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Improved Splash and Tidal Zone Coatings for 40-year Design Life

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Tasked by Industrial Members in the oil, gas and offshore wind energy sector to generate quantitative corrosion rate data for coatings used to protect steel structures and components operating in sea water, TWI has recently completed an extensive study of the performance of thermal spray aluminium (TSA) in laboratory simulated splash and tidal zone conditions.

Based on data generated during the 2½ year programme, a target life of 40 years with little or no maintenance is a realistic goal. Performance of thermal spray coatings was benchmarked against a leading marine organic paint system.

The effect of Al alloying additions (including Mg, Zn, In and Ti) and the use of epoxy, silicone and polyurethane sealants on coating performance was measured. Other data generated during the project included the effect of surface contamination, surface preparation and corrosion exposure on coating adhesion.

This project was sponsored by AVIC BIAM, British Gas, ConocoPhillips, ENI, ExxonMobil, GE Wind Energy, Northern Wind Innovation Programme (NWIP), Petrobras and Single Buoy Mooring. In addition, International Paint, McNulty Offshore, Monitor Coatings and the University of Manchester made notable contributions through NWIP.

More information on the project work scope is available in the Publishable Summary and the results of this project are available to all TWI Industrial Members on a buy-back basis. For further information, please contact Dave Harvey (dave.harvey@twi.co.uk).

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For more information please email:


contactus@twi.co.uk