PROTECTING BRUNEL’S VISION >> - Sherwin-Williamsprotectiveemea.sherwin-williams.com/Documents/Distributor/ECoating...PROTECTING BRUNEL’S VISION FOR ANOTHER 25 YEARS >> Use of coatings

IN-DEPTH >>Dangers of assumed design.

FLAME PROTECTION >>Azerbaijan’s latest, tallest building.

PROTECTING BRUNEL’S VISION FOR ANOTHER 25 YEARS >>Use of coatings to preserve the historic Royal Albert Bridge.

Autumn 2014

Your Source For Coating Solutions

Introduction

Protective & Marine Coatings Europe, Middle East & Africa

http://protectiveemea.sherwin-williams.com/


2 | sherwin-williams.com/protectiveEMEA

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Autumn 2014e coatingsolutions

I would like to extend a warm welcome to this, the first e-coatings magazine for Sherwin-Williams Protective & Marine Coatings in Europe, Middle East & Africa.

Welcome

We want to share the latest news and developments from around our division, including product news, projects and people.

Our Joint Venture with Saudi Arabia-based Red Sea Housing in the Middle East to create Premier Paints puts into perspective how we are seizing opportunities wherever they may arise. This collaboration is already up and running and paying dividends for us, serving customers in the busy architectural, energy and construction sectors in the region.

With Ceramic Polymer Coatings, Sherwin-Williams will be the sole UK distributor for the range of coatings which feature integrated micro-ceramic particles for diverse sectors worldwide including the petrochemical, maritime and biogas industries.

Development of our technology, too, is vital and has enabled us to launch a range of new, key products including Dura-Plate 301W, Heat-Flex® Hi-Temp 1200 and Acrolon 1850, bringing benefits to our customers across the Europe, Middle East and Africa region.

Even our name has changed for all to see, with the iconic tower now bearing the Sherwin-Williams name.

Indeed, we are making progress throughout our business and as we move past the halfway point of another year, we can report a positive start all round, and long may it continue.

Gordon Bell, General Manager – EMEA

Contents



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Contents Software Launch

Dangers of assumed designBy Bob Glendenning

9

new products

case study:royal albert bridge

8

13

CE markingBy Dr Andrew Taylor.

17 news

contacts21

23

In-depth



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FDE2.0A new level in fire design estimation

Coatings PlusSoftware Launch

Sherwin-Williams’ market-leading FIRETEX® Design Estimator 2.0 software has been updated to offer customers increased benefits.For the first time, the software offers the capability of providing calculations for all shapes of apertures within cellular beams as well as efficient handling of unfilled voids with trapezoidal profiled metal decking systems.

Other benefits include project sharing and guidance to all emerging Eurocode Design, independently tested and fully verified under the Exova Certifire scheme and, in the case of cellular and fire engineered beams, further verified by the University of Manchester.

Sherwin-Williams’ Fire Engineering & Estimation Team, made up of fully qualified structural engineers, provides fire design calculations for the most complex of needs for both cellulosic & hydrocarbon fire scenarios.

Bob Glendenning, Fire Engineering & Estimation Manager, at Sherwin-Williams, said: “This software is breaking new ground in terms of its availability and capabilities, and we believe it offers unrivalled accuracy and time and cost savings for our customers.”



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The programme of technical seminars aimed at key Sherwin-Williams customers has been extended.

Coatings Plus was launched to help fast track new product technology launches, and consisted of an innovative series of seminars allowing customers to gain a fuller understanding of products.

The programme’s existing modules include:

■ Best in class epoxy linings with Optically Activated Pigments (OAP).

■ Next generation Corrosion Under Insulation (CUI) protection.

■ Advanced abrasion resistance.

■ Advanced surface and humidity tolerant coatings.

■ Glass flake technology.

Now the next phase of the Coatings Plus scheme has been unveiled, with modules:

■ Fire – a general introduction.

■ Fire – hydrocarbon.

■ Fire – cellulosic.

■ Acrolon 1850 offshore top coat product.

