GA lepepeiPCE NOTES ON the Application and Maintenance of Marine Coating SystemsOURS s10N The mission of the American Bureau of Shipping is to serve the public interest as well as ‘the needs of our clients by promoting the security of life, property and the natural environment primarily through the development and verification of standards for the design, construction and operational maintenance of marine-related facilities. quality, oy Itis the policy of the American Bureau of Shipping to provide quality services in support of our mission and to be responsive to the individual and collective needs of our clients as well as those of the public at large All of our client commitments, supporting actions, and services delivered must be recognized as expressions of quality. We pledge to monitor our performance as an on-going activity and to strive for continuous improvement. a ABSGUIDANCE NOTES ON the Application and Maintenance of Marine Coating SystemsSaxe Sree: A Guonce Man Fn Feo Sunes ABS INTRODUCTION Steel structure of a vessel is prone to corrosion throughout its’service life. Due allowance must be made at the new-building stage, and by periodic maintenance to provide effective corrosion protection to ensure continued structural integrity of the vessel. With the emphasis on coatings in the Enhanced Survey Scheme, and with the unprecedented acceleration of coating technology, the field surveyor should have some basic factual knowledge on coating systems. It is the intent of this guide to meet this need in a straight forward and practical manner.Conrivs Svereus: A Guoance Manual ron Fin Suavevons ACKNOWLEDGEMENTS This guide draws on many sources for its contents. ABS wishes to acknowledge the assistance and guidance provided by all who contributed to it, in particular the following active members Bemard Michael Phi Ron Dennis Helena sim Rong Owen Joseph Tom Tom Ramesh Bruce Bob Charles Richard Dave Frank of the ABS Ad Hoc Panel on Coatings: Appleman, Steel Structures Painting Council Bentjae lempel Paints Birleson .. IRS Ship & Offshore Briggs. -Matson Navigation Buffo. sabine Transportation Co. Buist si NACE Denny... {Courtaulds (International Paints) Huang vusChevron Shipping Jones. Royal Chemical Madden. = ‘Arco Transportation Malniyte.. Marine Transport Lines Mulligan Devoe Coatings Raghavan. Sigma Coatings Sawvel 2 Esgard Stanley Maritime Overseas Carriers Stuckey, .-Drew Ameroid/Ashland Whiteside. BP Oil Shipping Co. Witmer LBP Oil Shipping, Co, Chairman NACE TC-14B Windler.. a Scherwin Wiliams. Zagraecki Unitor ~ Gus Bourneuf Chie? Surveyoreu: A rome Nai on Fa Smo ABS CONTENTS CHAPTER ONE: What is Paint? Paint Technology. Binders “Thermeset Coatings. Air Drying Resins. Oleoresinaus Varnishes... Alkyd Resins. Epony Ester Resins, Urethane Oi/Alkyd Resins Silcone Alkyd Resins Siento miele AR ees Inorganic Resins ‘Thermoplastic Coatings. Chlorinated Rubber Resins. Vinyl Resins Bituminous Binders... Pigments and Extenders - ‘Antieonosive Pigments. Red Lead Zine Chromate. Zine Phosphate... Zinc... ~ Barrer Pigments. Coloring Pigments... Extended Pigments. Solvents ‘Other Paint Additivites... ‘Typical Groups of Paint Additives. CHAPTER TWO: Corrosion Introduction. Steel and the Corrosion Reaction Principals of Corto 0M eve Corrosion in Humid Environment... Corrosion in Acide Environment Galvanic or Bi-metalic Corrosion ‘Types of Cortasion. Uniform Corrosion Pitting Corrosion Crevice Corrosion. Deposition CarDsion enn Mictobiologically Influenced Corrosion (MIC). Types of Bacteria that Cause Corrosion Detecting Bacteria Coatings and MIC. Protection from MIC... CHAPTER THREE: Paints for PurposesCoarime Systews: A Guidance Manuat ron Fieio SunvevoRs —_.. Shop Primers nnn Demands. Properties. Types of Shop Primers Antifouling Paints. Fouling ‘The Organisms. ‘Miero-Orgamisms nnn Macro- Organisms. Distribution . Antifouling Paint Classification of Antifouling Paints, Soluble Matrix (non-polishing) Insoluble Matrix {non-polishing) Self Polishing Roughness. CHAPTER FOUR: Surface Preparation Solvent Cleaning (SSPC-SP= Hand Too! Cleaning (SSPC-SP-2) Power Toal Cleaning (SSPC-SP-3}.. Rotary Wire Brushing. Mechanical Descling Rotary Power Discing AAbrashe Blast Cleaning (SSPC-SP-5,67,10] . SSPC-SP-5, NACE No.1, Swedish Sa 3. SSPC-SP-10, NACE No, 2, Swedish $9 2 1/2. SSPC-SP-6, NACE No. 3, Swedish $3 Bunn SSPC-SP-7, NACE No. 4 Swedish Sa 1 Water Jetting and Hyeroblasting o CHAPTER FIVE: Methods of Paint Application Methods of Application. Brush application Roller application... Conventional spray. Altless spray. : High-Volume, Low Pressure Spray. CHAPTER SIX: Alternatives to Hara” Coatings # Cathodic Protection Chemistry 34 Method of Protection. a4 ‘Thickness. a Opacity a4 Preparation nA Application Sh Cathodte Protection nn s. 35 CHAPTER SEVEN: Glossary of Frequently Used Coating Terms 37 CHAPTER EIGHT: Assessment Scale for Breakdown, Assessment of Existing Surface Coating Systems... — - CHAPTER NINE: How to Use this Guide... Al CHAPTER TEN: Examples. 43CHAPTER ONE: What is Paint subsequently dries or hardens to form a continuous adherent barrier coat. Im the past, paint technology and ‘aint making were arts or crafts developed over many years and supported by results of practical experience. ‘The performance limitations of the paints produced were basicaly altibuted to the available raw materials. These were predominantly of natural origin. For example, oxides of iron were used 35 pigments and various blends of vegetable oils and natural resins used as binders. These traditional coatings, however, did generally fulfil the accepted demands of time. P aint can be described as a liquid material capable of bcing applied or spread over a solid surface in whic it Significant advances in paint technology came about with the demand for higher performance and longer life coatings. These were eventually tealized by the progressive introduction and development of synthetic raw materials and intermediates helping Co alleviate the restrictions imposed on the paint chemist by traditional technology, and to ‘tablish a much more scientifically based industry. Reproducible products with predictable perfarmance resulted, “The modem surface coating industry provides many different generic types of coatings used in many different circumstances and applied by many different methods. These range fom conventions! liquid paints applied by brush and drying at ambient temperatures by oxidation, to powder coatings applied by electrostatic spray and cured by heat. ‘The following notes describe the principle components of paints, their funetions, and the properties they impart to the finished product. PAINT TECHNOLOGY Paints are mixtures of many raw materials, each of which in turn has been manufactured to give certain specif properties. Basically, however, paints consist of tInee major components and many additives which are Included in minor properties. “The major components are ‘Binder [other terms used include: vehicle, medium, resin, fim, polymer) ‘Pigment and extender «Solvent OF these, only the first two form the final dry paint film. Solvent is necessary purely to facilitate application andl initial film formation; it leaves the film by evaporation and can therefore be considered an expensive waste product.Cosine Systeus: A Guidance Manual FoR Fie.o SunvevoRs BINDERS, Binders are the film forming components of paint. They are predominant in determining the principle characteristics of the coating, both physical and chemical, Paints are generally named after thelr binder component (e.g. epoxy paints chlorinated rubber paints, alkyd paints, etc). The function of the binder iso give @ permanent continuous film which is responsible For adhesion to the surface and which will contribute to the overall resistance of the coating to the environment, Binders used in the manufacture of paints fll into two classes, Thermoset and Thermoplastic. This clasifcation is solely dependent upon how they form a film, and whether that film formation is reversible. In the case of liquid paints, they change state, ic. from a liquid to a solid. This transformation in paint is known as drying or curing. 1c will be teadly appreciated that 2 Thermoset coating when dry will be chemically quite different from the paint in the can, ‘Thermoset coatings are not affected by solvent wipe, once cured. With a Thermoplastic coating, the dry film and the wet paint differ only in solvent content, but chemically these remain essentially similar. If solvent is applied to a thermoplastic coating, it will soften and try to retum to its original state THEROSET COATINGS 1m Tiquid paints where solvent is involved, drying fs considered a two stage process, Both stages actually occur together but at different rates. * Stage Onc; Solvent is lost from the fm by evaporation and the film becomes dry te touch, + Stage Two: The film progressively becomes more chemically complex by one of the following methods: 1) Reaction with atmospheric exygen, known as oxidation, 2) Reaction with an added chemical curing agent. 3) Reaction with water (moisture in the atmosphere) 4) Artificial heating. 5} Radiation curing (eg. ultraviolet ‘The flims formed by the above methods are chemically different to the original binders and will nat re-dissohe in their original solvent. Air Drying Resins Historically, binders were based on various drying oils, cither vegetable or animal. These materials are slow drying, cass Tinking of the molecules taking place slowly in the presence of atmospheric oxygen. The addition of various metal catalysts normaly refered to as dryers can significantly accelerate the drying process. Vegetable drying ofls alone are unsuitable as paint binders. To obtain the optimum film properties, it is necessary to modify the oil with a range of natural or synthetic resins. The following notes describe the various modifications of vegetable ails ta produce suitable paint binders, all of vihich dry by oxidation, Oleoresinous Varnishes ‘These materials are developed from vegetable olls where the oil is reacted, or “cooked” with other compatible resins, rosin, ester gum, coumarone or phenolic resins. The intraduetion of the resin component upgrades the fm properties and Improves hardness, gloss, drying time, and weathering characteristics, The description of the vamish is normally based on the amount and type of oil present. Normally only the more “oily” materials are used for exteriar primers and finishes, where {good adhesion and flexibility are important requirements, One of the mare important classes of binders from this group are ‘the tung ail phenolics. These are used widely in both primers and finishes particularly where improved water and chemical resistance are required from 3 conventional coating.Sue Si: A ower Ma on fe. inva ABS Alkyd Resins ‘These are the most widely used air drying resins, Unlike oleoresinous materials, they can be described as pure polyesters “They are formed by the reaction between a special organic acid (e.g. Phthalic acid), a special alcohol (e.g. Glycerol or Pentzerythritll, and a vegetable olor its fatty acids. The final properties of the alkyd depend an the percentage of oil (termed ‘ofl length’) and also on the alcohol and organic acid used. Typical variations are shown as follows: ong of length ays (60-80% of} Normally used in gloss finishes for brush application and also in primers for hand prepared steel ‘Meciu ol ength alts (40-60% ot) ‘Used in undereoats or in quick drying finishes where appearance and flexibility are of less importance Short oil engdh aya fess than 404% oi) Suitable as binders