Propeller Cone Repair: Marine Ship, Italy

3rd December 2024

Industry: Marine
Location: Italy
Application: Propeller Cone Repair
Products: 507 DWPU

The Problem

A Kamewa propeller cone at a marine facility in Italy required urgent repair following the discovery of extensive erosion and corrosion damage. Prolonged exposure to high velocity seawater and turbulent flow conditions led to severe metal loss and pitting. The surface degradation compromised the hydrodynamic efficiency of the propeller cone, directly impacting the vessel’s fuel consumption and overall operational reliability. Localised pitting posed a high risk of through wall failure, which would necessitate a costly and time consuming full component replacement. The client needed a repair solution that could be completed during a standard dry dock window to avoid extended operational downtime.

The Solution

The repair process utilised Resimac 507 DWPU, a high performance polyurethane coating. Preparation began with abrasive grit blasting the substrate to SA2.5, achieving a 75-micron profile per ISO 8501/4 standards. This ensured optimal adhesion by removing contaminants and corrosion from the propeller cone.

Following preparation, deeply pitted areas were systematically stripe coated. Technicians used specialised plastic applicators to force the Resimac material into the profile, effectively filling all voids and restoring the structural integrity of the metal. Once the repairs were levelled, two separate layers of 507 DWPU were brush applied to the internal surfaces of the propeller cone. Each layer was applied at a nominal thickness of 500 microns, totalling a 1000 micron dry film thickness. This multi layered, wet-on-wet application prevented air entrapment and created a seamless, non-porous barrier against impingement and electrochemical corrosion.

The Outcome

Successfully restored to its original structural integrity and performance specifications
Established a durable 1000 micron barrier engineered to withstand harsh marine environments
Significantly prolonged the lifespan of the propeller cone, reducing costs by avoiding of a full replacement
Improved vessel reliability and minimised the risk of unplanned downtime
Reduced long term maintenance costs by providing a high performance, wear resistant surface
Verified the repair through rigorous ISO 8501/4 surface preparation standards for guaranteed coating longevity