Case StudyLunch & Learn



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As an iconic, inspirational project breaking new ground in tall buildings, the Flame Towers project in Azerbaijan presented numerous safety challenges, not least of which was the fire protection of the steel structure itself.

With large numbers of people moving about in the three separate towers reaching 650ft tall, the concept for the buildings in the Baku district on a hill overlooking the Caspian Sea presented a leap of faith in the development of the region.

The estimated cost of the Flame Towers was around 350million US dollars, with the construction phase taking from 2007 to 2012. Only recently has the full scale and investment of the towers been fully realised.

The Challenge

Case Study: Flame Towers, Azerbaijan Next Page


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In Summary

Given the height and nature of the buildings, the ability to buy two hours of fire protection was of crucial importance, providing the fire services enough time to evacuate the buildings and make any rescue necessary during that time.

Without this protection, and in the event of a real fire, the steel would collapse before that timeframe, creating a potentially life-threatening situation for those moving about the building.

The choice of FX5120 from the FIRETEX® range for the last 22-26 metres of steel structure – known as ‘the flicks’ – meant the fire protection of two hours was possible, along with ease of application for the applicators from Prosys Protective Systems Ltd, working with consultant engineers.

Having made a comprehensive assessment, experts from Sherwin-Williams recommended FIRETEX® FX5120 for its protection qualities along with its easy application as a water-based coating with strong humidity, adhesion and strength.

With the FIRETEX® FX5120 intumescent coating system approved to all relevant international standards, the protection offered to a project of this nature has met all safety protection requirements for all parties.

Indeed, since completing the Flame Towers project, PROSYS has used FIRETEX® FX5120 for the Renault Project at Bursa factory in Turkey, a large spare parts warehouse covering 32,000m2.

The SolutionNext Case

Study


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Acrolon 1850Next generation coating protects offshore assets

Product Launch

Acrolon 1850 is a new, non-isocyanate topcoat technology developed to assist the offshore maintenance sector.Maintenance in offshore environments provides a range of challenges for the coatings industry. Acrylic urethanes are generally regarded as the standard topcoats for many industries, but contain isocyanates which are prohibited or undesirable in many offshore markets including the North Sea.

One of Acrolon 1850’s key benefits is the ability to achieve full coverage in a single coat by brush or spray allowing rapid return to service and reduced downtime for customers.

Other properties include strong gloss retention, good results in UV, and weathering performance to prolong service life.

Lee Spoor, Oil, Gas & Chemical Project Development Manager, said: “The use of isocyanates in the offshore market is not normally possible, but this product gives those in the maintenance sector a next generation alternative, providing features that were not an option previously.”

Macropoxy C88


9 | sherwin-williams.com/protectiveEMEA Autumn 2014e coatingsolutions

Dangers of assumed designBy Bob Glendenning, Fire Engineering & Estimation Manager – Global

In-depth

In scoping out designs for today’s modern complex buildings in our cities and where large numbers of people move about, design engineers have a host of considerations to take into account.

In-depth Cont’d



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The principal material used today is steel - now one of the key elements of any new building design – often due to the loads steel members can bear such as long span beams which require both strength and serviceability considerations.

With these parts of the building infrastructure already designed and prescribed, the fire engineer working with the designer can then advise on the most effective level of fire protection.

Traditional ‘prescriptive’ approaches use pre-defined limiting steel temperatures based on the individual parts of the steel structure, usually following recognised codes of practice.

These limiting temperatures are agreed in codes of practice with conservative calculations of maximum loads to ensure the relative passive fire protection – including intumescent coatings which offer resistance to fire – is more than adequate.

Some of those in the supply chain may question why these steel parts – whether a beam, column or brace for example – would be overly-specified and under-utilised in terms of their load bearing capacity in their ambient design state.

In reality, this performance-based approach allows designers to account for different applied loads being used in various parts of a building for a diverse set of reasons rather than a ‘one-size-fits-all’ prescriptive approach which assumes loads and tolerance.

The trend to assume loads well under the reality of performance-based modelling on each section of steel in today’s complex buildings – thus creating savings for the project in fire protection – is dangerous indeed.