for quick drying paints. Only soluble in stronger solvents like xyll (aromatic solvent}. Not normally suitable for broshing paints Alkyd are not resistant to acids or alkalis and many oF the modifications given below are aimed at improving this weakness, however, none provide complete resistance. Epoxy Ester Resins Sometimes called ane-pack epoxies, these resins are more closely allied in performance properties to allyds. They are ‘manufactured by reacting fatty acids from vegetable offs with high molecular weight epony resin. The resulting materials ive similar properties to alkys with improved chemical resistance, but have poorer weathering properties. Epoxy ester paints aio suffer fom ‘chalking’ an effect caused by degradation ofthe uppermost layers ofthe paint by UV radiation. This results ina premature loss of glo. ‘Urethane OI1/Alkyd Resins Often refered to 25 a one-pack polyurethanes, but as with epoxy esters, it fs better to consider them as modified alkyd They are formed by the reaction between an alkyd and Wocyanate to produce a prodiict with improved drying, gloss, and hardness over the corresponding alkyd but which can sometimes be more difficult to overcoat after aging. Silicone Alkyd Resins The modification of an afkyd with a silicon resin results In 9 material which probly has the Dest retention properties anallable in resistance, being stable to temperatures in excess of 200°C. Unfortunately, due to the high cost of silicone resin, slicone alkyds are three to four times more expensive than conventional alkyd. This severely limits their use. Styrenated and Vinyl Toluenated Alkyd Resins Reaction of alkyds with either styrene or vinyl toluene monomers produces rapid drying resins with good chemical resistance, hhowever they have a tendency to yellaw an aging and their exterior durability inferior to that of conventional alkyds.Coating Svevems: A Guioance Manuat ron Fieto Sunvevons Epoxy Resins ‘These resins ate particularly Important, and their development for use as binders was one of the mast significant advances in paint technology. They are examples of the modern approach to synthetle resins, and provide high polymer materials of predetermined structure. These have predictable properties which can be taflored to suit numerous uses. ‘The resins are produced hy the condensation or polymerization af epichlorhydtin and diphenylol propane (bis-phenol ‘A ‘The reaction conditions and relative proportions of the reactants determine the properties of the final product. For example, the molecular weight or chain length, and the numberof reactive cross-linkable groups ean be varied with wide limits. Thus pow resins can vary fom low molecular weight, low viscosity liquids a room temperature, ta fairy high molecular weight high melting point solids Situated at the terminal ends of each resin molecule are cyclic epoxide groups which cross-link by chemically reacting with added curing agents such as amines, amine adducts, and polymides, Liquid cpoxy resins give high cross-link densities whereas sold materials have fewer reactive groups resulting im a less coss-inked film. n fact, some very high molecular weight epoxy resins are used as uncured one-pack coatings. The rate of cross-linking or curing is dependent on temperature, Below 5'C the curing rate is considerably reduced, and to ‘obtain optimal film properties, full cure is essential The choice of curing agent is very important as this determines the principle resistance properties of the film. There isa wide choice of both resins and curing agents which allows for Formulation of products to suit most applications Polyurethane Resins These are polymers formed by reaction between hycroxy compounds and compounds containing isocyanates. The resins are available in both one-pack and two-pack farms. The one-pack materi is hase on a resin which has been parilly reacted to give a prepolymer; when applied as 2 film, further reaction with atmospheric moisture occurs, giving fll polymerization ofl cure ‘In two-pack systems a special polyether or polyester resin with free hydroxyl groups is reacted with a high molecular weight isocyanate curing agent, A major problem with these materials is thelr water sensitivity an storage and one application. Polyurethane resins haye excellent chemical and solvent resistance and are superior to standard epoxies in acid resistance. Polyurethane finish coats are very hard and have extremely good gloss, gloss retention, and can be formulated to be non- yellowing. In view of all these good fim properties, polyurethane paints are considered to be the best all-around coatings produced. Unfortunately they are expensive and can be difficult to overcoat after aging and require very clean surfaces for ‘optimum adhesion, Because of the isocyanate curing agent there is also a health hazard when sprayed. This health hazard has been reduced by minimizing the presence of “fice” isocyantes. Inorganic Resins ‘These types comprise the silicates which are almost always used in conjunction with zine dust. There are inarganic silicates 1uased on lithium, potassium, or sodium silicate and organic silicates normally based on ethyl silicate. inarganie types are by far the most commonly used. Coatings based on these resins are very hard, corrosion resistant, and temperature resistant.Be . Beg mea arama nae ence sancend ABS THERMOPLASTIC COATINGS ‘These types of paint binders are simple solutions of various resins or polymers dissolved in suitable solvents). Drying is simply effected by the loss of the solvent by evaporation. This fs termed physical drying as no-chemical change takes place ‘The resulting film is therefore always readily soluble in the original solvent and can also be softened by heat. Since these coatings, by definition, require the presence of significant amounts of solvent, they are disappearing from markets where volatile arganie content is regulated, particularly the USA. Generic types of binders in this category include: * Chlorinated Rubber Resins += Vinyl Resins * Bituminous Binders * Cellulose Derivatives Chlorinated Rubber Resins ‘These are normally considered to be chlorinated polyisoprene (polyisoprene being synthetic rubber) but also included in the group are chlorinated polypropylene and chlorinated polyethylene. All of these polymers are similar in their general properties. ‘The esis are dissolved in aromatic hydrocarbon solvents like xylene, and form solutions which are film-forming in their own right. However, they produce brittle film. Thus, in most formulations, high levels of plasticser are required, normally between 30% and 50% of the total binder. The plasticisers normally used are chlorinated paraffin, Chlarinate rubber resins have very good chemical and water resistance. These properties are somewhat adversely affected by the addition of plasticiser and the chemical make-up of these binders pravides the reason for their poor resistance to some cis and greases. Anather inherent property of the binder is its thermaplasticty which makes these coatings unsuitable for use at temperatures above 80°C. This temperature sensitivity can lead to various film defects when used in very hot climates. In addition, white and pale colors have 3 pronounced tendency to yellow when exposed to bright sunlight. Due to the viscosity ‘of chlorinated rubber resin solutions its only possible to rake paints with maximum volume solids of about 45%. For spraying versions, much lower volume solids sre necessary. Chlorinated rubber paints will dry at low temperatures and give excelent intercoat adhesion in both freshly applied and aged systems, making them particularly suitable and popular for maintenance purposes, Vinyl Resins ‘These are based on fm forming polymers consisting of varying ratios of polyvinyl chloride, polyvinyl acetate, and polyvinyl aleahol. Compasition of the final polymer depends on the ratios of the components used in the polymerization. Whereas. Chlorinated rubbers are soluble in aromatic solvents, vinyl resins require ketone or ester solvents. Like chlorinated rubbers, vinys form brite films and therefore require plastcising. The plastcisng level necessary is about 20-25 ofthe total resin component. Plasticiser types used are treresyl phosphate or diocty! phthalate. The volume of solids in vinyl resin paints are relatively low because of their high solution viscosity. No more than about 25-30% volume salids can be achieved without the paint becoming t00 thick for application. This obviously creates a problem in formulating high build coatings. Higher ‘olume solid materials can be produced by blending the vinyl resin with other materials such a5 acrylic resins. These modifications detract from some af the more positive properties of the vinyl resins, such as chemical and water resistance. Generally the film properties and weathering characteristics alo show good law temperature drying and excellent intercast aaihesion characters, . Bituminous Binders Asphaitum and similar materials have heen used for thousands of years as water proofing systems. The majority of materials used today in paint form are based on cither petroleum bitumen or coal tar pitch. The latter material has the better water resistance and is mate chemically complex requiring stronger solvents for solution. Pigmentation of both types produces acy 10 use cheap products, Because of thelr inherent composition, only dark colored paints can be madeCCoarins SysTews: A Guinance Manual Fam Fie.o SuRvEvoRs a.) eessSSSs PIGMENTS AND EXTENDERS Pigments and extenders are used in paints in the form of fine powers, These are dispersed into the binder to particle sizes fof about 5-10 microns for finishing paints and approximately 50 microns for primers. ‘These materials can be divided into the Following types: Type Purpose “nticortosve pigments | To prevent corrosion af metals by chemical and electrochemical means. Barrier pigments To inerease impermeabilty of the paint film Coloring pigments To give permanent color Extending pigments To help give film properties required ANTICORROSIVE PIGMENTS Red Lead ‘This is probably the best known anticorrosive pigment, however, because of environmental and health considerations, lead is not used on coatings in most developed countries. When used in conjunction with linseed oil it gives excellent corrosion protection. The afforded is due to the lead complexes ('soaps’) which suppress the corrosion reaction of steel, while also ‘reinforcing the film and giving good penetration and adhesion even to weathered corraded stecl. The lead soaps are not Formed with *non-ofl” binders, consequently in quick drying binders based on chlorinated rubber, vinyl or epoxy resins red lead is much less effective. The slow drying time of the linseed oll, together with the toxicity of the red lead, drastically restricts the use of this type of coating. Other antieorrosive pigments based on lead are metallic lead. It depends largely on its owm inertness, but the actual mechanism of corrosion protection is uncertain, calcium plumbate is often used for use on galvanized surfaces. All ofthese ‘traditional pigments are decreasing in importance for the same reasons as red lead. Zine Chromate ‘There are two types, (1) zine potassium chromate, (2} zine tetroxy chromate. Bath Function as anticortosive pigments by releasing water soluble chromate ions which help to passivate the steel surface, They are used in a wide variety of binders ‘and are not restricted to oil based types. Once again, health considerations out weigh the benefits “heavy metals * bring to coatings, therefore, the use of chromates fs