INSIDE: PENGERANG TERMINAL | MAGNI | MELBOURNE STAR | TRAVEL SAFETY BOOSTED | TERMINAL CAPACITY | INDUSTRY EXCELLENCE
WWW.INTERNATIONAL-PC.COM ISSUETWENTYFIVE2014
Discover
what the new Intercure range
can do for your process
The new Intercure® range from AkzoNobel’s International® brand is suitable
for a range of assets including wind towers, gas turbines and auxiliary
equipment, transformers and a variety of other power OEM equipment.
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Contents
Fast curing properties
High volume solids
Products available with a wide range of dry film thicknesses
Low levels of volatile organic compound (VOC) emissions
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Movement is an essential part of life; it is the movement of people,
goods and services that have driven us to the modern age we live in.
In this edition of surfaces we start our movement around the world in
The Netherlands at the redeveloped Rotterdam Centraal Station. This
stunning railway terminal facilitates the movement of over 110,000
people every day; we take a closer look at the redevelopment and the
role protective coatings and intumescent fire protection have played in
keeping the station looking its best as well as safe for all its commuters.
Malaysia’s Pengerang
Independent Terminal
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Material Handlers
Receive the
Ultimate Lift
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Australia’s Newest
Icon
8
Travel Safety
Boosted
10
Terminal Capacity
12
Supporting Industry
Excellence
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The raw materials we use on a daily basis are rarely located where they are put to their ultimate
use, transported vast distances they then have to be stored safely before moving to their final
destinations. The Pengerang oil and gas terminal in Malaysia and the VTT Vasiliko Ltd (VTTV) oil
storage capacity terminal in Cyprus (featured on the front cover) are two examples of this. These
terminals are in constant service ensuring we can keep moving 24/7; protective coatings play a key
role in keeping these facilities protected and in service.
It can be argued that the most important invention in keeping us moving is the humble wheel. It
is this simple circular structure that has kept us moving forward for over 5,500 years but now we
put it to use not only out of necessity but for our leisure as well. The Melbourne Star Observation
Wheel, one of only four giant observation wheels in the world, towering 120 meters (394 feet) it is
the newest edition to the Melbourne skyline. Given its imposing position and the part it will play in
Melbourne’s leisure and tourism industry, it is essential that it not only looks good but that it keeps
on moving for years to come, we find out about the role protective coatings play in this iconic
structure.
Whether it is protecting forklift trucks in Italy or leading the industry in training standards we keep
moving forward and we have it covered in this latest edition of surfaces.
New Intercure Polyaspartic Based
Coatings Launched in Europe
Editor:
Amanda Rouse
Managing Editor:
Stuart Byers
Publisher:
AkzoNobel
Contact:
[email protected]
www.international-pc.com
3
Malaysia’s Pengerang
Independent
Terminal
International
is Now
Coatings
Operational
Used for
®
Premier
Terminal Project
Both
private
and
government
investments made into emerging
global economies are helping even the
smallest countries stake a claim in the
worldwide oil and gas industry. Casein-point is the burgeoning Pengerang
Integrated Petroleum Complex (PIPC)
development, located in Pengerang a
small town located on the southern
tip of Johor, Malaysia.
The PIPC sits on over 20,000 acres of land
and is expected to play a major role in creating
value to the downstream oil and gas value chain
throughout the Asia Pacific region. Some have
described the development as the ‘Rotterdam
of the East,’ following in the footsteps of the
famous Dutch port as the largest refinery
and petrochemical port on the globe; even
competing with the capabilities of Singapore’s oil
and gas hub. The PIPC will incorporate the latest
and most innovative technologies and expertise
from Singapore and Rotterdam into the overall
design of this new hub. When completed, the
development will house oil refineries, naphtha
crackers, petrochemical plants, as well as a
liquefied natural gas (LNG) import terminal and
a regasification plant.
PIPC currently consists of two major catalytic
projects namely Pengerang Terminal which
is a development by Dialog Group Berhad
and PETRONAS’s development known as
Pengerang Integrated Complex.
