted from this work, which combines all properties for all durable corrosion protection, especially for repair measures.

Development of Target Emission Reduction, CMR-Free and Solvent-Free Solution Fulfills Project Requirements

With Repacor SW-1000, our research department has been successful in establishing a further element of practical Sika products in our offshore portfolio by means of intensive research work.

The development target of emission reduction, CMR and solvent-free by means of the coordination and evaluation of most modern raw material technologies, led to the fulfilment of the comprehensive project requirements.

• Practically oriented packaging
• Single-layered
• Early resistance to water and curing under water
• Surface tolerant – can be used on many substrates and on many externally sourced coatings
• Corrosion protection at 500 µm as initial coating in shop (ISO 20340)
• Diffusion-tight
• Plate-like shaped glass flakes increase stability
• Impact and abrasion resistant
• Color stability as 2K-PUR top coatings
• Solvent-free, 100 % solids, CMR-free

This is confirmed by successfully passed tests with certificates in accordance to ISO 20340.

ABOUT THE AUTHOR

Dr. Jigar Mistry is a Global Business Manager for the Renewable Energy segment of Sherwin-Williams Protective & Marine and based in Minneapolis, Minnesota. With approximately 20 years of experience in the coatings and chemical industry – both as an educator and a Sherwin-Williams team member – he has specialized in multiple subject matter related to corrosion, coatings performance, asset protection, and coating solutions for the renewable energy sector.  Contact: jigar.mistry@sherwin.com.