becoming rate.si A GUOANCE Manual FoR FleLO SuvEvoRs ABS Zine Phosphate ‘This is a0 @ widely used anticorrosive pigment although the actual mechanism of protection is uncertain. However, iti thought that under normal exposure condition protection is afforded by a barr effect. This is reflected in the necessity of having to have high pigmentation levels to give adequate protection. In acidic atmospheres, zinc phosphate primers perform surprisingly well, and it is assumed thal this is because the phosphate Ton becomes more active in these conditions and electrochemically protects steel in a way similar to that of chromate ions Zine phosphate can be incorporated into almost any binder, and because ofits low opacity or transparent notune, paints of any calor can be produced. Zine ‘Metalic zine is widely used in primers giving excellent resistance to corosion of steel. Initial protection is by galvanic action. However, as the coating is exposed to the atmosphere, «progressive build up of zine corrosion products occurs, producing an impermeable barrier with little or no gahanic protection. To give gaod galvanic and barrier protection, high levels of zinc ore required, about 80% of zinc in dry film. Because corrosion products of zine with rain water ae alkaline, reaction would occur with saponifiable binders such as alkyds, and consequently these types should not be used as binders for zine primers ‘The most suitable resins are epoxy, silicate, or chlorinated rubber. Obviously, for the zine to function comectly it has to be ‘intimate contact with the steel substrate. High degrees of surface cleanliness are therefore necessary. Other available anticorrosive pigments which have not found general acceptanee because of their lack of cost effectiveness are; “= Barium Metaborate * Calcium Molybate * Zine Mobbate * Lead Silicochromate Barrier Pigments, The most common types of these pigments are aluminum {leafing aluminum) and micaceous ion oxide (M.L.O.). Both have particle shapes which are termed lameltar (plate-like). These materials are often used in combination, the aluminum lightening the almost black shade of MLO. M.LO. pigmented films have durability, but to achieve this, high levels of MALO. are necessary, of the order of 604% if the total pigment. Aluminum has been used for many years as the principle pigment in paints for use underwater, the lamellar shape helping to make the film more water impermeable. The diagram below ‘lustrates how the impermeabilty ofthe film is increased and hhow the binder is protected, both benefits being promoted by the lamellar structure of the incorporate pigment. Glass flake fs also often used as a batrier pigment. uw wareR \ | inet f Patt NON-LAMELLAR PIGMENTS LAMELLAR PIGMENTS Figure 1-1Goening Systeus: A GuoaNce Manuae FOR FIELD SuAVEvORS =] Coloring Pigments ‘These pigments provide both color and opacity and can be divided into either inorganic or organic types. Inorganic pigments can be either naturally accurting or synthetically produced whereas all the organic pigments are nowadays synthetically ‘manufactured. INORGANIC organic “ ‘SYNTHETIC ‘The most common coloring pigment is titanium dioxide, which is white, Commonly used inorganic pigments include oxides of fon, which can be black, red-brown or yellow-brown in color and lead chromates which can vary from yellow to scarlet Yellows, blues, greens, and reds are mote commonly obtained as organic pigments. They are generally bright in color and their low toxicity makes them more generally acceptable for decorative coatings. In paint, all pigments are normally dspersed toa very fine particle size in order to give maximum color and opacity (hiding power, Extended Pigments More commonty known as extenders, and as the name suggests, they basically adjust or “extend” the pigmentation of the paint until the required pigment volume concentration (PVC) is achieved, They are all inorganic powders with various particle shapes and sizes. Although making litle or no contribution to the color opacity of the paint, they can have significant ‘influence on physical properties. These include flow, degree of gloss, anti-setling properties, sprayability, water and chemical resistance, mechanical strength and hardness, fim build (volume solids, hold up thinotrophy. Mixtures of extenders ae often used to obtain the desited properties. They are relatively inexpensive when compared to resins, anticorrosive pigments and coloring pigments, Common Extenders Extender Uses Barytes (Barium Sulphate) | A medium hard powder which helps to reinforce the fim, China Clay Sometimes use to vary the level oF gloss. Has a relatively high oll absorption. MICA The lamellar properties oF this material enable [et act to some extent as a barrier pigment ta reduce permeability. It can also improve film durability by preventing cracking TALC Can have a similar effect to MICA but to a lesser degree,oars Sysres: A GuioaNce Manat roa Fieun Surveyors ABS SOLVENTS: Solvents are used in paints principally to facilitate application. Their function is to dissolve the binder and consequently reduce the wseosity of the paint to a level which is sultable for the various methods of application, ic. brush, rller, conventional spray, ailess spray, dipping, ete, After application, the solvent evaporates and plays na further part fn the final pain film, the solvent therefore becomes a high cost waste material. Liquids used as solvents in paints can be described in ine of three ways True Solvents ATiquid which will dissolve the binder and is completely compatible Latent Solvent A liquid whichis not a true sohvent, However, when mixed with a true solvent, the mix has stronger dissolving properties than the true sohent alone. Divent Solvent -Aiguid which fs not a true solvent. Normally used as a blend with true solvent/latent solvent mixes to reduce the cost. Binders wil only tolerate a Tiited quantity of diluent. ‘There are numerous solvents used in the paint industry. Ths is partly due to the number of different propertles which have tobe considered when selecting a solvent of solvent mixture. In addition to commercial factors such as price and availabilty, these include toxicity, volatility, lammabiity, odor, compatibility, and suitability ‘The table below outlines typical solvents and thelr uses, Solvent Type | Typical SoWvent Name Typical Paint Types ‘Aigatic | White Spirit Most conventional paints based on vegetable oils, eg, alkyd. ‘Aromatic | Tobuol Guick drying primers for automatic plants. Xylol Modified alkyd. Chlorinated rubbers, some stoving paints, A diluent solvent for epoxies, vinyl, polyurethanes Ketones ‘Acetone Quick drying primers for automatic plants. -Methyjlethy Ketone (MEK) True solvent for vin. Quick drying primers Methyl \sobutyl Ketone (MIBK) | True solvent for vinyls used sometimes for epoxies. (Cyekihexanone 2 Slow evaporating rue slvent ta give good law in vinys and epoxies ‘Aeohal Isopropanol Latent solvents for vinyls, wash and etch primers Butanol ‘Some stoving paints sed for epoxies in conjunction with aromatics tess Butyl Acetate, Cellosoive Acetate | Polyurethane and vinyls Water | Water Emulsion paits-some special epoxies 1 In certain countries certain types of solvents are not allowed. This is especialy true in the USA, where the Hazardous Air Potutont Substances Act, (HAPS) dictates a time line for removing mony solvents and extenders from coatings. Application properties, ty times ond overcoat windows will most likely be offected as this AACT i implemented.Cosme Systews: & GUIDANCE Manual FOR FIELO SURVEYORS OTHER PAINT ADDITIVES Modern paints along with the principle ingredients, Le. pigmentfbinder/solvent, require various other addltives which aid ‘manufacture, shelf life, application, film formation, film curing and film properties of the paint. The term additive covers a very wide range of materials which are essential fo good formulation, but which are used in miner proportions of the whole paint, ‘Typical Groups of Paint Additives Aids to Manufacture * Dispersion agents © De-foamers ‘Aids to Sheit Life * Stabilizers «© Antisetting agents + Antiskinning agents (antioxidants) * Preservatives, * Thickening agents = Moisture absorbers Aids to Application * Flow promoting agents * Solvent retarders = Conductivity controllers = Antistatic agents Aids fo Smoothness + Antiffoating agents * Pattern additives = Matting agents * Thixotropes * Antigas Checking agents Aid to Film Curing Driers + Curing agentsfcatalysts ‘+ Adhesion promoters Aids to Fle Formation ‘© Heat stabilizes Fire retarders Optical brighteners ‘Slip and amti-sip agents ‘= Anti-fouling agents ‘+ Fungicides ‘ Bactericdes ‘= Insecticides ‘= Absorbers ‘= Antiscuff agents + Comasion inhibitors Others '* Deodorants ‘+ Fash point contratiessCoanne Sveteus: A Gumance Manuat ror FieLo Sunvevons ABS CHAPTER TWO:Corrosion to form an oxide, or other compound, similar to the ore from which it was originally won. The strength of any metal is determined by the arrangement of atoms within the metal, but it fs the atamvic structure at its very surface that determines its tendency to corrode. C omosion of metals may be defined as an clectromechanical process in which the metal reacts with its environment IRON ORE HEAT IRON METAL, Iron Oxide oxveen | waren REVERSION rust REACTION IRON OXIDE: Chemically similar to original ore Figure 2-1: The Reversion Reaction ‘The majority of metals are found in nature in the mineral state, that is, in their stable exidized condition as oxides, chlorides, ‘atbonates, sulfates, sulfides, etc. The extraction of a metal from the appropriate mineral involves a reduction process in ‘hich 2 great deal of energy is absorbed. As a consequence of this large energy input the metal is in a high energy condition and vill endeavor to retum to its former stable oxidized low energy state as quickly as environmental conditions will allow. It {s this energy difference between the pure metal and its oxidized forms which is the diving force for corosion of the meta Mony corrosion produets show a chemical similarity to the corresponding minerals. Iron, for example, is extracted from its ores, mainly oxide and carbonate, by reduction with carbon In a blast furnace. in the presence of moisture the fron metal so ‘obtained is oxidized rust, which iT analyzed is found to have a composition similar to the mineral ore.CCoarins Sysrews: A Guloance Manuat Fon Fup Sunvevoas Steel and the Corrosion Reaction Al surfaces strive to achieve a certain balance, equilibrium, with their surroundings. On the atomic seale there fs no dstinet borderline between a metal and its envionment, The metal wil surrender atoms to its environment and in return absorb some atoms from the environment. ‘Metal atoms leave the metal and they go Into solution as positively charged metal ions, leaving behind negatively charged electrons. Consequently, the metal becomes more negatively charged. This makes it increasingly difficult or impossible for the remaining metal atoms to escape as positively charged fons as they are being held by the negative charge of the metal For the process of releasing atoms as positively charged ions to continue, or for the corrosion process to continu, the excess of electrons in the metal must be done away with. The manner and speed with which these cxeess electrons can be remaved determines the rate of corrasion. ‘The important step in the corrosion of stee! is the transformation of a metal atom to metal ion by the los of two electrons, “This is the anodic reaction: Fe Feet + 2 IRON ATOM, = IRON ATOM ELECTRONS (FERROUS) This reaction can