Powder coating is a type of coating that is applied as a dry, fine powder to produce high-quality and durable finishes. Unlike conventional liquid coatings and paints, which are typically applied via a brush or roller, powder coatings are applied as a free-flowing powder that streams smoothly and evenly.
This application can either be conducted through electrostatic spraying or a fluidised bed dipping process, followed by a necessary heat (or UV) curing process.
Since their early development in the 1940’s, powder coatings have come to take large swathes of the protective coatings industry by storm. Today, they enjoy a dominant position in a range of markets (including architectural, industrial and transport), and this dominance is only predicted to intensify. Indeed, whilst the current global powder coatings market stands at a significant $15.2 billion in 2024, this is projected to grow by a whopping $9 billion to reach $24.26 billion in a mere eight years’ time (Chemicals & Materials Industry – Fortune Business Insights).
The soaring popularity of powder coatings can be attributed to their many advantages over alternative protective coating materials. Firstly – and perhaps most importantly, given our ongoing climate crisis – powder coatings are significantly more sustainable than their traditional liquid counterparts. This is in large part due to their exceptionally low (or often non-existent) Volatile Organic Content (VOC), eliminating the health hazards and air pollution associated with solvent emissions. Additionally, the limited overspray powder produced in the application process can be recycled and reused, ensuring minimal waste.
Powder coatings are often more economical options than their liquid counterparts. Whilst initial set-up costs can be high, their transfer efficiency is streaks ahead of traditional liquid paint methods, reaching an impressive 95% when applied using the fluidised bed technique. Furthermore, the equipment used for powder coating requires relatively minimal maintenance, making it more convenient and cost-effective.
Remarkably, the huge environmental and economic benefits powder coatings incur do not lead to diminished performance. In fact, many powder coatings – when applied as a single layer and cured by heat – provide comparably exceptional durability, chemical resistance, toughness and flexibility. Taking all this into account, it appears evident that powder coatings constitute the future of the protective coatings industry.
It is in this context that Corrodere Academy is proud to announce its new Powder Coatings application course. Expertly crafted, engaging, and informative, the course is designed to ensure high-quality training is available within the industry – an availability that is essential as the powder coatings market continues to boom. Following the course’s launch, we sat down with Brendan Fitzsimons – Corrodere’s Technical Director and leading industry expert – to hear his thoughts.
What Motivated Corrodere to Design the Powder Coatings Course?
Our primary goal is to address the rapidly growing demand within the industry, driven in large part by increasing sustainability concerns. As the industry expands, more and more manufacturers are looking to bring powder coating capabilities in-house. However, the surge in demand has outpaced the availability of skilled professionals. Many companies have invested in powder coating units but find themselves without the trained staff necessary to operate them effectively. This is where we step in, providing the high-quality training needed to equip these companies with the expertise required.
Who is This Course Targeted At?
This course is primarily targeted at powder coating applicators and associated workers involved in the powder coating process. Our training is designed to be highly practical and hands-on, focusing on the real-world skills needed on the job rather than delving too deeply into technical or scientific theory. The theoretical components of the course are digestible, ensuring applicators gain the necessary knowledge without being overwhelmed by complex concepts.
The course will also be helpful for powder coating technical and sales staff from powder suppliers and equipment suppliers.
While the applicators are the primary recipients of this training, it’s essential for companies to recognise that powder coating is a team-driven process. From pre-cleaning to application, each step requires careful coordination and expertise. Therefore, it’s crucial for companies to invest in training across the entire team, ensuring that every stage of the process is executed with precision – a need our course is designed to fulfil.
Why Should Industry Professionals Take the Powder Coatings Course?
As the powder coatings market continues to boom, skilled application of powder coatings is an increasingly vital proficiency for anyone in the industry. Corrodere’s course ensures that students fully understand the many stages and intricacies of the powder coatings process, verifying their competence to carry out this high-skilled work effectively and safely.
