Sappi Saiccor Mill Expansion – 25-Year Protective Coating Specification

Project Overview

The expansion of the Sappi Saiccor dissolving pulp mill in KwaZulu-Natal, South Africa required a protective coating system capable of providing long-term corrosion protection within an aggressive pulp and paper manufacturing environment.

The project incorporated significant structural steel fabrication and required a coating specification capable of delivering a projected 25-year service life, alongside a 10-year guarantee.

Sustainability boost for world's largest dissolving pulp mill, Sappi South Africa | AFRY

Project Requirements

The project presented several simultaneous requirements.

The coating system needed to provide:

  • Long-term corrosion protection
  • A 25-year life expectancy
  • Efficient application across multiple fabrication locations
  • Technical support throughout the project
  • An aesthetically acceptable finish
  • Rapid application to support a demanding programme

The scale and schedule of the project meant coating productivity was an important consideration alongside the final performance of the system.

PPG Coating System

PPG proposed a three-coat system comprising SIGMAFAST 278 and SIGMADUR 1800.

SIGMAFAST 278 was used as the zinc phosphate epoxy primer and build coat, while SIGMADUR 1800 provided the final polymeric urethane finish.

SIGMAFAST 278's fast-drying characteristics were particularly relevant to the project, supporting airless application and allowing the coating process to progress efficiently.

Project Outcome

The coating proposal addressed both the long-term protection requirements and the practical demands of a large industrial construction project.

The specified system was designed around a 25-year life expectancy while supporting efficient application across multiple fabrication sites.

The project demonstrates the importance of considering coating lifecycle, application productivity and technical support together when specifying protective coatings for large industrial developments.

For industrial facilities operating in aggressive environments, coating selection should be considered as part of the wider asset lifecycle strategy rather than simply a construction-stage requirement.

Back to blog