only occur if there is suitable electron acceptor to combine with the electrons released by the fon atom. Freshwater or seawater contain dissolved atmospheric oxygen which readily serves this purpose. The oxygen is electrochemicaly reduced to hydroxy fons in the cathodic reaction. @ a + 2120 + 4 = 40H oxygen WATER ELECTRONS, HYDROXYL IONS The heterogeneous character of the metal surface allows for some areas or sites to favor reaction (1} anodes and others reaction (2) cathodes. The whole surface of the metal is therefore divided up into large numbers of anodes and cathodes, jure 2-2 shows the progress of corrosion where metal i lost from the anode, causing it to progressively become thinner, accompanied by a flaw of clectrans from the anode to the cathode whieh in turn react with both oxygen and water to form hydroxyl ions. Mild Steet Water Figure 2-2ved aly Fee + 20H = Fe(on2 FERROUS 10NS HYDROXYLIONS = FERROUS HYDROXIDE Ferrous hydroxide im the presence of an abundant supply of oxygen is oxidized to the familiar reddish brown rust. ()aFe (on + = Fe2032H20 FERROUS HYDROXIDE OXYGEN = RUST ‘The above reactions, (1) (2} (3) (4, are the basic reactions which occur when iron or steel transforms ta rust oF more specifialy, to iron oxide. In practical situations the process is not so simple, For instance, corasion of steel in seawater or in polluted atmospheres results fn more rapid and complicated reactions producing corrosion products in association with iron oxide. Some ofthese irom salts are water soluble and can cause major problems to paint coatings if not removed before application, Principles of Corrosion Corrosion in Humid Environment Stee! immersed in seawater or exposed to high humidity wall cortade as shown in Figure 2-3. |» Fet+ Fett Fet* J—+ Fett re Figure 2-3 2reas from where iron fons go into solution (the anodes) and areas where electrons are consumed in a reaction with the environment (Qe cathodes), may continuously change resulting in a comparatively even corrosion. ‘nan electrolyte of seawater, there is nothing to retard the dissolution of iron, and the rate or speed of corrosion is almost ‘exclusively determined by the rate at which exygen teaches the eathode arcas, ‘drow ions and iron ions with the addition of oxygen react further to form fron hydroxide, a major component of rust In given environments certain metals will form protective corrosion products, oxides, that prevent or retard further corrosion, ‘Aluminum and stainless steel are examples of this, asso aCCosrins Sverems: A Guoance Manual FoR Fie.o Suavevons Corrosion in an Acidic Environment Ia very acidic environment, such as diluted sulfuric acd, steel will comode evenly while creating hydrogen gos, See figure 2-4, I rie Figure 2-4 ‘The rate of corrosion of steel in an acid solution is much higher than in a neutral environment, partly because the hydrogen ‘gas easily and quickly escapes the steel surface and partly because the corrosion products are soluble in acid, This prevents the formation of a rust layer that could retard the corrosion process. Galvanic or Bi-metallic Corrosion Since stel is less noble, i. releases electrons more easly than copper, metallic contact between the two would cause any ‘excess electrons to travel ftom the steel to the copper. See figure 2-5. Figure 2-5 ‘In accordance with the traditional concept, an electrical current travels from the copper to the steel (from the positive cathode to the negative anode). ‘The cathode will strive to rid itself of the excess electrons it receives. The anode, on the other hand, will strive to regain it's ‘negative potential by releasing more metal fons, corrading. An expression for the rate of corrosion is the flow of electrical current that can be maintained through the electron consuming process on the cathode, and the electron generating process ‘on the anode, ase:Corasion of the steel is accelerated through fts contact with copper. The steel suffers galvanic corrasfon while the capper is protected cathodically. The most positive (noble) material willbe protected against corrosion at the cost of the most negative fignoble] materia See figure 2-6 table of materials in the Galvanic Series. GALVANIC SERIES CORROSION POTENTIALS IN FLOWING SEAWATER, (8 TO 13 FT/SEC.) TEMP RANGE 50° - 80°F VOLTS: SATURATED CALOMEL HALF-CELL REFERENCE ELECTRODE, 20 02 04 08 08 10 12-1418 ‘Magnes lee eer auriien rd © Gea [5 Mila Steet, Cast ron] [low Alloy steel 7 Austanitie Nickel Cast iron [1 Aluminum Bronze (J Navel Bross, Yellpw Brass, Red Brass OTin copper (JP b-Sn Solder (60/50) [1 Admiralty Brass, Aluminum Brass [Manganese Bronze CD Silicone Bronze Tin Bronzes (6 & Ma 1 | mimi staintess Ste Nickel Sitver Fi 20-10 Copper Nickel 20-20 Copper Nickel [FL | Mim {Stainless Stee! — Type «30. Load! 70-30 Copper-Nickel Nickel Aluminum Bronze ] MMM Nickel-Chromium Alloy 600 [J Sivver aronze Alloys J Nickel 200 Osiver 10,416 jo Mi stainless Stoo! — pes 302, 304,321,347 : | 1 Ncketcopper Alloys 40, k500 | = EINE StziriessStoei— pes 316,317 [Alloy "20" Staniess Steis, Cast ana Wought Nickellron Chromium Alloy 825 Ni crMe Cu-Si Alloy 8 3 Trenium 5 Nicest toy © 5) retina | cxspnte ‘Aloysoe sted in the order of the potential they exhibit in llowing seawatertain alloys Froiested by the sym00! MIN In lovevelocityor pooriyserated water andl shisidedaress, Imey become ecive and exRIDK @ potontia) near 0.5 vats, Figure 2-6 Galvanic SeriesCoane Srerens: A Guoawce ManuaL FoR Fieta Suavevcrs sees Types of Corrosion Uniform Corrosion ‘The most common {ype of corrosion encountcred is the general attack of a more or less uniform nature, although the loss of metal is concentrated at the anode sites and there isa continual change in the surface with time. With progressive metal loss areas which were initially anodic cease to be active and new anodic sites take over. There i thus @ continuous interchange between the anodie and cathodic areas, such that over a period of time the loss of metal over the entie surface fs lly tuniform. This isthe easiest form of corrosion to combat or allow for because structural life time can be predicted, a feature hich is not possible with the following corrosion forms Pitting Corrosion ‘The characteristic of this type of attack is that itis extremely localized and the penetration is dcep in relation to the area attacked, Pitting is one af the most dangerous forms of corrosion and often accurs in places where it cannot be really seen Pitting corrosion can be extremely intense on mill scaled steel left outside, as shown in figure 2-7 Pitting Corrosion. usr Wet Surtce we 2 on 1 I | | Mil Seale Figuie 27 Crevice Corrosion Ime aa orn ig fom Sot iso et aiken ais an ach row | cxevies formed bythe gcomety ofa structure, for xample: rected plats or tneaded ota Cave concise ; haat by a geome conguration In withthe exthodereactant yen at realy gon secret the met) sue ess he de eso ec Te twine Gees en snobs he sad | Stel and suf preferential comesion, ; | | Deposition Corrasion This is a similar type of attack to that oceuring in crevices. Wherever loose debris collect, there will bea depletion in 2 «crevice. Consequently, the attack i Focalized beneath the loose debris or sediment. See figure 2-8 Deposition Corrosion. HGH ACCUMULATED ne Sean “\ Anode ———_____ Cathode LOW 0» STEEL Figure 2-8if 9 Microbiologically Influenced Corrosion (MIC) All metal, even stainless steel, may incur corrosion fram microblologically influenced corrosion, MIC. This type of corrosion ‘has been in existence for a long time and is either completely overlooked or goes unrecognized. However, itis gaining attentian in the marine environment as a leading cause of corrosion in cargo, ballast and void spaces. Comasive bacteria thrive in low axygen or oxygen free environments and require some type of food source. In an ideal tervironment microbes may double their mass every 20 minutes, but such conditions rarely exist on board vessels. On board Ships microbes can thrive in the water layer at the bottom of oil cargo tanks and in the sediment in ballast tanks. Once bacteria become established, they become difficult to control and may corode steel up to 116 to 1/8 inch per year ‘The reaction of microbes and steel is not very clear, but this much és known in what they can achieve: |. Microbes produce acids 2. Destroy coatings 4. Create corrosive cells 4, Produce hydrogen sulfide ‘Types of Bacteria that Cause Corrosion The bwo mosl common types of bacteria that cause corosion are Acid Producing Bacteria (APB) and Sulfate Reducing Bacteria (SRB). Both live in colonies attached to the surface of the stecl where they assist each other in their growth Acid Producing Bacteria {APB's These are generally the fist to colonize the surface of the steel inside ballast and cargo tanks. APB‘ feed on organic compounds such as oil and ol products to form organic acids. APB's thrive in conditions where there is very litle oxygen. Stagantvaters i ballast tanks ereate this condition. In usilizing the residual exygen about them they create a very acidic cevronment beneath the colany. BY consuming the small amount of oxygen about them, an oxygen fee environment is developed making conditions ideal far Sulfate Reducing Bacteria to develop. Suffote Reducing Bacteria (SRB ) Sulfate Reducing Bacteria thrive anly in an oxygen free environment. The axygen they require is extracted by removing ‘oxygen from the sulfate ion in seawater. SRB's ako utilize hydrocarbons as a food source, but prefer the organic acids given off by the APB's. Once the oxygen is removed fom the sulfate fon, they discard the sulfide in the form of hydrogen sulfide The combination of the hydrogen sulfide and organic acids under the colonies create 2 condition that is highly aggressive to steel and the characteristic craters or pits are formed Detecting Bacteria Initial detection is frst achieved visually by nating a black slime deposit on the surface of the steel. Also, the detection of Hydrogen Sulfide, rotten egg smell, could possibly be noted. Conesion attrfbuted to MIC is almost always highly localized pitting. The pits are generally Nlled with a black ferrous product. The walls of the pit are generally terraced. The metal surface below the cartosion praduets is often bright and active Aaner method for detecting the presence of MIC can e accomplished hy taking samples and sending them to a recogized laboratory where cultures are grown to determine the typeof bacteria imvahed. Enzyme tests may aso be uz See gure 29. SS we = Poy aS ee seers oe Pailin ae a “actene 2? Or ete ~ Sey YO Oxide yer sate vCosrins SysTews: & GUIDANCE ManuaL FoR Fieto Sumvevors 2s Ss Coatings and MIC Soft cootings Rapid attack by bacteria on soft coatings is the result of the base product, paraffin and oil, being @ nutrient for bacteria growth Alkyals Alkyd coatings use an organic binder dissolved in solvents to form a protective barrier after the solvent evaporates. Because alkyds have a high base organic and hydrocarbon compounds, they would probably be rapidly attacked by bacteria Vinyt's Vinyls are also rapidly attacked by some types of bacteria, especially molds and mildew, and would not perform well when exposed to bacteria Epoxies Epoxies are chemically cured and their resistance to bacteria would be dependent on the type of epoxy and the sobvent used asa curing agent. 