Corrosion is a major challenge for industries operating in harsh environments, where exposure to saltwater, humidity, and extreme temperatures can significantly degrade materials over time. Without proper testing, coatings and protective treatments may fail prematurely, leading to costly maintenance and potential safety risks. This case study explores how accelerated corrosion testing helped a company identify the most effective coating for offshore structures, ensuring long-term durability and reduced maintenance costs.
Background
A company specialising in the development of industrial coatings sought to improve the corrosion resistance of its protective materials used in offshore environments. Their coatings were designed for application on oil rig structures, marine vessels, and underwater pipelines, all of which are exposed to harsh conditions, including constant saltwater contact, fluctuating temperatures, and prolonged UV exposure. The company faced a critical challenge in ensuring that its coatings would provide long-term durability while minimising maintenance costs and the risk of structural failure. Traditional field testing methods required years of exposure to gather meaningful data, making it essential to find a more efficient way to evaluate performance before large-scale deployment.
Challenge
One of the primary concerns was the need to validate the effectiveness of new anti-corrosion coatings in a controlled yet highly realistic environment. Engineers required a method that could replicate the combined effects of salt exposure, high humidity, temperature fluctuations, and UV degradation within a significantly reduced timeframe. Without a reliable accelerated testing process, there was a risk of deploying coatings that might fail prematurely, leading to costly repairs and potential safety hazards in offshore operations. In addition to assessing durability, the company sought to compare multiple coating formulations to determine which provided the best protection against corrosion-induced damage.
Solution
To address these challenges, the company conducted a series of controlled corrosion tests using advanced weathering chambers. A combination of salt spray testing and cyclic corrosion testing was employed to simulate the harsh conditions that offshore structures endure over extended periods. The salt spray test involved continuous exposure to a fine mist of saltwater, replicating the effects of marine environments on metal surfaces and coatings. This test provided valuable insight into the coatings' ability to resist salt-induced corrosion and maintain adhesion to the underlying substrate.
The cyclic corrosion test incorporated multiple environmental stress factors by alternating between salt fog exposure, high humidity conditions, and periods of drying to more accurately mimic real-world variations in temperature and moisture. This approach allowed for the identification of weaknesses that might not have been apparent in a standard salt spray test alone. Over the course of several weeks, the company tested multiple formulations, carefully analysing how each material responded to repeated exposure cycles. Data was collected on coating adhesion, surface degradation, and the extent of rust formation to determine which formulation provided the highest level of protection.
Results
After completing the corrosion testing, engineers identified a newly developed epoxy-based coating that exhibited significantly better resistance to degradation compared to traditional formulations. The results showed that this coating maintained structural integrity for a much longer period, with surface analysis indicating a 50 percent reduction in material breakdown when compared to the company’s previously used coatings. Additionally, one of the alternative formulations initially considered for deployment was found to have a critical flaw in its composition, leading to early delamination under cyclic exposure conditions. By identifying this issue before real-world application, the company was able to modify the formulation and avoid a potentially costly product failure.
By selecting the highest-performing coating based on test data, the company projected a 30 percent reduction in maintenance costs over the lifespan of offshore structures, as the improved corrosion resistance minimised the need for frequent recoating and repairs. The testing process not only allowed for the optimisation of material selection but also provided confidence that the coatings would perform effectively under the extreme conditions of marine environments.
Conclusion
Through the use of accelerated corrosion testing, the company was able to make informed decisions regarding the selection and formulation of protective coatings for offshore structures. The ability to simulate years of exposure within a controlled laboratory setting proved to be invaluable in identifying weaknesses and validating the durability of new materials before large-scale implementation. By integrating advanced weathering tests into their development process, the company not only improved the performance of its coatings but also achieved significant cost savings by reducing the risk of premature failures and the associated maintenance expenses. The success of this testing strategy reinforced the importance of corrosion resistance evaluation in the design and development of materials intended for extreme environmental conditions.
Contact Thermoline today to explore our range of corrosion testing solutions, and take the next step in safeguarding your materials against the harshest conditions.
