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Wind Energy

Ecological and Economical: Corrosion Protection Systems for Wind Energy

Onshore and offshore wind turbines now provide almost a fifth of Germany's total electricity generation. That makes them the most important renewable energy source – with further growth potential. Especially in the offshore sector, there are additional, very favourable conditions for Germany: On the one hand, the North Sea and the Baltic Sea offer good and continuous wind conditions. On the other hand, there are large areas there where the depth of the sea is only 20 to 50 metres and which are therefore ideally suited for the cost-effective construction of wind farms. Profitable investments in wind energy also depend very much on trouble-free operation and an appropriate service life of at least 20 or, better, over 30 years.

Efficiency and competitiveness cannot be ensured without adequate protection and continuous maintenance of the plants. The steel and cast iron components of wind turbines – such as tower segments, machine houses, shafts and hubs – require sophisticated corrosion protection in order not to be defective after just a few years.

Corrosion protection coatings for wind turbines on- and offshore

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ONSHORE CORROSION PROTECTION

Sherwin-Williams corrosion protection systems provide long-term protection of steel towers with high-quality, matched products. The coating systems are based on modern binder resins, which enable low-solvent production. Priming coatings with active pigments and thick-layer intermediate coatings ensure a long-lasting corrosion protection, the top coats based on polyurethane meet the highest requirements for weather resistance and colour stability. Sherwin-Williams systems have proven their worth on more than 10,000 wind turbines over many years of service.

The main advantages:

Permanent corrosion protection tested up to the highest corrosivity category. Onshore: C5 high according to EN ISO 12944-6.
Fast curing enables short coating intervals and delivery times.
High-quality top coats achieve lasting colour stability and gloss retention.
Low emission by using very low-solvent coating materials
Matched repair systems for the revision of transport and installation damage

Below are some examples of coating systems:

Component	Corrosion Protection System	Corrosion Protection Tests	Total Layer Thickness
Tower interior surfaces	1 x Macropoxy® 2440 MF / 1 x Acrolon® EG-5	C3 high	200 µm
Tower exterior surfaces	1 x Macropoxy® 2440 MF / 1 x Acrolon® EG-5	C4 high	240 µm
Tower interior surface	1 x Zinc Clad® NCG Base Coat / 1 x Acrolon® EG-5	C4 high	240 µm
Tower exterior surface	1 x Zinc Clad® NCG Base Coat / 1 x Acrolon® EG-5	C5 high	300 µm

Sherwin-Williams coating systems guarantee a long-lasting economical corrosion protection in the interior of nacelles. The cast iron and steel components such as hubs, base frames, generator carriers, rotor shafts, machine housings, etc. are protected from severe mechanical damage during transportation and installation. In later operation, the coating prevents corrosion, repels dirt and is easy to clean.

The main advantages:

Best protection during transport and assembly thanks to high mechanical durability.
Fast curing enables short coating intervals and delivery times.
Long-term corrosion protection by active pigmenting.
Environmentally friendly low-solvent product systems.

Below are some examples of coating systems:

Component	Corrosion Protection System	Corrosion Protection Test	Total Layer Thickness
Steel and cast iron components in the interior of nacelles	1 x Macropoxy®-2420 EMK / 1 x Acrolon®-2230 VHS	C3 high	180 µm
	1 x Macropoxy® EG Phosphate Rapid / 1 x Acrolon® EG-5	C3 high	180 µm
	2 x Macropoxy® EG Phosphate Rapid / 1 x Acrolon® EG-5	C4 high	240 µm

Transporting and assembling the partly very heavy parts and components can cause damage to the corrosion protection coating. To repair damaged components, 1-component coating materials ensuring the highest possible corrosion protection and easy usage are used in the onshore area.

Below are some examples of coating systems:

System	Type	Layer Thickness	Corrosion Protection System	Color Shade
Variant 1	Priming coat	2 x 60 µm	2 x Kem-Kromik™ Aktivprimer Rapid	beige yellow
	Top coat	1 x 60 µm	1 x Kem-Kromik™ CorroTop	RAL 7035, RAL7038
Variant 2	Repair coating	1 x 500 µm	1 x Repacor™ SW-1000	RAL 7035, RAL 1023, black

OFFSHORE CORROSION PROTECTION

Cyclic Corrosion Testing According to DIN EN ISO 12944-9:2018

A Sherwin-Williams protective paint system is applied according to the highest standards of the corrosion protection. Due to a very high mechanical durability, the tower sections are already protected during transport and especially during construction.

The main advantages:

Durable corrosion protection under loads on the high seas.
Offshore: Norsok Standard M-501, system no. 1.
High mechanic durability
High-quality top coats achieve lasting hue stability and gloss retention.
Low emission by using very low-solvent coating materials

Component	Corrosion Protection System	Corrosion Protection Test	Total Layer Thickness
Tower interior surface	1 x Zinc Clad® 2311 Rapid / 1 x Macropoxy® 2215 EG VHS / 1 x Acrolon® 2230 VHS	C5 high	260 µm
Tower exterior surface	1 x Zinc Clad® 2311 Rapid / 1 - 2 x Macropoxy® 2215 EG VHS / 1 x Acrolon® 2230 VHS	CX (Offshore)	280 µm

The construction of offshore wind turbines is carried out mostly on steel foundation structures such as monopiles, tripods, tripiles and jacket constructions. These surfaces that are in permanent contact with seawater require a coating system that is extremely mechanically resistant in addition to the requirements for corrosion protection. Dura-Plate® SW-501 and Dura-Plate® Poxicolor SW N meet all requirements and pass all tests. In addition, they are solvent-free or have a low solvent content and are therefore very environmentally friendly.

The main advantages:

Maximum corrosion protection for permanent sea water exposure and in the tidal zone.
Highly resistant to abrasion as well as mechanically sturdy
Suitable for an application in combination with cathodic protection systems (KKS)
2-component epoxy resin coating, very environmentally friendly.

*Optionally, for special requirements regarding the colour shade and the UV resistance, it is possible to apply Acrolon 2230 VHS as top coat.

Component	Corrosion Protection System	Corrosion Protection Test	Total Layer Thickness
Jacket / Monopile / Tripod / Tripile	2 - 3 x Dura-Plate® SW-501* / Dura-Plate® Poxicolor SW N*	Norsok M-501, system Nr. 7 / BAW: Im1 - 4	600 µm

Detailed repair instructions are created for offshore structures for repairing damage to the corrosion protection coating. These are individually adapted to the initial protection system used and thus meet the high corrosion protection requirements. Furthermore, we have developed Repacor™ SW-1000 for the protection and repair of existing structures, which can be simply applied under difficult conditions such as climate, weather and accessibility.

Typical Application Areas

Steel Tower

Machine Parts and Attachment

Repair

Foundation Structure

Repacor™ SW-1000 - The Offshore Repair Revolution

2-COMPONENT REPAIR COATING FROM THE CARTRIDGE

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

With Repacor™ SW-1000, our research department has succeeded in developing an abrasion-resistant, innovative 2-component coating material. It meets all requirements for the touching up or repair of (mechanically) damaged coating surfaces.

The main advantages:

USER FRIENDLY
2-component coating from the cartridge - low weight for the user
FAST
Curing in record time even under water, with just one work step. UV-resistant without additional top coat
SAFE
No waste, no emissions - solvent-free coating consists of 100% solids

Repacor™ SW-1000 Product Information Sheet

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Repacor™ SW-1000

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Reference Projects

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