1F the epaxy became porous or mechanical damage should occur, it would come under attack by bacteria Amine cured epoxies are the most susceptible to bacteria acid attack, with the imide cured epoxies being the most resilient. Epoxy Novolac is an example of a good, alte expensive coating. Coal Tar Epoxy has good resistance against acid attack due to the properties of the coal tar pitch, It resists bacterfal attack ‘due to its phenol content Urethones Urethanes are also chemically cured coatings and have shown good resistance to bacterial attack. Bacterla will grew an urethane, but will not degrade the costing, Cathodic Protection Supplementing a coating protection system with anodes causes the pH within the tank or space to increase. The high pH creates a calcareous deposit to occur on the surface of the steel. Bacteria do not usually thrive in areas where the pH level the space is in the range of 10 to 11. If the pH level goes Delow this level the bacteria growth level will return to normal Tevels in fess than a half a day. Protection from MIC Utilizing a protective coating system or a combination of coatings and cathodic protection in cargo and ballast tanks can protect a vessel ftom the onslaught of MIC. Locations where MIC can become a problem are in the ballast tank, where water tan become stagnant, and in the sediment in the bottom of the tank. MIC is a problem in cargo tariks in the water layer thet collects in the bottom of cargo tanks where generally there is a good supply af hydrocarbon food source in this arca. Coatings act as a barrier between the surface of the steel and the environment itis being subjected to. Anodes protect the steel at the imperfections in the coating, Bacteria are able to utlize some of the compounds within the various coating systems as nutrients, causing deterioration within coating ystems, Uilizing biocides for treating bacterial affected areas have been used, but these have short time effects. Biocides such as chlorine, hydrogen peroxide, iadine and quatemary amine have been used, ‘Also, at the new construction phase, design features should be utilized in eliminating ateas for the accummlation of mud and sediment. Also, pfofcr drainage ofall liquids to a common stripping area is desired to eliminate the possibility of stagnant Water accumulating. Good design fs safe, environmentally aeceptable and permanent, References 1. John.S. Smart, PhD. — Microbilogically Influenced Corrosion of Ships 2. Gregory Kobrin — Corrosion by Microbiological Organisms in Notural Waters 3.EC Hill and G. C Hill ~ Mierabialogica!Piting Corrosion ~ Old Prablems in Nev Ploces 4. Bruce Sane! — bcrobiologeally influenced Corrosion | “|Coane Stews: A Guinunce ManuaL roa FiEi0 SuavevoRS ABS CHAPTER THREE: Paints for Purposes ‘These general properties cannot be notably changed, but in the formulation of paints i i possible to entiance, ‘modify, of even add to these basic characteristics, The result Is a much wider range of paint “types” than would off had oppear from the generic classification. Some of these types are more often refered to by ther funetion or purpose, ‘than by their generic type. In this chapter the following are described: M ast oF the important properties of a paint are determined by its binder and the manner in which the film is formed. + Anticorosives + Shop Primers/Holding Primers + Antifoulants ANTICORROSIVES In comosion prevention with paints, three main principles are employed: ‘+ Create a barrier that keeps out charged fons and retards the penetration of water and oxygen. ‘Ensure that water am its passage through the paint coating takes on special properties or compounds inhibiting its comoshe action. * Ensure metalic contact betwee the steel and a Tess nable metal, such as zine, affords cathodic protection ofthe ste! by utilizing the galvanic effect. Barrier Effect ariereffect is obtained by applying thick coatings, 10 to 20mils, of paint with very Tow water permeability Typical representatives are Bitumen * Coal tar epoxy + Epo By aiding Moke pigments, such as eafing aluminum, a barrier effect can be achieved at lower film thickness, The flake pigments are oriented paralcl to the steel surface, and water trying to pass through has to select the more complicated and longer passage around the pigments. Sec figure 3-1 Figure 3-1 For permanently immersed steel, the first and often the only choice of protection in coating protection is to utlize the banter effec. Ifa barier coating is damaged, the damaged area is open for corosion to begin. Corrosion can then proceed inlo the steel substrate and outwards under the intact coating, known as under rusting. Thus, where there i a risk of ‘medhanicel damage, additional protection such as cathodic protection fs sometimes provided, 19 | sa50Coerms Systems: A GuioaNce Manuat Fam Fic.a SURVEVOS SSS Inhibitor Effect A corrosion inhibitive effect is achieved by using primers containing inhibitors. These are soluble or basie pigments designed 10 suppress the corrosion process. Example of types of inhibitors utilized are: Zine Chromate '* Zine Phosphate + Zine Metaborate Red lead * Calcium Plumbate (The fist three inhibitors do not contain metallic zine particles) Inhibitors are and! must he somewhat water soluble. To prevent them from being washed out of the primer coats, top coats ‘without inhibitors are applied to provide the barier necessary for the inhibtive primer to last Due to water solubility of the pigments used, inhibitive primers are not sulted for prolonged immersion. This exposure would result in blistering and early breakdown af the coating system, When damaged, a reasonable protection against rust creeping or under rusting is afforded, but the damaged area is exposed to comasion, Galvanic Effect : Protection of stee! through the galvanic effect, cathodic protection, can be achieved with paints containing large amounts cof metalic zine. A condition for effective protection is that the paint is formulated to give metallic contact between the individual zine particles and between zinc particles and the steel. Typical binder for zine dust paints are: *Enoy = Ethyl Sicate © Alka} Silicate ‘The very nature of these paints requires an absolutely clean steel surface and, especially for the zine silicates, a rather well defined surface profile fora lasting coating system, When applied, zine silicates are initially rather porous. After a while the pourousness is filled with earrasion products from the Zine, and a barter is formed, When damaged, the galvanic effect is re-established at the damaged ara and protected effectively against rust creeping. Since the corrosion products of zinc (zinc salts} are slightly water soluble, zine dust paints are not normally suited for permanent water immersion service, but zine silicate, because ofits superior solvent resistance, is the favored protection in ballast tanks.aS ld d the .ac@ Coane S¥ 6: A Gunance Marvel ron Fre.o SunvEvoRS ABS SHOP PRIMERS, Shop primers, also refered to as pre-construction primers, ae anticortosives designed for application in automated plants to plates or profiles priar to assembly or construction, Demands The special demands of these primers are: + Provide protection against corrosion during the construction period, Spray applicable ina variety of automatic installations. Time between application and dry to handle fs very brief. Should not influence the speed of welding ar cutting, ‘Must not produce noxious or toxic fumes during the welding or cutting process. ‘Must not influence the strength of the welds Should be able to withstand comparatively rough handling. Should for a suitable base for the widest possible range of coating systems. Properties Consequent to the requitements listed above, shop primers possess properties not normally found in paints designed for other ‘pmposes. They are applied in low Alm thickness, 3 to 5 mils, and do not interfere with the speed of cutting or welding. Reasonable protection at such low fflm thickness can only be achieved if the coating follows the contours, (surface profile), ofthe blasted steel. a Figure 3-2 Inherent inthe formulation of shop primers are fast drying and retarded low properties. Aside eFFect of this is low cohesive strength. Shop primers applied with excessive dry film thickness, DFT, have a pronounced tendency to crack. To achieve the desired protection and avoid immediate or subsequent cracking, the dry film thickness of the primer must be {losely monitored and the manufacturer's specification followed closely. This exactness is usually found in automated paint Facies, Where temporary protection to blest cleaned steel i applied by hand spray, as In a maintenance situation, ane would choose suitable anticorosive, holding primer with a reasonably long re-coating interval and apply it in a lower then sual film thickness, Anicorrosive primers suitable, and frequently used, for this purpose are refered to as holding primers. They are ‘dealy based on the same generic type as the top coat to fallow,‘Types of Shop Primers The most widely accepted shop primers are: = Poly Vinyl Butyeal (PVB) * Epoxy Iron Oxide Zinc Epoxy * Zine Silicate Connie Systems: A Guioance MaNuaL Fon Fie.o Suavetes) $a A general summary of the more important properties of these shop primers are in Table 3-1 Type of Shop Primers Property Zine Expoxy | Zine Silicate Epoxy Iron vB Oxide Delivery ‘two pack two pack or ‘wo pack ‘two pack or fone pack tone pack Solvents and esters, water or esters, alcohols, Thinners ketones, alcohols ketones ketones, aromaties aromatics aromatics Dry Film 12-20 um 12-20 um 20-20 um 15-25 um Thickness Anticorrosive very goad ‘excellent good fair Properties Mechanical ‘good excellent ‘900d ‘good Stiength Recoatability sometimes critical sometimes good critical critical Resistance to 4 ‘Not usually Not usually ‘good limited rece. used with used with reep rece TableaS Shine Sm: A Gomes Minn Fen Smo ABS ANTIFOULINGS, Ships underwater hulls are painted ta protect the building material, usually steel, and prevent undue roughness. The effect ‘of toughness on the hull area is an increase in resistance tb movement, resulting in reduced speed andor increased fuel consumption, The penalty is 2 higher operating cost. Fouling ‘The most severe hull roughness is that caused by fouling, the growth of various marine plants, animals, and organisins, ‘Some 208 of the fuel bill for the Royal Navy, it estimated, is caused by Fouling. ‘The Organisms Many of the species populating the oceans swim or are carried by the ocean currents, Others are compelled to attach thenmsehes to 2 firm surface to fulfil their life cycles. Every available space is contested and covered by a variety of marine growth. The number of species involved in fouling is estimated to be as high 4 to 5,000. ‘Micro-Organisms ‘The micro-organisms are the fist to settle. They form the primary bia-film or lime layer. The most significant ones are: Bacteria * Diatoms (unicellular algae) Maero-Organisms Macro-organisms are big enough to be seen without the aid of = microscope. Example of macro-organisms are: ‘Algae (Gea weed oF grass) ‘Animals (Hard and Soft Shelled) Among the hard shelled animals, barnacles, goosenecks, tubeworms, bryozoans, and mussels are the most common. Soft bodied animals found most commonly are hydroids and tunicates, Distribution Fouling is generally regarded as being most dominant in ports, harbors, and coastal areas where firm surfaces on which fo settle abound, ‘The distribution of macro-organisms on a ship & seldom uniform. This is due partly to differences In flow conditions on the Inland party to differences in the settling pattern of the organisms. A relatively well defined vertical zone division can normally be observed, Since algae depends on light for its existence, this type of fouling is predominant to @ depth of approximately two meters. “Ths the algae zane and is fouled first and most heavily. (nthe vertical bottom, below the algae zone, scattered fouling of bamacles, encrusting bryozoans, tubeworms and ‘goosenecks are common, ‘The fat bottom is dominated by hydroids, barnacles, mussels, tunicates, bryozoans, and sometimes goosenecks, Severity and distribution of macro-organisms on a ship’s underwater hull will be influenced by the ship's trading and ‘operational pattern, Algae settles in 2 matter of hours, whereas animals normally require @ couple of days. Very few organisms ‘an attach themselves at speeds in excess of four knots. The settlement of micro-organisms, beeteria and diatoms, are not confined to specific zones or areas. It is comparatively uniform and independent of the vessel's service pattern. 