A lifecycle approach to corrosion protection

Fundamental to the safety, reliability and appearance of steel and concrete structures, corrosion protection is crucial in harsh coastal and industrial environments such as those found across New Zealand. 

By reducing corrosion‑related failures, protective systems contribute to safer workplaces and a smaller environmental footprint, minimising the risk of leaks, contamination, and unplanned replacement of large steel components.

So, choosing the right coating specification at the design or maintenance stage is a practical and high-value decision that safeguards for decades. According to the World Corrosion Organisation, corrosion costs the global economy trillions each year, mostly on infrastructure. 

Organisations such as the Heavy Engineering Research Association (HERA) have been working to strengthen industry capability in coating inspection and quality assurance. Alongside meeting industry standards, HERA encourages fabricators and asset owners to treat coatings as part of the overall steel quality management system and not as a finishing activity. 

HERA also promotes a lifecycle approach to corrosion protection. Protective coatings are viewed as engineered systems that must be specified, applied and inspected correctly to achieve the intended design life of the structure. That means considering corrosion protection from design and fabrication through to inspection, maintenance and eventual refurbishment. 

For many projects, the biggest opportunity to improve durability occurs before the first coating is even applied. Simple steelwork design decisions, such as providing drainage holes, avoiding water-trapping details, and adequate access for abrasive blasting and coating, can significantly improve coating longevity. These design-for-durability principles are recognised in guidance associated with standards such as AS/NZS 2312 and SNZ TS 3404.

Asset owners can also adopt lifecycle thinking by designing with inspections and maintenance in mind. Platforms, safe access points and inspection zones allow coating systems to be monitored and repaired efficiently throughout the structure’s service life. Without this access, even minor coating damage can go undetected until corrosion becomes advanced and expensive to remediate.

Coating inspection data is an emerging industry practice. Recording surface preparation, environmental conditions, film thickness measurements and inspection outcomes creates a valuable dataset that can inform maintenance planning years later. This allows infrastructure owners to track coating performance and schedule preventative maintenance rather than reacting to unexpected failures.

By combining strong lifecycle planning with proven coating technologies, manufacturers help engineers, fabricators and asset owners protect critical infrastructure and extend the service life of steel structures. They specialise in the formulation, manufacture, and specification of high-performance industrial and marine protective coatings.

Taking an integrated approach not only reduces long-term maintenance costs but also enhances safety, reliability, and sustainability across the lifecycle of every steel structure.