Beyond Corrosion Protection: The New Role of Additives in Protective and Marine Coatings

Protective and marine coatings have always been expected to deliver reliable corrosion protection in some of the world’s most demanding environments. However, the market is evolving. Regulatory pressures, sustainability goals, rising maintenance costs, and the need for greater operational efficiency are driving demand for coatings that offer performance benefits beyond corrosion resistance alone.

As a result, formulators are challenged to develop coatings that combine long-term durability, low VOC emissions, improved application properties, and extended service life without compromising protection. Advanced formulation and performance additives are playing an increasingly important role in helping meet these demands.

Balancing Sustainability and Corrosion Protection

The shift toward lower-emission coating technologies is one of the most significant developments in the protective and marine coatings market. High-solids, solvent-free, and waterborne systems continue to gain momentum as manufacturers work to reduce VOC emissions while maintaining performance.

However, reducing solvent content often introduces formulation challenges such as increased viscosity, pigment dispersion difficulties, and handling issues. Advanced dispersing technologies help overcome these obstacles while supporting the development of high-performance, lower-VOC systems.

For water-, solvent-based, and solvent-free formulations, Efka^® FA 4620, a high-acid, low-molecular-weight dispersing agent helps improve pigment wetting and reduce viscosity, supporting efficient dispersion and formulation stability across a wide range of applications.

For waterborne systems, Dispex^® Ultra PX 4575 delivers excellent performance with inorganic pigments, broad resin compatibility, and strong rheology control. Based on Controlled Free Radical Polymerization (CFRP) technology, it delivers a more advanced dispersing approach than conventional polyacrylate dispersants, helping formulators achieve robust performance in demanding protective coating applications. 
Together, these technologies help optimize low VOC coatings systems while maintaining pigment stabilization and application performance.

Advancing Corrosion Protection

Corrosion remains the primary challenge for assets operating in marine, offshore, infrastructure, and industrial environments. Coating systems must withstand moisture, salt, chemicals, and weathering while maintaining long-term adhesion and barrier properties.

Beyond pigment dispersion and film formation, corrosion inhibitors from BASF’s portfolio can further enhance long-term performance. Loxanol^® MI 6627 is a highly effective corrosion inhibitor that works synergistically with zinc phosphate in both water- and solvent-based systems. By supporting the formation of protective layers in the anodic zone and offering extremely low water solubility, it contributes to long-term corrosion protection and system stability.

Efka^® MI 6613 is a corrosion inhibitor that protects through a different mechanism. Designed for solvent-based primers and one-coat coatings based on oxidatively drying binders, it helps passivate rust residues remaining after mechanical surface preparation while also promoting the removal of residual moisture from the paint film. This can be especially valuable where complete rust removal is difficult to achieve.

Together, these technologies help formulators maximize asset protection and extend service life in demanding environments.

Improving Application Efficiency

As labor costs rise and maintenance windows become more limited, application efficiency has become a key performance driver. High-build epoxy primers and other protective coating systems can encounter challenges such as air entrapment, microfoam. cratering, pinholes, and poor leveling, leading to rework and reduced productivity. 

Advanced deaerating and defoaming technologies help address these issues and improve film quality. For waterborne systems, FoamStar^® ST 2438 provides effective deaeration and foam control, helping reduce air entrapment and surface defects. Hydropalat^® WE 3225 combines strong substrate wetting with pronounced defoaming action, supporting the formation of smooth, defect-free films across a wide range of aqueous formulations.

For solvent-based protective coatings, Efka^® SI 2041 and Efka^® SI 2042 are silicone-based defoamers that help prevent foam and blister formation during both manufacturing and application. They provide effective foam control, helping formulators improve film appearance and reducing coating defects that can lead to costly rework. 

Surface quality can be further enhanced with flow and leveling additives. Efka^® FL 3740 EH improves leveling, air release, substrate wetting, and crater resistance in solvent-based and solvent-free applications. For waterborne and solvent borne systems, Efka^® FL 3782 improves substrate wetting at low film thickness, exhibits low foam stabilization, and has minimal impact on intercoat adhesion, supporting excellent recoatability in multilayer coating systems.

These technologies help reduce rework, improve appearance, and support more efficient coating applications.

Enhancing Marine Surface Performance

Marine operators are increasingly focused on reducing operating costs and improving sustainability. Surface condition plays a critical role, as rough or damaged coatings can increase drag, fuel consumption, and maintenance requirements.

Surface-modifying additives can improve cleanability, durability, and long-term surface performance. Efka^® SL 3299 enhances scratch and abrasion resistance while improving surface smoothness and anti-blocking properties in water-, solvent-based, and solvent-free systems. Similarly, Hydropalat^® SL 3683 delivers excellent slip, mar resistance, and scratch resistance across a broad range of water-based formulations.

By helping maintain surface integrity and appearance over time, these additives support easier maintenance and improved operational efficiency.

Extending Asset Life Through Durability

Reducing lifecycle costs remains a major priority for infrastructure owners, offshore operators, and industrial asset managers. Longer coating service life helps extend maintenance intervals and reduce total cost of ownership.

One of the leading causes of coating deterioration in exterior environments is UV degradation. Prolonged sunlight exposure can cause gloss loss, color fading, cracking, chalking, and other forms of surface damage. Advanced light stabilization technologies help mitigate these effects by combining ultraviolet absorbers (UVAs) and hindered amine light stabilizers (HALS).

For solvent-based and other non-aqueous systems, Tinuvin^® 400 and Tinuvin^® 479 provide UV protection by absorbing harmful ultraviolet radiation. Tinuvin^® 123 and Tinuvin^® 249 complement these UV absorbers by preventing polymer degradation and extending coating service life.

For waterborne formulations, BASF’s Tinuvin^® DW-ECO portfolio provides comparable performance tailored to aqueous systems. Tinuvin^® 400-DW ECO and Tinuvin^® 479-DW ECO deliver strong UV protection and excellent photo-permanence, while Tinuvin^® 123-DW ECO and Tinuvin^® 249-DW ECO enhance weathering resistance and long-term durability.

Selecting the appropriate combination of UV absorbers and HALS technologies can significantly improve weathering resistance and durability, helping coating systems maintain both appearance and protective performance during extended service intervals.

Looking Ahead

The future of protective and marine coatings will be defined by the industry’s ability to balance several performance objectives, including corrosion protection, sustainability, application efficiency, durability, and lifecycle value.

Advanced additive technologies are helping formulators meet these demands by enabling lower-VOC systems, improving corrosion resistance, enhancing application performance, and extending service life. From dispersion and corrosion-control solutions to defoamers, wetting agents, and durability-enhancing additives, BASF’s portfolio continues to play a strategic role in supporting the next generation of protective and marine coatings.