For intumescent coatings, any compromise of the thickness could severely affect the level of fire protection where a steel section may carry a higher load than was allowed for by the fire protection expert and collapse under stress when subjected to a real fire as the section properties change.

The risk of collapse is relative to how far the original assessment has been made below the real applied loads – and with the subsequent protection also reduced accordingly – this type of scenario offers little reassurance of what will happen in reality and is unsafe.

Dangers of assumed design Cont’d.

In-depth In-depth Cont’d



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In-depth CE Marking

Dangers of assumed design Cont’d.

In-depth

It is more time-consuming – but still potentially cost-saving for the project – to apply accurate calculations of each key section of a building but much safer for all concerned including the building owners or managers, who are liable under the Regulatory Reform (Fire Safety) Order 2005.

In principle, if these separate steel sections are under-utilised in all calculations, they should be safe in a real fire where adequate fire protection has been designed and applied.

This guarantees safety and strength of the steel and of the fire protection coating, which enables fire safety services to enter a building, read the fire alarm data and enact a safe evacuation of any occupants from the building.

The potential level of savings when structural fire engineering is used genuinely can still be worthwhile – and more importantly safe.

It is the responsibility of the fire protection expert to establish the correct level of steel ambient utilisation and with it the appropriate level of protection.

Working with designers, the fire performance expert can then agree the safe level of protection necessary for the sake of lives and property.



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Macropoxy C88Full coverage in a single coat

Dura-Plate 301WProduct Launch

Macropoxy C88 complements Sherwin-Williams’ existing epoxy portfolio, and offers customers cost-effective performance in corrosive environments.A multi-purpose tolerant epoxy, the product is suitable for use as a primer, build coat or finish coat and boasts a versatile formula which can serve new building and maintenance projects in both atmospheric or water immersion services.

Macropoxy C88 is recommended for the petrochemical, oil & gas, power and infrastructure sectors, on projects including onshore and offshore structures, steel bridges, refineries, tank exteriors and petrochemical assets.

Key features include a full colour range, fast drying times, ease of use and a range of approvals including ISO12944, NORSOK M-501 and Network Rail.

Customers will benefit from a reduced application time and versatile usability in both maintenance and new build. Macropoxy C88’s formula achieves full coverage in a single coat, allowing rapid return to service and reduced downtime.



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Case Study: Royal Albert Bridge

Protecting Brunel’s vision for another 25 years.Designed by Isambard Kingdom Brunel and completed in 1859, the bridge provides the only rail connection between Cornwall and the rest of England.

Next Page



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In terms of preserving important, historic landmarks, the task of protecting the Royal Albert Bridge spanning the River Tamar presented a number of challenges, not least the number of rivets, back to back angles and the chains.

Opened by His Royal Highness Prince Albert, this industrial looking structure with spindly piers and beefy tubular arches, retains a period elegance and appeal, while still providing the route for modern rail transport.

The environment is aggressive due to the relatively high levels of humidity and salinity from the tidal river below so the specified protective system had to provide a protective envelope that will give 25 years’ anti-corrosion protection to first major maintenance.

Next PageThe Challenge


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In Summary

Based on the successful application of glass flake epoxy systems used to repaint the Forth and Tay Rail Bridges, Network Rail decided to continue along these lines and specified a glass flake epoxy system. Main contractor, Taziker Industrial Coatings, selected Sherwin-Williams as its paint supplier.

The existing paintwork was totally removed by abrasive blast-cleaning. The coating system comprised Metagard L674 Epoxy Blast Primer at 50μm minimum dry film thickness (MDFT), Epigrip C123 Glass Flake Epoxy at 400μm MDFT and Resistex C137V2 Acrylic Urethane Finish at 50μm MDFT. A stripe coat of Epigrip C123 Glass Flake Epoxy was applied at 250μm MDFT between coats one and two to all rivets, sharp edges and joints, etc. A total minimum dry film thickness of 500μm was applied.

Working over a live railway, the applicators applied the stripe coat by brush to all rivets and sharp edges. The internal surfaces of the chains were coated using a roller, all the other coats were applied by airless spray.