Pengerang Terminal is built on 500 acres of
reclaimed land and Phase 1 of Pengerang
Terminal is jointly developed by a joint venture
between Dialog Group Berhad of Malaysia,
Royal Vopak of Netherlands and the Johor State
Secretary Incorporated. Phase 1 of Pengerang
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Terminal which consists of Phase 1A, 1B and
1C began construction in early October 2011. It
will have 57 storage tanks with a total capacity
of 1.3 million m3 (45,909,067 ft3) for the storage
of liquid petroleum and crude products. Phase
1A is already in operations while Phase 1B
was completed in mid 2014 and Phase 1C is
expected to be completed by the end of 2014.
AkzoNobel was one of several paint
manufacturers being considered for the
coatings contract. A total of 975,500 m2
(10.5 million ft2) of steel piping, support
structures, and internal and external storage
tanks would need to be lined and coated.
The project’s strict coatings specifications
required rigorous demonstration by each
manufacturer as to their lining system’s ability
to meet environmental compliance, fast and
efficient application, and long-term durability
and anticorrosion protection standards.
A dedicated research team based at AkzoNobel’s
International® tank coatings laboratory in
Felling, UK, conducted extensive testing of
the recommended tank linings to provide
the performance data and coatings samples
needed for the field team to back up the
brand’s product claims. The Interline® 399 and
Interline® 850 tank linings were particularly
chosen for their well-established global presence
and performance track record in the tank linings
arena. After careful scrutiny, the Dialog E & C
awarded AkzoNobel the contract in June 2012.
A range of International® coatings are being
used for the premiere terminal project. In all,
approximately 500,000 liters (109,985 gal) of
protective coatings and an additional 100,000
liters (21,997 gal) of tank linings will protect
external tanks, piping and external structures,
as well as internal tanks at ambient temperature
and internal tanks with higher heat temperatures.
According to Kevin Chan, Sales Manager,
Malaysia for AkzoNobel Protective Coatings,
“the relationship between Dialog E & C and
AkzoNobel flourished during the bid process
and has continued throughout the project.
Due to a very tight construction schedule,
we needed an innovative coatings solution
to help speed up the application process.
By introducing the Interline® direct-to-metal
system, paint crews could significantly reduce
on-site equipment usage and application time.
As a result, the tanks were completed ahead of
schedule in March 2014; just in time to receive
the first ship delivery.”
The remainder of Phase 1 of the Pengerang
Terminal is scheduled for completion by the end
of 2014, with additional projects to begin as
early as 2015.
Mr Chong Chong Wooi, the Project Director
from Dialog E & C concludes:
“
Pengerang Terminal is central
to the entire PIPC master plan
and the International® coatings
and linings systems have given
us confidence that our equipment
assets will be well protected for
many years. The high level of
technical expertise, NACE training
and community support AkzoNobel
provided were especially valuable
and we look forward to working
together in other future projects.
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”
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For Magni Telescopic Handlers, it is only fitting that stateof-the-art telescopic forklift trucks and handlers should
receive a state-of-the-art coatings package. That’s
why the Italian original equipment manufacturer (OEM)
conducted a search in 2013 to find a protective coatings
supplier who could not only provide technically advanced
coatings with high durability and aesthetics to match their
own high standards, but who could also help reduce time
and operational costs during the manufacturing process.
Although Magni’s brand new, ultra-modern 6,000 m² (64,584 ft²)
Modena province facility was completed in 2012, the family’s
entrepreneurial metal-working legacy began in the 1950s with
founder and patriarch, Pietro Magni. By 1972, Magni had designed
and manufactured continental Europe’s first telescopic fork lifts with
patented boom. Magni’s son, Riccardo, succeeded his father in
1981 and grew the business globally where today he holds more
than 40 national and international patents for his own innovative
rotating and non-rotating telehandler inventions. With the completion
of the new plant, the Magni enterprise was now ready to partner
with a reputable coatings supplier for a new generation of telescopic
handlers that offer superior operational safety and performance.
