A major refurbishment programme is underway at the Meyer Werft shipyard, in Germany, where 7600m² of drydock sheet pile walls are being recoated using Steelpaint’s Stelpant corrosion protection system. The work is being carried out by industrial coating contractor Tecton Service.

Located in Papenburg in north-west Germany, Meyer Werft has a history going back to 1795 and has built some of the most significant cruiseships to date in its covered building dock.

The current project involves the refurbishment of the steel sheet pile walls of the 200m x 38m uncovered drydock used for shiprepair work. This was yard’s old building dock, which was commissioned in 1987 but extended in 1990.

Sheet piles, interlocking steel profiles driven deep into the ground to form retaining structures, are widely used in ports and shipyards to create quay walls, docks and waterfront infrastructure. Over time, these structures are exposed to highly aggressive marine conditions, including saltwater spray, moisture, and mechanical wear. As a result, periodic surface preparation and recoating is required to ensure long-term structural protection.

The sheet pile walls were last repaired and treated in 2009. However, as part of the current refurbishment works, the existing coatings are being stripped from steel surfaces using abrasive blasting to Sa 2½. The sheet piles will then be coated with a two-layer Stelpant system based on Stelpant PU-Zinc primer and a Stelpant PU-Combination 500 topcoat.

Unlike new steel structures coated under controlled factory conditions, the remedial coating of installed sheet piles is often time consuming and problematic due to variable weather conditions. Steelpaint says its polyurethane zinc coating systems, however, are particularly well suited to these applications.

“Refurbishing installed sheet pile structures presents a number of challenges,” said Nils Baumfalk
Steelpaint’s Key Account Manager and lead on the project.

“The geometry of sheet piles makes it more difficult to achieve consistent coating coverage compared with flat steel structures. But our Stelpant technology combines strong adhesion with active corrosion protection, essential to ensuring a long service life in harsh marine environments. Outside weather conditions do not usually delay application.”

The Stelpant PU-Zinc primer provides cathodic protection due to its high content of elementary zinc, helping to prevent corrosion even if the coating is damaged, while the PU-Combination 500 topcoat forms a high-build barrier layer designed to withstand mechanical impact and environmental exposure.

According to Steelpaint Director Frank Müller maintaining the integrity of the sheet pile walls is critical for safe and efficient drydocking operations.

“Stelpant technology is a key component in a shipyard’s drydock maintenance strategy as the coating provides very durable, reliable protection and is very easy to apply.”

The project marks Steelpaint’s return to the Papenburg shipyard after more than a decade. In 2016, the company supplied coatings for 10,000m² of sheet pile structures in Meyer Werft’s covered building hall – the world’s largest.

“Returning to Meyer Werft after more than ten years is a strong indication that our coating systems have delivered,” said Müller.

“Shipyards operate in extremely demanding environments, so long coating lifetimes are critical for reducing maintenance costs and operational disruption.”