Corrosion protection for steel structures, particularly in aggressive environments, is a critical challenge across various industries. Traditionally, thermal spray metallization (TSM) has been an effective method against corrosion. Yet, the development of novel high-performance zinc-rich epoxy coatings can offer a sustainable and effective alternative to TSM. This paper explores the potential of a novel zinc-rich epoxy technology as a potential alternative to thermal spray metallization in offshore environments. Both technologies were tested beyond the requirements of the most recognized industry, ISO 12944 and Norsok. The results showed that novel zinc-rich epoxy primers have maintained their integrity and protective properties even after an extended exposure in accelerated testing– 6720 hours of cyclic ageing tests. Furthermore, additional benefits deriving from the use of the novel zinc-rich primer as an alternative to TSM were estimated. These benefits include sustainability gains (e.g. less zinc consumption), cost reduction and less energy consumption.