For employers, offering the course to staff defends against potential costly coating failures by ensuring application is done correctly, first-time around. Investing in training is also a way to boost job satisfaction (and, by extension, job performance), ensuring employees know they are rightly perceived as an invaluable resource. Any registered Train the painter company that is engaged in powder coating application can – and should – deliver the course.
How Valued do You Foresee the Powder Coatings Course Being by the Industry at Large?
Ultimately, we foresee our powder coatings course becoming an industry norm. The benefits of the course are simply innumerable for applicators, companies and clients alike. Applicators benefit from verifiable expertise and enhanced confidence in their work; companies benefit from well-trained staff and an elevated reputation as a consequence of staff investment; clients benefit from knowing they are enlisting highly qualified trade personnel. Indeed, the failure of powder coatings can be costly – Corrodere’s course (the only one of its kind) ensures that rather than relying on reputation, companies and clients alike can trust their powder coating Applicators to have certifiable, accredited skills and expertise.
Who Endorses the Course?
We’re delighted to say that the British Coating Federation (BCF) has endorsed the programme. Their endorsement highlights the high-quality and necessity of the course, and we’re excited to be working with them.
The Powder Coating Application course is available globally through the Corrodere Academy’s Train the Painter programme. To find out more, please get in touch with the team at.
Wood is very proud to become a new sustaining member of the Institute of Corrosion.
About Wood
Wood is a global leader in consulting and engineering, delivering critical solutions across energy and materials markets. They provide consulting, projects and operations solutions in 60 countries, employing around 35,000 people.
It’s team of integrity management specialists works with energy and industrial operators to keep assets safe, reliable and efficient throughout their lifecycle.
Asset Integrity Solutions
Whether it’s corrosion analysis and control, cathodic protection, integrity management, risk assessments or maintenance planning, Wood aims to identify potential issues and implement targeted strategies to improve the performance and longevity of energy and industrial assets.
Expertise You Can Trust
The Wood team has a proven track record with numerous global majors and a strong commitment to innovation, ensuring its clients benefit from the latest technologies and industry best practices.
Comprehensive Lifecycle Support from Initial Design to Decommissioning
Wood works across every stage of the asset lifecycle using a holistic approach, ensuring to anticipate and address challenges before they become problems.
Through partnering, its clients gain a trusted advisor committed to their long-term success.
Advanced Technology to Identify Risks Early
Wood uses digital tools, data analytics and predictive maintenance techniques to identify and mitigate risks early, reducing costs and improving operational efficiency. Being vendor-independent, its clients can have the confidence that their assets are managed using the best available technology.
For example, the ECE® (Electronic Corrosion Engineer) corrosion analysis and materials selection software is the leading tool to provide realistic corrosion modelling and lifecycle cost assessments calibrated to actual field data.
Global Reach with Local Expertise
With a presence in key markets around the world, Wood combines global reach with local expertise. By understanding the specific challenges and regulations of each region, it is able to provide solutions that are both globally informed and locally relevant, ensuring the best possible support, no matter where assets are located.
Sharing Our Knowledge
Wood regularly shares its knowledge at industry events in committees and online training.
To join its mailing list or to watch its on-demand webinars, visit: woodplc.com/webinars
To learn more about corrosion and integrity management please visit us at: woodplc.com/integrity
Wood assists all to stay up-to-date and earn professional development hours too!
New Corporate Member – ICorr Welcomes Hempel: Helping Shape a Brighter Future with Sustainable Coating Solutions.
Shaping a Brighter Future
Hempel is a global supplier of coatings across industries. From bridges and ships to wind turbines and homes, Hempel’s products can be found in almost every country, protecting the world’s buildings, infrastructure and other assets from corrosion. Hempel coatings are essential to their customers’ businesses. They help minimise maintenance costs, improve aesthetics, reduce waste and increase energy efficiency in the operation of assets. They extend the lifetime of the assets they protect – helping lower the asset’s environmental and carbon footprint across its entire lifecycle.
Hempel was established in Denmark in 1915 and today employs people across the globe. It’s headquartered in Kongens Lyngby, near Copenhagen, Denmark.