Originally developed to protect offshore structures from the severe marine environment in North Sea oil & gas applications, the epoxy glass flake resin system adapted well for this purpose.

The system eliminated the need for ongoing maintenance, significantly reducing environmental impact, saving on repair costs and extending asset life.

The three-coat preventative maintenance coating system provides excellent adhesion and anti-corrosion properties and acts as a powerful barrier against the harsh weather conditions in this aggressive marine environment.

This technology – first used to famously complete the painting of the Forth Rail Bridge in 2001-2011 – has put glass flake epoxy-based systems at the forefront of bridge painting.

The SolutionDura-Plate

301W


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Dura-Plate 301WAddressing the maintenance challenge

Product Launch

Sherwin-Williams has extended the Dura-Plate 301 line of products to help meet the challenge of year-round coating work.To date, more than 15million sq m of steel has been protected by the suite of Dura-Plate 301 products across the world, including offshore platforms, ships, steel bridges, refineries and tanks.

These products have become well known for durable application over damp surfaces, flash rust, existing coatings and excellent adhesion.

Now the product line has been extended to further meet the demands of the market, with Dura-Plate 301W unveiled, offering cold curing down to 0°C and extended re-coatability of up to six months.

The new product will offer customers a longer painting calendar and increased efficiencies with reduced project costs. Following low temperature trials in the UK, it is successfully being used on major projects in South Brazil, China and Japan.

Heat-Flex® Hi-Temp

1200



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In-depth Intumescent

Coatings

In-depth

One of the most significant impacts on the European coatings market in the last 12 months has been the introduction of the Construction Products Regulation, which came into effect in July 2013.

CE MarkingBy Dr Andrew Taylor, Head of Science

This directly affects the entire supply chain, from manufacturers to end-users and architects. The introduction made it mandatory for manufacturers to apply the CE mark to any products covered by a Harmonised European Standard (hEN) or European Technical Assessment (ETA).

A hEN does exist for steel, but not for intumescent coatings so CE marking is not compulsory in this sector. However, the industry is working towards a hEN – but this is unlikely to be in place until 2020 at the earliest.

Until this point, individual countries may continue to use their own classification systems until they are superceded by CE marking.

In Germany, the Deutsches Institut für Bautechnik allows the use of two possible approval routes:

1. Bauaufsichtliche Zulassung (Ü Mark), tested to DIN 4102-2.

2. European Technical Assessment (ETA), classified to EN13501-2, tested to EN13381 (CE Mark).

Both approvals also require additional environmental classifications to ensure that any internal coatings used meet the necessary Indoor Air Quality safety standards.

It is important to note that although CE marking is not compulsory at this stage, the ETA listed above is still accepted as an approval route. However, there is significant resistance within the German market.

The Ü Mark is still by far the most widely used approval route, currently used in an estimated 90 per cent of approvals.

However, with CE marking set to become compulsory once the necessary hEN is in place, Sherwin-Williams has been at the forefront of communicating the potential benefits that this change will bring and encouraging its early adoption in preparation.

Experience shows that the CE Mark is as rigorously tested as the Ü Mark, so it is important that the German market begins to prepare for what will be a major change. Early adoption will help smooth the way for the CE Mark’s eventual introduction.

Mat

eria

lprüfanstalt f. d. Bauw

esen

B r a u n s c h w eigVMPA

Z-19.11-1963(F30, F60, F90)



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Heat-Flex® Hi-Temp 1200CUI breakthrough product is unveiled

Product Launch

A breakthrough coating for the Corrosion Under Insulation (CUI) petrochemical market has been unveiled by Sherwin-Williams.Heat-Flex® Hi-Temp 1200 boasts high heat resistance up to 650°C, and is already having widely-acclaimed success in America thanks to its effective applications to carbon steel or stainless steel.

Project applications include pipes, tanks, vessels and stacks in offshore and marine installations, power plants, refineries and major chemical industry facilities.