That’s when Magni turned to AkzoNobel for a coatings
recommendation to match their strict specifications. Given
Magni’s long-term durability needs, AkzoNobel’s local
distributor, Colorline Srl of Reggio Emilia, Italy, enlisted the
help of AkzoNobel’s local International® coatings sales and
technical team to identify an appropriate anticorrosive coatings
solution. The recommendation included a two coat system of
Intergard® 3210 from the International® protective coatings
range which was then topcoated with Autocoat BT from
AkzoNobel’s Sikkens vehicle refinishes range, for the material
handling telescopic booms. For the equipment’s chassis, one
coat of Interthane® 1070 acrylic polyurethane primer/finish from
the International® range was recommended. Colorline worked
diligently with AkzoNobel to supply the OEM with supporting
test data and on-site technical support.
Magni’s Purchasing Manager, Enrico Artoni, commented,
“AkzoNobel’s coatings products were the perfect match with
Magni’s high quality standards. Through this partnership, we
now have easy turn-key access to the products, service and
technical support we need for our premier vehicles.”
“The coatings system is also helping Magni save time and
operational costs during the production of a large number of
units annually. The high solids, fast drying Intergard® 3210 epoxy
primer actually reduces paint consumption per square meter
and along with the Interthane® 1070 acrylic polyurethane primer/
finish, we are able to deliver faster throughput.”, added Simone
Mazzoli, AkzoNobel’s local International® sales representative.
AkzoNobel’s OEM Business Development Manager, Emre
Karapinar said, “Our local sales network and customer
focused approach was instrumental in helping deliver value
and cooperation between the Protective Coatings and Vehicle
Refinishes teams, providing one solution from AkzoNobel and a
winning solution for Magni. We are very pleased to be the sole
coatings provider for an OEM of this caliber.”
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7
Australia’s
Newest Icon
s the capital of the state of Victoria and
second most populous city in Australia,
A
the vibrant and colorful city of Melbourne
is attracting locals and tourists alike to
its newest tourism and entertainment
attraction; the Melbourne Star Observation
Wheel. Standing at a towering 120 meters
(394 feet) tall - equivalent to a 40 storey
building - the Melbourne Star is the only
giant observation wheel in the Southern
Hemisphere, with its seven jutting spokes
representing the seven-pointed star of the
Australian flag.
The
Melbourne
Star
Observation
Wheel
One complete rotation of the Star takes approximately 30
minutes, giving guests an uninterrupted 360-degree view of up to
40 km (25 miles) that includes such landmarks as the Docklands
Precinct, Melbourne’s city business district, Port Phillip Bay,
Mount Macedon and the Dandenong Ranges.
The Melbourne Star Observation Wheel was commissioned by
Sanoyas Rides Corporation, to engineering house Arup, Alfasi
Steel Construction in Melbourne and Haywards Steel Fabrication
and Construction of Tasmania. AkzoNobel’s International® brand
was selected as the sole supplier of protective coatings for the
massive steel structure. The Melbourne Star Observation Wheel
officially opened on December 23, 2013, and has already
received a string of prestigious accolades. The Melbourne Star
was awarded a Steel Excellence Award in Engineering Projects
at the 2014 Australian Steel Institute (VIC) Awards, as well as a
High Commendation award at both the Buildings and Structures
category at the 2014 Victorian Engineering Excellence Awards;
and 2014 National Steel Institute Awards.
The Melbourne Star is constructed from approximately 1,200
tons of steel, (this is the whole of the superstructure including the
columns and hub) which was fabricated and transported to the
site in giant steel sections by Alfasi and Haywards. AkzoNobel’s
position as sole coatings supplier was initially attributed to the
strength of a long-standing relationship with Alfasi; having worked
together on a number of other successful large scale projects
using International® coatings products. However, the technology
of its International® products, technical expertise and supply
capabilities were the driving factors that helped AkzoNobel
secure the contract for the Melbourne Star.
Painting Contractors, Action Alliance of Melbourne and McElligott
Partners of Tasmania, were contracted to spray apply the
coatings to the complex steel sections after fabrication, and later
provided touch ups at the job site – both on the ground and
after the sections were erected, which was no easy feat. The
high durability of the two coat system will ensure an extended
maintenance lifecycle of the tourism attraction for up to 10 years.