1550 23Corns Systews: A Guience Manual For Fito SuRUE\a ee ssssssS—————CSF Antifoulant Paints ‘The antifouling paints used today are based on physically drying binders. They prevent fouling by releasing bioactive ‘materials that interfere with the biological processes of the fouling organisms. Bioactive materials used today are mainly ‘cuprous oxide or organo-tin compounds. These compounds are used either individually or as a combination of each. Classification of Antifouling Paints AAntifouling paints differ basically in their load or concentration of bioactive material and in the mechanism controling the release of that material. According ta the manner in which bioactive material is leached from the coating, antifoulants may be grouped as the following: * Soluble Matrix Types (non polishing) = Insoluble Matrix Types (non polishing) © Self Polishing Types Particularly in the latter two groups a great number of grades (Lype fconcentration of bioactive material) will be found: Soluble Matrix (non polishing) Such antifoulants have, as a main constituent of their binder, a sea water soluble resin. As the binder dissolves, the bioactive material is released, The release rate fs uneven and since the binder is comparatively weak the load of bioactive material is low. Non-Folishin ‘soluble mast 0 war ur Release rato of BIOACTIVE MATERIAL Figure 3-3 Soluble Matrix (non polishing) General Properties ‘Effective protection rather limited (up to approximately 12 months), ‘= Only aniifoulant type that can be safely applied over soft, bitumen, primers. ‘The binder oxidizes and is sensitive to sunlight. ‘Therefore the vessel must be launched or floated soon after curing. * Sensitive to ofl pollution (mineral and fish oils) * Due to the low sttenstn of the binder, subject to old flow. Binder HB taticorrosive primer LT Lifetime of antiouling TV Throshotavalue, ie. minimumeelease rate ofbioactivematsialequiedtorprotection against foulingCome Ss A Guice Mana fon Feo Seas ABS Insoluble Matrix (non polishing) ‘These antfoulants may be based on a vinyl binder. These have high mechanical strength and are not affected by Seawater, therefore, the load of bioactive material must be high enough for the particles of this material ta be in contact with each other. Nen-oishing “soluble matrix SeltPoshing Figure 3-4 Insoluble Matrix (non patishing) Bindor Frc) Ponetes HE sascorrosive primer * Medium extended effective protection (up to 24 to 30 UT Ltetime of antifouting montis depending on trading patter) ae TryesholdVale, ie, minimuresiease ate 4+ No rk to cold flow. itvosctvematsaliequiediorprotecvon + Reactivation (removal of empty matrix) possible against fouling ‘through scrubbing {"Scamp” cleaning) + Enpry matrix may become blocked by poliutants. + An empty matrix, hecause of Its sponge like properties, should be scaled off prior to a fresh or new coal of antifoulant is applied, 2Coanns Srsrens: A Guinance Manual FoR Fie.o Sumi Self Polishing ‘These ate bascd on acrylic binders incorporating organo-tin in the very polymers of the binder. In contact with sea water dissolves at an even and predictable rate. As the antifoulant wears offfpolishes the bioactive materia, organo-tin fs released alan even rate, ° yur uw rs Figure 3-5 Self Polishing: General Properties = Medium to very high effective protection against fouling (up to 48 months), + Excellent mechanical strength and stability. + Effective life is directly proportional to applied film thickness + No sealer cost required at subsequent dry dockings . ‘+ Remaining antifoulant becomes an effective part of the new system (can overcoat) Roughness Self polishing entifoulants cannot tum a rough hull nto 2 smooth one. They can maintain and preserve an exiting smoothness and, since the polishing rate is higher on rougimess peaks than valleys, even improve smoothness, ‘The use of self polishing antifoulants prevents the accumulation over the years of old and spent antifoulant ystems ‘and thus greatly contribute to maintaining a smooth underwater hull. Roughness development versus time, asa function ofthe type and grade of antifaulant, can Be qualified by computer simulation and the economical impact predicted. This can serve as the bais for selecting the most economical coating system for cach individual vessel,Corre Svsvews: A Guoance Manuae Fam Fie.a Sunvevons CHAPTER FOUR Surface Preparation cd surface preparation is, perhaps, the most Important part of the entire coating job, iy that the greatest pereentage of coating fahores can he traced directly to poor surface preparation. No paint system will give optimum performance ‘over a poorly prepared surface. Al paint systems will fail prematurely unless the surface has been properly prepared to receive the coating material. F contaminants such as ol, grease, drt, salts, chemicals, ele. are not removed from the surface to be coated, adhesion wil be compromised, andor osmotic blistering will occur. Loose rust left on the surface will cause a loosening of the coating and eventual loss of adhesion. Also, good surface preparation roughens the surface to assist in btaining the proper surface prof, thereby promoting better coating performance in the areas of adhesion, abrasion. restanee, chemical and water resistance, as well as the long term cosmetic appearance of the paint system The following table provides 2 Summary of Surface Preparation Standards and a cross-reference of those Standards by sarious world-wide agencies. There are differences which can be Important in some instances; care is advised when a aossorer is required. While these standards ate Iimited to steel substrates by use of common sense, many of the ‘echriques, with thelr inherent advantages and disadvantages, hold true for substrates. PREPARATION STANDARDS Nonabrasive Blast Cleaning NACE’ spc: Solvent Cleaning SSPC-SP1 Hand Toot Cleaning SSPC-SP-2 Fovie Toal Cleaning SSPC-SP-3 | Power Tool Cleaning to Bare Metal SSPC-SP-11 Abrasive Blast Cleaning White Metal NACE-T SSPCSP-S Near White Metal NAGE? S5PC-SP-10 Commercial NACES S5PC-SP-6 Brsh-OFF NACE-4 S5PC-SP-T Water Blasting NACE-5 SPs-SP-12 Figure 4-1 MADE = Notional Association of Corrosion Engineers SSPC= Ste! Structures Painting Councit 2- * Goernwa Systews: A Guioance Manuat FoR Fieeo Suave Solvent Cleaning (SSPC-SP-1) A process of using solvents, expanded more recently to include other leaning compounds, to remeve of, grease, and othe Contaminants. This pracess is best utilized as a preliminary step in the total surface preparation procedure Solvents are no Tonge the recommended cleaner, as they may become an impediment rather than a hep, if not propery removed If solvent cleaning is chosen, then safety i very important. Adequate ventilation and minimizing the potential ie hazard are paremount. Clean-up rags should be changed often to prevent smearing. A proprietary water soluble ol and ‘grease remover and fresh water washing isthe perfect method of achieving this stondard. (Some will ako eich the surtace, Further promoting adhesion.) Hand Tool Cleaning (SSPC-SP-2) ‘This method is the slowest and usually the least satisfactory method of surface preparation. Wite brushing, in fact, can mate the surface worse by polishing rather than cleaning the rusted surface. Scrapers, chipping hammers, or chisels can be used yemeve Toose, non adherent pa, rast or scale, but fs usually considered incomplete, For this reason, the area to be p should be sufficiently small to allow for the time required, Ey2A ke nese (Castine SrSTEMS: A GUIOANCE MANUAL FOR FietD SuaVEvORS: ABS Power Tool Cleaning (SSPC-SP-3) ice ‘The advantage of power (clectrical or at} tool methods over hand tools, is that they are generally less laborious, but, 2s with manual, easier to feather loose coatings heck to tight impact paint. The effectiveness of cleaning will depend on the effort 1nd endurance of the operator, and becomes especially tiring when working above shoulder height. Some of the more popular methods are as follows: Rotary Wire Brushing This method does have some value, depending upon the condition of the surface, Loose “powdery” rust can be removed but hard scale wal resist the abrasion of the wire bristes. When rust scale is intact and adherent to the substrate, rotary wire ‘bushing fends to merely burnish the surface of the rust scale, but dacs nat remave it. Care should be exercised, in that the bumised surface may give the appearance of a well cleaned surface, which is often misleading. ‘Mechanical Descaling ‘rece Guns, Roto-Peen, and ather pounding type instruments are effective to some degree in remaving thick rust and scale. The action of these types of devices is dependent upon cutting blade or point pounding the surface-and breaking away the sce, Clearing és only effective at the actual points of contact. The intermediate areas ate only partially cleaned, because the ‘tle scale disintegrates, but the lowermost layer of rust and scale remains attached to the substrate, This may be sufficient For surface tolerant epoxies. (Ofte power tool methods, this one is the mast effective in producing a surface suitable for the application of most types of ‘cating systems, especially for most on-board maintenance. While effective, aiscing should generally be limited to localized areas of funy severe corrosion or more widespread light corrosion, because, once again, this method can be quite slow and Ishor intensive. Normally silicon carbide discs are used and the grade selected to suit the conditfons of the surface to be abraded. Its important to change the discs at regular intervals in order to maintain efficiency. Care should be exercised In ‘he selection of the grit size and type of disc to be utilized, so that the surface is not excessively smoothed, thereby reducing the ability ofthe paint to adhere. Inegular and pitted surfaces may require a combination of the various power tool cleaning methods to maximize effectiveness. 