Marine Coatings: The 2% investment that determines a ship’s fate

Riviera Maritime Media recently published the Marine coatings: the 2% investment that determines a ship’s fate article written by Edwin Lambert featuring Dr. Raouf Kattan, founder of Safinah. In the article, Dr. Kattan advocates for shipowners, operators, and shipyards to adopt data-driven coating selection based on actual vessel performance. Current practices, often reliant on generic paint systems, lead to costly failures that undermine vessel longevity and operational efficiency. 

Read the article highlights below or go to the original publication. 

The role of marine coatings in vessel longevity

Marine coatings are critical to the structural integrity and operational performance of ships. As Dr. Kattan explains, a vessel is essentially a steel structure held together by a thin layer of paint. Without anti-corrosive coatings, a ship’s lifespan could be reduced from 20 years to as little as five years. Despite their importance, coatings historically have been undervalued, often viewed as minor considerations during construction. Coatings account for just 0.5–2% of newbuild costs but can consume up to 10–20% of construction man hours. When coatings fail, the financial and operational impacts can be severe, leading to vessel downtime and significant opportunity costs.

Bridging knowledge gaps in the industry

When he established the Safinah Group in 1998, the marine coatings industry was fragmented. Expertise was divided between paint inspectors and consultants with limited collaboration. Dr. Kattan introduced the concept of a “coating engineer” to bridge the gap between paint manufacturers’ chemical expertise and the practical needs of shipyards and operators. This new role integrates functional requirements with technical knowledge to optimise coating selection and performance.

Challenges with regulatory frameworks

Dr. Kattan is critical of the regulatory landscape, noting that regulations are often developed through compromises that can lead to technical shortcomings. He emphasises the importance of assessing the full impact of regulations across the value chain. For example, efforts to reduce volatile organic compounds in coatings during the 1990s introduced challenges in product safety and manufacturing due to the resulting high-solids formulas.

He also questions the unclear distinction between regulations and guidelines, which complicates their interpretation and implementation.

Advancements in Coating Technologies

Dr. Kattan is optimistic about emerging technologies that could revolutionise the marine coatings industry. Some promising developments include:

• Smart paints: These coatings contain embedded electronics for data gathering, enabling early detection of problems.
• Alternative coatings: Solutions like films, already in use on yachts and cruise ships, can address challenges in complex geometries where traditional coatings often fail.
• Biocide-free antifouling solutions: Innovations like UV-C light-emitting diodes (as part of the Runwell Project) and Selektope are reshaping biofouling prevention without environmental harm. However, Dr. Kattan stresses the need to assess the broader impact of these technologies, including their effects on global shipping capacity and environmental sustainability.

The importance of data-driven decision-making

Dr. Kattan emphasises the necessity of structured, independent performance data to guide coating decisions. Currently, shipowners lack comprehensive data to compare coating systems effectively. Safinah Group’s large-scale operations—managing coatings for over 200 vessels and overseeing 250–300 drydockings annually—enable performance benchmarking across fleets and trade routes. This data helps optimise coating strategies based on specific operational profiles, such as trade routes, cargo types, and activity levels.

Balancing environmental goals with practical needs

Dr. Kattan highlights the importance of balancing environmental protection with operational requirements. For example, the industry’s shift toward biocide-free antifouling systems requires careful analysis. A move to regular hull cleaning instead of biocidal coatings could necessitate 10% more ships to maintain current shipping capacity, increasing environmental and operational costs.

Transforming the marine coatings industry

Dr. Kattan’s efforts have elevated marine coatings from a “Cinderella subject” to a recognised engineering discipline. For his contributions, he has been honoured as a Fellow of the Royal Academy of Engineers and awarded an OBE in 2025.

Despite this progress, much work remains. Dr. Kattan calls for a comprehensive understanding of vessel performance and coating interactions to identify optimal solutions tailored to specific operational needs. By combining vessel performance analysis, coating expertise, and operational data, the industry can unlock new opportunities for innovation and efficiency in marine coatings.