“Action Alliance was very pleased with the uninterrupted process
of application due to the fast curing performance of Interfine® 979
polysiloxane. Not only did this assist with the off-site application,
once Action Alliance proceeded with on-site touch up and
rectification works it really enhanced its abilities of recoating
with minimal effort. This will be a positive product for the future
maintenance programs”, according to a spokesperson from
Action Alliance.
Mutimer commented, “The success of this project was a true
team effort across the business. Through strategic collaboration
on detailed specifications, warranties, maintenance plans, site
visits and meetings, random inspections, problem solving and
uninterrupted product supply, project owners experienced a
seamless, first class outcome; and that’s something we’re very
proud of.”
Today the Melbourne Star Observation Wheel is one of only
four giant observation wheels in the world (the London Eye and
Singapore Flyer having also been coated with protective coatings
from AkzoNobel’s International® range), it offers breathtaking
flights in 21 spacious air conditioned cabins. AkzoNobel’s
advanced International® two coat system will help keep the
Melbourne Star looking its best for years to come.
AkzoNobel’s Brendan Mutimer, Project Manager Victoria,
recommended a two coat Interzinc® 52 primer and Interfine® 979
polysiloxane topcoat system, instead of a traditional three coat
system. Together, the coatings’ excellent adhesion and fast
curing properties helped fast track the construction schedule,
without compromising the corrosion standard for the job.
The polysiloxane topcoat color was appropriately named
Melbourne Star Observation Wheel White, after the original color
specification. AkzoNobel received high praises for the accuracy of
the color match and for the long term color and gloss retention its
International® topcoat will provide.
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All photos courtesy of Melbourne Star Observation Wheel
“…project owners
experienced a
seamless, first
class outcome…”
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9
Rotterdam is positioned strategically, in the
middle of Europe, with Paris only two and
a half hours away and Schiphol, Europe’s
fourth busiest airport, only 20 minutes
away. It was therefore vital that the new
station was able to cater for international
travelers in large numbers; with its
capacity, comfort and practicality mirroring
other major European central stations.
A collaborative group of architects known
as ‘Team CS’ and made up Benthem
Crouwel Architects, MSVA Meyer en
Van Schooten Architecten and West 8,
was commissioned to transform existing
designs into a fully-fledged plan for the
new railway station. As with all great
architectural projects, Rotterdam Centraal
Station brought with it, challenges. The
footprint of the station was so large that
it was required to fit seamlessly into two
very distinct architectural styles. Ensuring
Rotterdam Centraal Station was fully
protected from the effects of fire was
another challenge faced during the early
phases of development.
Thanks to Intumescent
Fire Protection
W
ith a staggering 110,000 passengers repor ted to go through
Rotterdam’s main railway station ever y day, it’s no wonder
that a complete redevelopment of the area was deemed necessar y.
As a result of increasing passenger numbers, constr uction began in
2004 to demolish the old station and build a new ‘super-station’ in its
place, capable of coping with this passenger increase, repor tedly
expected to reach daily highs of 323,000 by 2025.
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In September 2008 AkzoNobel was
invited to submit a specification to
provide an intumescent fire protection
solution for the structural steelwork.
Products from its International® range of
intumescent fire protection coatings were
suggested, accompanied by products
from its wet paint portfolio. One of
AkzoNobel’s UK based Fire Engineering
Specialists examined the steel structure
and
submitted
recommendations
regarding film thickness. Torino Jansen,
AkzoNobel Protective Coatings Account
Manager explained:
“Following this process, we
then took our calculations to the
construction company and the
Rotterdam Municipal Authority
where we explained in full, the
importance of focusing on safety
and film thickness rather than
price per liter.”