For The Wider Good
Hempel is majority-owned by The Hempel Foundation, which ensures a solid economic base for the Hempel Group and supports cultural, social, humanitarian and scientific purposes around the world.
In 2023, The Hempel Foundation donated €23 million to development initiatives in the fields of education, biodiversity and science.
Committed to Sustainable Development Goals
Hempel are committed to the UN Sustainable Development Goals. The UN SDGs are integrated and indivisible, and our Hempel goals work in a holistic way to support them.
We are reducing CO2emissions in our own operations and in our value chain and switching to renewables.
Our products contribute to a more sustainable and resilient infrastructure.
We are pursuing resource efficiency and circularity and reducing harmful substances.
We are committed to health and safety and the promotion of diversity and inclusion.
We promote ethical behaviour and good environmental practices in our supply chain.
We collaborate widely and pursue effective partnerships.
Sustainability at the Heart of Business
Sustainability leadership is a key pillar of Hempel’s Double Impact business strategy. For Hempel, sustainability leadership means being a frontrunner within the paints and coatings industry by enabling customers to meet their sustainability ambitions.
To achieve on these ambitions, Hempel works dedicatedly on sustainability initiatives, with a focus on reducing its environmental footprint, enhancing its social impact and maintaining its strong corporate governance standards.
Liquid Engineering – R&D
Hempel strives to be the best in the business – and that means always looking for innovative ways to improve coating performance, as well as new ways for coatings to improve the world. With R&D centres across Europe, the Middle East, Asia and America, their R&D teams work with customers, research institutes, suppliers and other industries to push the boundaries of what coatings can do – always with the aim of improving customers’ business performance.
Hempel’s R&D work Research into the latest paint technologies
Developing new customer-focused products and solutions
Partnering with customers to tailor solutions
Reducing the environmental impact of coatings
Increasing the sustainability value derived from the use of coatings, including extending the lifetime of assets and increasing the energy efficiency of operating assets
Focuses on Driving Innovation in Protective Coatings
As a global supplier of coatings across industries, Hempel develops advanced coatings solutions to protect assets, reduce maintenance and enhance performance. One leading example is ‘Avantguard,’ a patented technology that sets new standards in corrosion protection.
https://www.hempel.com/inspiration/sustainability
For over 10 years, this innovative coating solution has extended the lifetime of steel structures across a wide range of applications, from wind towers and bridges to airports and skyscrapers. It not only prolongs the lifespan of assets but also simplifies application, reduces maintenance costs and lowers CO₂ emissions. It’s the ideal corrosion protection solution for any forward-thinking asset owner, consulting engineer, contractor or applicator.
Avantguard is the world’s first zinc-rich primer to fully utilise its zinc content by activating all three methods of corrosion protection: the barrier, the inhibitor and the galvanic effect.
With its unique properties, Avantguard ensures superior durability and reduced environmental impact in addition to its easy application, offering fast drying, fewer coats, and an excellent crack-resistant finish.
And with the recent launch of Avantguard 750 Pro, setting a new industry standard for corrosion protection and building on over a decade of Hempel’s patented Avantguard technology, Hempel reaffirms its dedication to sustainability and high-performance coating systems.
Contact
For more information, visit Hempel’s website www.hempel.com or reach out to the team athempel@hempel.com
ICorr is delighted to introduce Dr. Joshua Owen as the newly appointed Interim Chair of the Yorkshire and Humber branch. An AGM to endorse the full committee will follow in the near future.
Stepping into this leadership role, Dr. Owen brings a wealth of expertise and a strong commitment to advancing corrosion science and engineering in the region. Learn more about him in his own words below.
“I am Josh, a lecturer in the School of Mechanical Engineering at the University of Leeds. I have a PhD from the University of Leeds, focused on the erosion-corrosion of carbon steel. Having previously been part of the Young ICorr committee, I now chair the Yorkshire and Humber branch of ICorr.