2Coarins Systems: A Guigance Manuat FoR Fie.o SuAVENRS e Abrasive Blast Cleaning (SSPC-SP-5,6,7,10) C This is by far the most efficient and effective method of removing paint, rust, mil scale, etc. from substrates, ao, iti generally considered to provide the proper surface profile to promote coating adherence. However, compared to the methods discussed above, itis also the most expensive method. For this reason, iis chosen to reduce the time for surface preparation, or to achieve standards of cleanliness that are only attainable by some type of abrasive blasting. It s not feasible 1o previea complete treatise on the types of blasting, types, and sizes of grt available, surface profiles, and mechantes of abrasive gr blasting, however, cach abrasive blast standard willbe defined as follows SSPC-SP-5, NACE No. 1, Swedish Sa 3 White Metal Blast Cleaned Surface Finish, This blast standard is defined as a surface with a gray-white, uniform metalic color, slightly roughened to form a sultable profil for coatings, This surface shall be free ofall ei, grease, ct, visible rl scale, rust, corrosion products, oxides, paint, or any other foreign mater. This surface shall have a color characteristic ofthe Mi abrasive media used, SSPC-SP-10, NACE No. 2, Swedish Sa 2 1/2 ‘Near White Blast Cleaned Surface Finish. This finish surface is defined as one from which all cil, grease, crt, mil scale, us, corrosion products, oxides, paint or other foreign matter have been removed except for vey light shadows, very ight steals, Or slight discolorations. Atleast 959 of a surface shall have the appearance af a surface blast cleaned to a white metal surface finish, and the remainder shall be limited to the light discoloration mentioned above. SSPC-SP-6, NACE No. 3, Swedish Sa 2 Commercial Blast Cleaned Surface Finish. This finish is defined as one from which all oil, grease, dirt, rust seale, and foreign matter have been completely removed from the surface and al (Sa 2 provides for almost all) rust, mil see, and old paint | have been completely removed except for slight shadows, streaks, or discolorations, At least 6790 of the surface area shall he 7 frec of all visible residues and the remainder shall be limited to light discoloration, slight staining, or light residues mentions above. SSPC-SP-7, NACE No. 4, Swedish Sa 1 Brush Off Blast Cleared Surface. This finish is defined as one fiom which cil, grease, dirt, rust scale, loose mill scale, loose rust and loose paint or coatings are removed completely, but light mill scale and tightly adhered rust, paint, and coatings ae permitted to remain, provided they have becn exposed to the abrasive blast pattem sufficiently to expose numerous Tecks oF the underlying metal fairly uniformly distributed over the entire surface Water Jetting and Hydroblasting As discussed previously dry abrasive blasting is the most commonly used method of surface preparation. Accompanied with this style of preparation are some known problems. In general with abrasive blasting the resultant flying abrasive parties al rifting dust may damage equipment, clog filters and create possible environmental problems. Aso it possible to trap contaminants on the surface of the substrate being cleaned Government regulations are continuously investigating and developing more environmentally sensitive and user fiendly ‘methods of surface preparation, The use of hydoblasting is becoming an increasing viable means to accomplish this, Standards from both NACF and SSPC are icing developed ta satisfy this need) I should be noted that hydroblasting does not produce a profile on the steel surface as does abrasive blasting. It does, however, expose the original abrasive blast surface profile, To be an effective agent the water being used should be pure {enough that it does not contaminate the surface being cleaned. Pressures used in hydroblasting can exceed 35,000 psi. This pressure remaves most contaminants, such as salts, dit, grease ‘and rust scale. Utilized sometimes in this type of preparation are inhibitors which are added to the water to help prevent lash rusting prior to coating being applied. Advantages to hydroblasting are: * Water as a cleaning material is generally available in inexpensive large quantities. * Lack of contamination of surrounding areas because there are no abrasive particles. # Lack of dust.nd thins Sos A Gone Ma on Fata Snir ABS CHAPTER FIVE: Methods of Paint Application he aetiein appbing paint coatings ae to provide ins which wl ge protection an normal oa [issn cotinine cg pce ats HN gna se a ay sition se * arte pepaaton $F bu and tol thks of stem + Mets of apleaton + prospec conn during applation Methods of Application The normal methods of application of paint coatings are b + Brush Roller * Conventional Spray * Ailess Spray * High-Volume, Low Pressure spray (HVLP] Other methods may also be encountered, such as dipping and pouring, andl more sophisticated adaptations of spraying such as lecttostatic. powder coatings application, and automatic plants, but in this paper we will concentrate an the four basic methods detalled Brush Application The “historical” method of paint application is not as fast as spraying or vlling and is generally used for the coating of small ‘complicated or complex areas or where the need for ‘clean’ working with no overspray precludes the use of spray application. When painting i s important to dip the brush in paint frequently and not to ‘over-brush’ the surface, as this will result in lage variations in fim thickness, the inherent problem with brush application. Cholee of brush, both size, length and type of birstle, and shape, are important, and the type of paint being applied will modify the selection. Thus, large flat brushes arc nomally wed for the majority of purposes, but round brushes are better for painting bolt-heads and ‘éiffcult’ areas. Special brushes are available with offset heads and long handles to facilitate painting the ‘backs’ of structures and inaccessible areas. Brash application fs most suited to the slower drying, normal build type ef coatings, and will not always be suitable for the ‘ote sophisticated ‘fast-drying’ or “*hi-build’ materials. 1 is often not possible to achieve the required film thickness in the same number of coats as with spray application, and multi-coat applications are necessary to give the specified film build Roller Application Rolle application is Taster then brush on large, flat surfaces, such as tank sides and tops and walkways and deck areas, but it ‘snot so good for ‘difficult areas. 1 is hard to control film thickness, however, and care must always be taken that the “cating is not ‘ovcr-rolled' in the same manner that it can be “over-brushed: Choice af roller pile (short or long hair, sponge or ambs wool) is dependent on type of coating and roughness and irregularity of surface being coated, suse aCoanine Systeus: A Gunance Manat Fan Fluo Sune Conventional Spray ‘This sa widely accepted, rapid method of applying paint to large surfaces. The equipment is relatively simple and i usually confined to fay Tow-vscosty paints, although newer techniques using ‘pressure-pot’ or ‘hol spray” apparatus alow application of some of the higher builé" ype coatings. Whatever {ype of equipment is used, the mechantsms fhe sme Faint and air are fed separately to the spray gun and mined ot the nozzle, where the paint & atomized and ai s mixed with ‘these droplets forming a fine mist of paint which is cari by the alr pressie to the work surface. If important to have nly sufficient air to provide good atomization, as excess air gies rise to overspray and ‘rebound’ fromthe work surface ‘The gun should be held at right angles to the work surface with the nozale some 6-8" (15-20 cms} away. Normal i is from 40-60 psi (2.8-5.6 kg/em2). The pattem ofthe fan’ so produced fs controlled by adjusting the a and fd ‘Achange in paint type can be accommodated by diferent sizes of nozzles. Airless Spray Ty far the most important and efficient method for the application of heavy duty marine coatings. As the name implies, is a technique of spray application which does not rely on the mixing of the paints with air to pr atomization, which is achieved by forcing the paint through 2 specially designed nozzle or ‘ip’ at very high pressures, as compared with air pressure associated with conventional spray, 2500-3500 psi, (176-246 kgfem2}. High-Volume, Low Pressure Spray High-Volume, Low Pressure spray systems use a high volume of air delivered at 10 psi or less to atomize 2 coating into Jow velocity pattern. This reduction in the air stream compared to conventional spray systems (40 - 70 pei) results © A more controled spray pattem + Reduced bounce back * Reduced overspray * Reduced VOC emissions + Savings in materials Less hazardous waste Reduced averspray improves visibility, which reduces operator error, and therefore improves finish quality. For example, two thirds or more of every gallon of coating sprayed by conventional methods can he lost to averspriy, compared with one pit pet gallon ar less when using high-volume, low pressure HVLP is made more graphic by the current trend in regulations regarding the amount of material being applied versus the ‘amount lost to over spray. California enacted legislation requiring all spray equipment deliver at least 654% transfer of ‘material to the surface being coated. Similar legislation & pending in other states.me ide oft nt CHAPTER SIX: Alternatives To Hard Coatings & Cathodic Protection here ate several different alternate coatings to choose from other than a hard coating, Thé altemative coatings are "T sisi tr coer spent on er pope + Solt Coatings + Semiiard Coatings Soft Coatings Soft Coatings are coatings that remain soft, 50 that they wear off ata low mechanical impact or evenly only when touched ly hand. These coatings will give temporary protection of rusted steel surfaces and mist be maintained ot re-oated every year or every second year. These coatings always remain soft and can be damaged or removed by ualkng or touching. Serihard Coatings Semihord Coatings are coatings that dry in such a way that they stay soft and flexible, but are hard enough to touch sand walk upon and will not wear off or erode by ballast water movement. This coating also gives temporary protection of usted steel, Of the two aforementioned coatings, the semi-hard is the preferred coating for protection of steel surfaces when @ good hard coating is not applied, It'simportant to note that alternative coating products are very diverse and can vary by: * Chemisty * Method of Protection + Thickness + Opacity + Preparation “Application a34 y CCosrie SysteMs: A GUIDANCE MaNuaL For Feta Sum Chemistry Products can be one or a combination of the following: + Lanolin/wool grease based » Petroleum based * Vegetable oil based * Organic or inorganic Each type has its own unique characteristics and corrosion protection capabilities. ‘Method of Protection Products can be classed by one or a combination of the following: ‘* Corrosion inhibitor (interacts with oxides to prevent further oxidation) ‘+ Corrosion barricr (prevents oxygen from reaching metal surface) 1 should be noted that a pute corrosion barter product wal stil allow a corrosion cell to be active underneath the produc while a corrosion inhibitor stops this activity. Thickness Product fm thickness can vary from a thin fim of 3 mils. up 10 @ thick film of 80 mils This fs an important feature to ‘consider when inspecting a tank, since a thicker product may be a safety hazard and require spot removal in arder to vew the steel surface or structure undemeath. Opacity ‘The products are either * Opaque (dark or black) * Gray = Transparent ‘This feature will have an impact on the inspection of the tank. The opaque products will require spot removal to allow for inspection of the stec! surface, whereas the transparent product could allow the inspector to view most of the steel surface, ‘without removing the coating, Preparation AAI silt, mill scale, sheet scale, cement, oil, qrease or chemical contaminants must be removed. The bare metal substrate m be visible. This Is to 9 SSPC Standard of SP-2. De-sealing until all loose material Is removed is required. Old grease, Its remaining, should be scraped off, followed by degreasing using hot water jetting. Hydroblasting, when used, should be ata recommended pressure of 6000 psi. Prior to application the surface should be dry. This to be accomplished cither by ventilation or dehumidification, Application Products are to be applied by cither brush, roller, ar airless spray. Most soft coating are applied via a float method. This ‘method will quite additional produet, but no staging. Care must be taken to adhere to pollution prevention procedures ‘when applying coatings In this method.Charns Srerews: A Guan: Cathodic Protection Metalic Corrosion & an electrochemical phenomenon, metal degradation being accompanied by the passage of electrons. Consequently, as a metal corrode it takes om its own electrical potential, known as the corrosion potential, with respect ta fixed reference. Table 6-1 gives the relative tendencies of commercially available metals to corrode in seawater. Metal Electrode Potential (VOLES Versus: Standard Calome! Electrode) Magnes occa conn 150 BASE (IGNOBLE Tine. seven 03 CORRODED END Aut enc Cos hon Mls Stele ne DBI a SS as 1. a eee a Conner. Cupeo Micke Bronze. Niel 014 Seton sane 013 Tania. 