Through the assessment of film
thickness, huge savings in the quantity
of paint and coatings needed, can be
made, which in turn, results in significant
cost savings. Following AkzoNobel’s film
thickness assessment, they were given
the go ahead in 2011 to supply both
protective coatings and intumescent
fire protection products for structural
steel. The anticorrosive primer from
AkzoNobel’s International® range was
topcoated with their acrylic polyurethane
finish, Interthane® 870. Their intumescent
fire protection coating, Interchar® 404
was also chosen to protect structural
steel from the effects of fire. “Thanks
to AkzoNobel’s Interchar® 404, if a fire
should break out, passengers have an
hour to leave the concourse without the
risk of it collapsing,” said Aad Bosselaar,
Sales Manager - Benelux for AkzoNobel’s
Protective Coatings business.
Since its official opening in 2014, Rotterdam
Centraal Station has claimed several
architectural and design awards. It was
recipient of the 2014 National Steel Award
for the inspiring use of steel where it was
described as “an attractive and dynamic
station with international allure” by judges.
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11
Bulk storage terminal operators are responsible
for the handling and storage of hundreds of
millions of liters of petroleum products 24
hours a day, seven days a week. Any reduction
in storage capacity is equivalent to a loss of
potential earnings and the longer the service is
disrupted the greater the financial impact. It is
therefore vital for terminal operators to keep their
storage tanks in service for as long as possible
with minimum downtime.
At no time is this consideration more important than
at the beginning of the facility’s lifespan during the
construction phase. A high performance coating
system applied effectively can significantly delay the
time to first maintenance and minimize downtime later
in the terminal’s service life. It is also possible to optimize
the available capacity for the variety of liquids passing
through the facility at one time, by selecting a tank lining
system which enables the rotation of cargoes.
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These are factors that storage operator VTTV
took into account when constructing the new
544,000 m³ (19,211,179 ft³) capacity facility in Vasiliko,
Cyprus. The terminal will be completed in November
this year and will provide a strategic storage hub in
Cyprus to capture the flow of oil and petroleum
products between Eastern Mediterranean, Middle
Eastern and European markets.
For VTTV the ability to contain a variety of different
cargoes within a single tank over its lifetime was
a key consideration. For this to be possible the tank
lining system would require chemical resistance
to a range of common petroleum products, as well
as resistance to the cleaning processes employed
to prevent cross contamination during the switchover
of cargoes. Interline® 984, part of the International®
range of protective coatings from AkzoNobel,
was selected as the most suitable solution
based upon these requirements, following close
cooperation with project engineering contractor
Joannou & Paraskevaides (Overseas) Limited (J&P).
Interline® 984 is an ideal lining for use in the bulk
storage industry, due to its versatility and resistance
to an extensive range of cargoes including crude oil
up to 90°C (194°F), unleaded gasoline blends, MTBE,
alcohols, aviation fuels and aromatic and aliphatic
solvents. It can also withstand a variety of common
cleaning methods including high pressure fresh
water washing and steam cleaning at temperatures
up to 120°C (248°F).
Not only did Interline® 984 satisfy the engineers’
requirements, but it also provided coatings applicator
SEM SA, Barondin Cyprus, with a number of
key benefits. The high performance lining can be
applied to full thickness in a single coat, eliminating
the additional curing intervals required by a multi-coat
application. This means that storage tanks can
be returned to service in as little as 24 hours after
application at ambient temperature maximizing
potential earnings for the owner of the facility.
Furthermore, when applied as part of a chopped
glass or laminate system, Interline® 984 complies
with the widely recognized API 652 and 653
standards for storage tank maintenance compiled
by the American Petroleum Institute. The standards
provide guidelines which enable the tank operator
to extend the interval between internal tank
inspections. This allows the operator to reduce
the frequency of tank shutdowns, decreasing
the overall time spent out of service.
In addition to the benefits delivered by the coating
system itself, the project team was able to benefit
from technical support and after sales service
provided by AkzoNobel throughout the various
stages of the project.
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13
New Training
Programs Support
Protective Coatings
Industry Excellence
The global protective coatings market is experiencing explosive growth and new
technologies at a record pace. While this presents unprecedented project opportunities,
many fabricators, applicators and engineers are calling for clear industry approved
standards that help to ensure higher quality coating installations. Adding to this challenge
are a number of social factors such as an ageing workforce in the more developed
economies, who may not have qualified younger personnel to replace them. Or the newer
emerging economies that are taking advantage of these growth opportunities and, as a
result, are adopting many of the existing quality standards from more established regions.