At the University of Leeds, we host the Institute of Functional Surfaces research group, dedicated to the study of corrosion and material degradation. We have over 20 active PhD and postdoctoral researchers tackling various corrosion challenges, from flow accelerated corrosion to corrosion challenges faced in the energy transition, with a strong focus on addressing industry needs.
As Chair, I am excited to establish a committee and organise events for the Yorkshire and Humber corrosion community in the coming months. My vision for the branch is to create a vibrant community within the region that bridges leading academic research and industry expertise through a series of events”.
If you are interested in joining the committee or participating in our events, please contact yorkshirechair@icorr.org
On 20th February 2025, the newly established Wales and South-West of England regional branch held its inaugural event in Pembroke, marking a significant milestone in bringing together professionals from across the region. The event, hosted at Insite Technical Services, was a collaborative effort with the Institute of Chemical Engineers (IChemE) and featured insightful presentations from experts in the field.
The first presentation was delivered by Adeeba Zachary and Sabrina Gregory from Valero Energy. Adeeba, the Corrosion and Materials Engineer at Valero’s Pembroke Refinery, has a Master’s in Mechanical Engineering from Swansea University and is also the current Vice Chair of the Wales and South-West Branch of ICORR. Adeeba has experience in multiple areas of mechanical integrity, including being a registered American Petroleum Institute (API) piping and pressure vessels inspector. Sabrina Gregory, a Process Engineer working on the Reformer Unit at Valero’s Pembroke Refinery, has a Master’s in Chemical Engineering from Swansea University. Sabrina has experience in daily operations of the Reformer Unit as well as during a major unit turnaround/upgrade.
Adeeba and Sabrina’s presentation titled “Where process and corrosion engineering meet: Implementing a material operating envelope at a refining facility,” provided insight into the concept of Material Operating Envelopes (MOEs) and the multidisciplinary collaboration required for their effective implementation in a refinery setting. They explored the critical considerations needed to complete an MOE study, including materials selection, operational changes, and contaminant control. A key part of their presentation was a case study on implementing an MOE for a Catalytic Reformer Unit, detailing how such frameworks ensure the longevity and safety of complex industrial equipment. Their expertise illustrated how blending process engineering with corrosion and materials engineering can help mitigate potential operational risks, minimise turnaround times and optimise performance in refining operations.
The second presentation was given by Sahana Cooper, a Senior Process Engineer at Insite Technical Services. With five years of experience in process design, Sahana has worked on a diverse range of projects, from surge analysis to distillation column replacements and co-processing renewable feedstocks. Sahana’s academic background includes a degree in Chemical Engineering from Loughborough University, complemented by an industrial placement at Valero’s Pembroke Refinery and a research project at Chalmers University in Gothenburg, Sweden.
The presentation, “Corrosion mechanisms in hydrotreaters during co-processing of renewable feeds.” delved into the challenges faced when co-processing renewable feedstocks in diesel hydrotreaters. Her talk focused on a specific project where a client sought to co-process up to 5% by weight renewable feedstock in their diesel hydrotreater. The process posed unique corrosion challenges, particularly related to managing salt deposits and adhering to the high temperature hydrogen attack (HTHA) limits, which are crucial for ensuring the integrity and safety of refinery operations.
The event saw an excellent level of interaction from the audience, with many questions and plenty of further discussions following each presentation. The delegates were highly engaged, seeking deeper insights into the technical aspects of the topics covered and exchanging ideas on how to apply the learnings in their own work. The lively discussions highlighted the thirst for knowledge and collaboration among professionals in the region. With 45 delegates in attendance, the first Pembroke event was deemed a resounding success! The positive feedback from participants and the high level of engagement with branch activities to date bode very well for the future of the Wales and South-West regional branch, which plans to continue providing such events for professionals to connect, learn, and grow.
The next event is due to take place at Cardiff University on 9th April. For more information, contact: swchair@icorr.org
You can also keep up to date on events by visiting our LinkedIn page; https://www.linkedin.com/groups/12992293/.
Photo: Delegates Observing Adeeba Zachary and Sabrina Gregory Presentations.
Photo: Sahana Cooper from Insite Technical Services.
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