Heat-Flex® Hi-Temp 1200 has been tested under the boiling water test, with no adhesion loss, no blistering and increased flexibility, and the CUI Test, during which it had no adhesion loss after 80 cycles, an excellent rating for both rust and blistering.

Lee Spoor, Oil, Gas & Chemical Project Development Manager for Sherwin-Williams, said: “Heat-Flex® Hi-Temp 1200 raises the bar in its field, with higher temperature applications, extending service life and offering improved environmental benefits with fewer volatile organic compounds emitted and long-term durability.”

In-depth Intumescent

Coatings



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In-depth Cont’d

The changing face of intumescent coatings in GermanyBy Dr Andrew Taylor, Head of Science

The science behind intumescent coatings

Intumescent coatings are a crucial part of any structural steel development, providing vital passive fire protection.

Thin Film Intumescent Reaction

In-depth

Appearing to all intents and purposes an ordinary coating, with a thicker film, in a fire they demonstrate unique properties.

A series of chemical reactions swell the coating to many times the original thickness, to provide an insulating char or foam. As this char has low thermal conductivity characteristics, this in turn protects the steel substrate from the effects of the blaze for as much as two hours – extending the time for the steel to reach structural failure and potentially saving lives.

Intumescent coatings are broadly classifiable into two different types: thin film and thick film. Thin film coatings are solvent or water-based and mainly used to protect against cellulosic fire conditions as described above.

Typically, a thin film coating will expand to as much as 50 times its original thickness when exposed to the necessary temperatures thanks to a mix of three components – a primer, a basecoat which reacts to the fire, and a sealer coat.

Column B has 1.07mm of coating applied.Column A has 3.2mm of coating applied.

Steel columns applied with FIRETEX® FX Systems, before and after fire test burn.

A BA B



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NewsThe science behind intumescent coatings Cont’d.

In-depth

Thick film intumescent coatings were developed for the offshore and hydrocarbon industries for use in protection against pool and jet fires, but are now more widely used thanks to industry advances. They typically expand to five times their original thickness as opposed to a thin film at 50 times.

FIRETEX® thick film intumescent jet fire test

Sherwin-Williams has many years’ experience in manufacturing and supplying specialist intumescent coatings. Its FIRETEX® FX Systems, for instance, is a leader in the field of cellulosic passive fire protection and has been used in projects including The Shard Glass in London, Turkey’s Sonkar Hilton Hotel, Bay Arena for Bayer Leverkusen in Germany and the UK’s Heathrow T5.



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Sherwin-Williams sole UK distributor for specialist coatings.

Middle East market to benefit from joint venture.

NewsCustomers working in sectors requiring the highest levels of protection will benefit from a new range of coatings brought to the UK by Sherwin-Williams’ Protective & Marine Coatings division.

Working with Ceramic Polymer GmbH, Sherwin-Williams has been chosen as the sole UK distributor for the coatings, which feature integrated micro-ceramic particles, aimed at markets including petrochemical, maritime and biogas.

The coatings are applied directly onto steel, stainless steel and concrete without use of a primer, with subsequent savings in time and cost over conventional multi-layer systems.

They offer unrivalled levels of corrosion protection, outstanding adhesion, extreme abrasion resistance, excellent resistance to impact, high bending flexibility and are 100% solvent-free. They also provide excellent chemical and thermal resistance for extreme operating environments.

Carl Flavell, Sales Director for Sherwin-Williams, said: “The combination of the range of products and our network support will provide UK customers with a further service, enabling access to specialist protection where required.”

Middle East markets including architectural, energy and construction are to benefit from a new business created as part of a joint venture in the region.

The venture, between Sherwin-Williams and Saudi Arabia-based Red Sea Housing Services Company, has created the Premier Paints Company.

The company will support the distribution and sales of Sherwin-Williams’ architectural and protective coatings systems.

It was officially opened by His Excellency Dr. Tawfiq Al Rabiah, Saudi Arabia’s Minister of Commerce and Industry, and the facility is supported by a dedicated technical team offering advice across the portfolio of products and services.

