Interview: “Corrosion creates a major but often hidden environmental burden”

How significant is the environmental burden caused by corrosion-related waste streams and what are the broader environmental implications?

Jorrit van Rijn: Corrosion creates a major but often hidden environmental burden. Globally, around 40% of new steel production is used to replace metal that has already corroded, driving unnecessary energy use, emissions, and waste. This replacement cycle is estimated to account for about 3.2% of global CO₂ emissions that could be avoided with better corrosion protection.

In Europe, this issue is becoming more visible as regulations increasingly focus on embodied carbon, durability, and product lifespan. Corrosion-driven early replacement leads not only to more waste and landfill, but also to higher carbon footprints and compliance risks. Extending the life of products through better corrosion protection is therefore one of the most effective ways to reduce both environmental impact and resource consumption.

What role do coatings play and how can coating formulators technically contribute to reducing the environmental waste highlighted in the report?

Van Rijn: Coatings play a critical role in slowing corrosion and extending product life, which directly reduces scrap, rework, and premature replacement. Their environmental value comes from durability: the longer a product lasts, the fewer resources and less energy are needed to replace it.

Coating formulators can contribute by:

• Delivering higher protection levels: As environments become harsher and product lifetime requirements increase, many applications are moving from the ISO 12944 ‘medium’ C3 protection standard to ‘high’ C4, or even ‘very high’ C5 levels to achieve expected durability
• Reducing edge corrosion: Corrosion often starts at sharp edges, where coatings naturally thin during curing. Formulators can adjust powder flow so enough coating remains on these areas, an essential factor for achieving high-durability performance in C4/C5 environments
• Developing single-coat or thinner-film systems that maintain performance while reducing material use and waste.

With up to US$875 billion in preventable corrosion costs, how can advanced testing methodologies help coating suppliers better validate long-term environmental benefits?

Van Rijn: Advanced testing helps coating suppliers prove that longer-lasting corrosion protection delivers real environmental benefits. Historically, the industry relied on continuous salt-spray tests, but today the focus has shifted to cyclic corrosion testing, such as those referenced in ISO 12944, which combine salt exposure with drying phases, humidity, and UV light. These more realistic cycles better reflect real-world weathering and give manufacturers greater confidence in a coating’s true service life.

This is important because the corrosion costs are considered preventable, and avoiding premature failure reduces the need for replacement materials, energy use, and emissions. Strong testing also supports European regulatory and customer expectations by providing credible evidence of long-term durability.

To what extent can advanced powder-coating technologies lower the environmental footprint of manufacturing by extending product lifecycles and reducing resource consumption?

Van Rijn: Advanced powder-coating technologies can significantly reduce environmental impact by extending product lifecycles and improving manufacturing efficiency. Survey data shows that 76% of manufacturers say powder coatings extend product lifespans, while 74% believe they reduce environmental impact and 68% say powder coatings provide the best production efficiencies, underlining the direct link between durability, efficiency and sustainability.

By extending service life, powder coatings help reduce the need for replacement steel and remanufacturing, an important factor given the scale of corrosion-related material loss. At the same time, innovations such as single-coat systems and thinner films allow manufacturers to use less material while maintaining performance, further reducing waste and resource consumption.

How are evolving environmental and performance standards driving innovation in sustainable corrosion protection across global manufacturing markets?

Van Rijn: Globally, environmental regulations and rising durability expectations are encouraging manufacturers to place greater focus on product lifetime, material efficiency, and carbon transparency. Long-lasting corrosion protection is increasingly seen as a way to support sustainability goals while improving asset reliability. To support these efforts, the industry is making wider use of Environmental Product Declarations (EPDs), which provide independently verified data on the embodied carbon of coatings. This helps manufacturers calculate the full lifecycle impact of finished products and make more informed, sustainability-led choices. At the same time, manufacturers are increasingly relying on third-party performance approvals, such as Qualisteelcoat in steel applications, to validate the long-term corrosion resistance of powder coatings. These certifications provide confidence that coating systems deliver proven durability in demanding environments.

Together, these trends are driving innovation in coatings that extend product life, reduce resource use, and contribute to more sustainable manufacturing.

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