AkzoNobel has responded to this need with a commitment to leading the way in improved
protective coatings standards. And it begins with training.
Reaping the benefits
The benefits of having skilled personnel
are immediate and measurable. For
applicators and fabricators, a highly
trained team produces a better quality
coatings application from the start, which
reduces the risk of costly re-work. This
includes proper surface preparation and
application techniques, inspection and
safety protocols that mitigate unsafe
behaviors and accidents on-site. Greater
labor and cost efficiencies can also be
achieved by adopting best practices for
reducing overspray and waste, while
increasing the longevity of application
equipment through proper use and
maintenance.
For asset owners, consultants and
specification houses, effective training
results in increased confidence and
allows engineers to build more accurate
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Developed specifically with
applicators and fabricators
in mind
coatings specifications. It also provides
the education needed for reviewing and
interpreting vendor painting procedures
and reports, in order to make informed
coatings selections for their projects.
These benefits and more are now
available to AkzoNobel’s Protective
Coatings customers worldwide, through
two new training opportunities designed
to raise the bar of professionalism, skill,
safety and efficiency; while promoting
confidence and a competitive edge.
The
comprehensive
TrainthePainter
program is accredited internationally by
Lloyd’s Register and fully endorsed by the
Society for Protective Coatings (SSPC).
It was developed in tandem with respected
global marketing research firm, MPI
Group, based on extensive field data and
analysis collected from the global Marine,
Offshore, Construction, Petrochemical
and Civil protective coatings industries.
Using high quality video and animation,
AkzoNobel’s highly trained team delivers
a complete training experience covering
topics across all aspects of application
from coating types, to pre-work
inspection and surface preparation, to
quality control. This basic training can
be supplemented with more in-depth
With more than 100 years of combined
experience, the IAC team can address
a broad range of topics from coatings
basics, to specialty areas such as linings,
temperature resistance, fire protection
and asset management solutions. This
means attendees receive in-depth
training that’s tailor made for their
specific needs. The on-site location also
provides a firsthand look at how product
technologies are developed, tested and
applied, with opportunities to meet the
“people behind the paint.”
modules that cover abrasive blast cleaning
and spray equipment methodologies and
practicums.
Each TrainthePainter session contains
a range of theoretical and practical
elements; from basic principles for new
recruits entering the industry, to new
application methods for more experienced
painters, and advanced training for lead
hands, foremen, supervisors or third
party personnel.
Aidan Mernin, AkzoNobel’s Protective
Coatings Technical Director asserts, “in
order to improve industry standards it is
essential to partner with our customers
at all levels of the protective coatings
contract chain. The IAC program is a
perfect vehicle for doing just that. It not
only allows our customers to learn from
us, but we in turn learn from them. This
mutual knowledge sharing helps us
respond to the needs of our customers
faster, overcome new coatings challenges
facing the industry, and provide ongoing
value as a trusted coatings leader.”
The
convenient,
digital
platform
provides the flexibility of training right
at the customer’s own business
location and according to individual
schedules, even if that means over a
number of days, weeks or months.
Asset owners, engineers and
specification houses get the
VIP treatment
The International Academy of Coatings
(IAC) is a fully customized training
program held at AkzoNobel’s UK sites for
those with a high degree of influence over
coatings and/or passive fire protection
specification. The AkzoNobel team
works in partnership with attendees
to understand their existing coatings
knowledge and specific areas of interest,
in order to develop an interactive program
combining both theoretical and practical
training.
“IAC is a concise, yet informative
training for our engineers to
understand the role of coatings for
corrosion protection in the offshore
oil and gas industry. The fireproofing
coating material training was
precise and detailed, providing our
engineers with greater knowledge
about this special material and its
critical application in our industry.”
Sr. Metallurgist, Engineering Division,
ADMA-OPCO
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