Chris Connor, Chairman and CEO of Sherwin-Williams, said: “We thank the Red Sea Housing Services Company for their expertise and support as we embark on this exciting joint venture opportunity to increase the presence of Sherwin-Williams in the Middle East market.”

News Cont’d



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Major investment in Bolton site announced.

NewsA significant investment is to be made in the historic home of Sherwin-Williams in Bolton.

The investment programme, totalling £1.7million, will largely support health & safety programs. It will also focus on equipment developments such as labelling and additional top coat tinting capacity.

As part of the work, the site’s Leigh’s Paints branding has been removed from the historic 100ft high tower which forms part of the 355,000sq ft site, to be replaced with Sherwin-Williams branding.

The tower is part of the five storey former mill building at the heart of the site which houses the main production areas. The Kestor Street site was originally built as a cotton mill in 1844 and in 1939 was transformed into a paint factory.

Gordon Bell, General Manager of Sherwin-Williams, said: “This is a significant investment in the site, and marks Sherwin-Williams’ commitment to Bolton and the team of staff we have based here.”

“Working at the cutting-edge of such a fast moving industry requires continual investment and our customers expect us to remain at the forefront of the sector. This investment will allow us to continue to lead the way in developing new technologies to better protect customer assets.”

Gordon Bell, General Manager.

Contacts



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Below are contact details for some of our experts should you wish to know more about topics covered in this edition of e-coatingsolutions

Contacts

Lee SpoorOGC Project Development Manager

email. [email protected]

Lee Spoor is OGC Project Development Manager,EMEA region. With more than a decade’s experience in the technical services department, and over 15 years in total, Lee is involved with all types of protective coatings and fireproofing systems. He is a NACE certified coatings inspector, and an ICorr fire proofing inspector – level 2.

Sandra BallProduct Manager


Sandra Ball is Product Manager, EMEA region, responsible for driving profitable growth through active management of the product portfolio. Her role oversees the complete Protective Coatings & Passive Fire Protection portfolio for the EMEA region with regards to its life cycle, continuous rationalisation, positioning, new product development and competitive intelligence.

Dave BottomleyProject Development Manager


Dave Bottomley is a Project Development Manager, EMEA region, focusing on highways and rail bridges and infrastructure. Dave has over 40 years’ experience in this sector having worked for British Rail Research, Corrosion & Corrosion Group for over 25 years before joining Sherwin Williams 16 years ago. Dave is a Chartered Chemist and a Professional Member of the Institute of Corrosion.

Dr Andrew TaylorHead of Science


Dr Andrew Taylor is Head of Science for Sherwin-Williams Protective & Marine Coatings’ EMEA region. In his role he oversees the work of the Innovation team, investigating novel technology platforms for both protective coatings and fire resistant materials. He also sits on various European committees in the field of fire protection standard development.

Bob GlendenningFire Engineering & Estimation Manager


Bob Glendenning is Manager, Fire Engineering & Estimation, Sherwin-Williams Protective & Marine Coatings EMEA region, focusing on specialist fire protection products, operating globally whilst overseeing two offices in the UK and India. He is an expert in assessments of steel structure engineering and also manages training internally for employees and externally for customers.

Hakki TurerOwner – Prosys, Inc. Specialist Paint & Coatings


Hakki Turer specialises in the distribution and application of paint and coatings for industrial and commercial structures in the oil & gas, pipelines and chemical industries and for fire protection of steel, flooring and construction materials. Hakki has a Bachelor of Science in Civil Engineering, Middle East Technical University and Masters in Industrial Engineering, University of Bolton.

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To learn more, contact us

Europe & Middle East: +44 (0)1204 521771 North America: +1 800 524 5979Asia: +8621 5158 7798

sherwin-williams.com/protectiveEMEA

©2014 The Sherwin-Williams Company Protective & Marine Coatings

[email protected]

Front Cover

Autumn 2014

Your Source For Coating Solutions

Protective & Marine Coatings Europe, Middle East & Africa

Thank you, we hope you enjoyed reading the first edition of e-coatingsolutions. We always like to hear feedback with any of our communications, so please feel free to email us any comments.

http://sherwin-williams.com/protectiveEMEA


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