0.10 ‘CORROSION RESISTANT END Toble 6-1: Galvanic Series \Vinen two dissimilar metals become electrically connected and are exposed to the same solution (seawater) their individual ‘onasion behavior can become significantly altered, particularly if the difference in their corrosion potential i large. When rildstel and copper are in contact, for example, the mild steel, being the more base metal, suffers greater corrosion than I: would iF the two metals were iolated. The corrosion of the more noble copper is reduced. ELECTRON FLOW coPren MiLD STEEL {caTHODE) ~~ (ANODE) PROTECTED ACCELERATED CORROSION ‘SEAWATER Figure 6-1 ce 90Coanine Systews: A GuioeNce Manual Fon Fie.o Gum Tite some way that the corrosion of capper is reduced, 2s showm above, the comasion rate of mild stel can be sig Towered by connecting it to zine, which is near the end of the galvanic series. The zinc is refered to as the earicel 2 and the prevention of corrasion of the mild steel is by cathodic protection, ELECTRON FL OW zine Miuo sree. \ANODE| ~ ~ (CATHODE) ACCELERATE PROTECTED ‘CORROSION ‘SEAWATER, Figure 6-2 As an altemative to sacrificial cathodic corrosion protection, it s also possible to suppress the corrosion of mild stel in Seawater by using impressed current cathodic protection. Inthe same way that coupling mild steel to zine results in a flow of electrons to the mild steel to prevent metal toss, an auxiliary anode made from a non-consumable materi, platinised niobium, replaces the anode of the sacrificial system, ‘The arrangement is shown sehematieally in igure 6-3. et ANODE D.C POWER SOURCE x cunRENT REF FLOW ELECTRODE PaorecreD SFaveruse \\ HAAN Figure 6-3 Generally the structure would be coated, otherwise the current requirement for protection would be too expensive. Cathodic protection ystems are generally used in conjunction with painted steel, protection being afforded to gaps ‘or breaks in the coating., eee ABS CHAPTER SEVEN: Glossary of Frequently Used Coating Terms AIRDRYING PAINTS: are paints which dry and form a film when exposed to air, without any extemal heat being applied Oil and alkyd paints are usually air drying. ARLES SPRAY: 16a method of patnt spraying wich doesnot use compressed alto atomize the palnt. I tis method, the paint is put under great pressure (up tp 5000 psi - 360 kg/sq.cmi) and is atomized by being forced through a small nozzle. Airless spray i a very fast and efficient method of application since the paint 's forced into the surface at very high speed, which assists in wetting the surface. AIK: {sa cymthette resin made by reacting two chemicals in the presence of @ natural oF processed il Because of the wide variety af possible constituents, alkyds can be ‘tailor-made’ to meet conditions. Found in practice. None: 2 piece of metal fixed to steel to provide cathodic protection. Anodes must be fixed so that they are in elecrical contact with the steel they have to protect, and must not be greased or painted ANTIFOULING: for underwater use on hulls. Contains agents which prevent the adhesion and growth of organisms on the hull. Antfoulings are formulated so that the control agents migrate into water closest to the hull, ‘making it repel organisms, BINDER: the component in paint or varnish which binds the constituents to the surface. Depending on the type of paint, mast manufacturers use binders based on alkyd, chlorinated rubbers, epoxies, ete. GETHODIC PROTECTION: a method of altering the electrical characteristics of stecl so that iti less Habe to rust in water. Steel protected in this way has to be painted with particlarly resistant paint systems. (ONL TAR EPOXY: 2 combination of epoxy resins and tar which, ina paint, give a very water resistant film, A curing agent must be added if curing is to take place. CONVENTIONAL PAINTS: a collective description of paints based on naturally occurring binders, such as bitumen, alkyds, and oils. They are all one pack types, and usually eact with att to dry and cure. MULSION PAINTS: paints in which the binder is dipersed in water (emulsified) eg. polyviny! acetate (PVA), acres ete. ‘The paints dry as soon as the water evaporates and the emulsified droplets of resin join together to form a sof fim Po: epoxy resins which are cured by chemically reacting with a curing agent such as amines, amine adducts, and polyamides. Properties can be tailored to meet a wide range of needs. FFM THICKNESS: {the thickness of the paint or system. The recommended film thickness for each product are given in the Technical Data Sheets. The protection given by a paint depends on the applied thickness Specialized equipment is available to measure the film thickness FLASHPOINT: ‘the temperature at which the vapor of @ material will he ignited by a spark or open flame. 1 is measured under standardized conditions. HARD COATINGS: ‘sa coating which chemically converts during its curing process, normally used for new construction, or non-convertible air drying coating which may be used for maintenance purposes. Hard coating can be either inorganic or organic. LATE 2 resin used in emulsion paints. PIGMENTS: ‘poviders, insoluble in resins, which give the paint its color, finish, and protective properties. a‘POLYMER: POLYURETHANE: PVA PAINT: RESIN: SEMI-HARD COATING: ‘SHOPPRIMER: ‘SOFT COATINGS: SOPHISTICATED PAINTS: ‘SPREADING RATE: TAR EPOXY: ‘THERMOPLASTIC PAINTS: ‘THIXOTROPIC PAINTS: ‘TWO PACK PAINTS: ZINC PHOSPHAT ZINC SILICATE PAINTS: ZINC-RICH PAINTS: w CCoarins Systews: A Guioance MANUAL Fon Filia Su a high molecular weight material created from lower molecular weight constituents by chemical reaction. Polymers with resinous characteristics are frequently sed in paints. 2a resin with special characteristics. Paints based on polyurethane are either ane or two pack, ae ‘extremely hard wearing, and are generally resistant to chemicals. They may be formulated to be ‘exceptionally color stable and weather resistant the time for which a two pack paint or varnish can remain mixed before it should be discarded The paint should be used within this time, since the curing will be so far advanced by then that the ‘ll not behave in the normal manner. Paint must never be allowed to remain in spray equipment after the expiry of it potlife see Emulsion Paints 8 material used as a binder constituent whieh forms 2 nonerystalline film when dried. Coating which dries in such a way that it stays flexible, but stil hard enough to touch and walk u ‘These coatings do not appreciably erode with the usual ballast water movement, Such coatings provide temporary protection of existing structures, 2 rust preventing paint for temporary protection of blasted steel immediately after blasting. ‘Shopprimers will protect the surface from corrosion during construction and until the Final paint system is applied. coating that remains soft so that it wears off at fow mechanical impact or when touched hy hand: often based on oils (vegetable of petroleum) or lanolin (sheeps wool grease}, these coatings are {generally used to give temporary protection to existing structures ‘are paints which are based on unconventional binders, such as epoxies, chlorinated rubbers, vinyls Generally, sophisticated paints give a higher level of protection than conventional paints, but are not so simple to handle. the area which is covered by one liter of paint, see Coal Tar Epoxy ‘are paints which dry by evaporation of solvent only. The binder is ueactve have a semi-solid or gel consistency when undisturbed, but flow readily when stitred or shaken, or \when being applied. The process fs reversible, and a fluid paint reverts to a gel consistency when the disturbance ceases. When applied, thixo-tropie paints will flow easily as long as they are being but quickly regain a gel consistency which assists in preventing runs and sags. tused to describe paints which are supplied in two separate containers and which have to be mised together before use 2 pigment with corosion preventing properties ~Zinc-filled paints based on an inorganic binder. Zinc silicates, * Zine filled paints based on a large proportion of metallic zinc in powder form. They usually conan ‘more than 85% zinc in the dry film and provide very hard flms, and are resistant to solvents,S . ed, See ABS CHAPTER EIGHT: Assessment Scale for Breakdown ASSESSMENT OF EXISTING SURFACE COATING SYSTEMS . For the purpose of consistent assessments of the ‘degree of effectiveness’ of an existing surface coating system, 1s suggested that the following ‘rating’ be used. * GOOD condition with only minor spot rusting ‘FAIR condition with local breakdown at edges of stiffeners and weld connections andjor light rustling over 204% or more of areas under consideration, but les than as defined for POOR condition. * POOR condition with general breakdown of coating over 20% or more of areas or hard seale at 10%e or more of areas under consideration, “Taker Structure Co-Operative Forum has tabulated the above definitions as follows: DEFINITION OF COATING CONDITIONS Rating/Condition Good Fair Poor Spot Rust Minor Ligit Rust Minor 20% ages Wiel <20%0 20% Hard Seale Minor > 1080 > 10% ‘General Breakdown Minor 220% 220% Other References 80) RIS Ria is European RED Res Re? ust Seale Note: The lowest rating within any category sholl govern the final rating, ‘An ‘sessment Scale for Breakdown’ of coatings is shown in Examples of coating system condition categorized under the above rating system. These are shown on the following pages.eee tee ABS HAPTER NINE: How to Use This Guide he complete tank. However, ifthe conditions vary to a great extent between the various main parts (bottom, eck, jongitudinal bulkheads, and transverse bulkheads) of the tank, then an evalvation of the various parts tay be advantageous. Te ‘coating condition should normally be judged over larye areas, For classification purposes, itis normal to judge 1 Some of the pictures shown in this guide are not from tankers but from ballast tanks of dry cargo ships. However, since the ton fs in Focus here, it was decided to use them i this context. The photographs should be considered a too! to assist the Surveyor in the performance of his duties, and this Guidance INanval is mtended to be used as such. It does not set a standard. It fs not part of the Rules for Building and Casing Stee! Vessels. | a @pe Sie: A Guo Maw Fon Fao Sines ABS CHAPTER TEN: Examples ‘A.small handbook is also provided for the following pages For easy reference: i: ifivins Srsvews: A Guinance Manual FoR FleLO SuRVEvoRS } Notes: 1. Blisters 2, Surface discoloration TSCF Assessment Scale: less than 19% Coating Condition Example Number: 1 aCCoarine SysTeNe: A Guioance Manuat ror Fito Notes: 1. Coating intact 2. Filmy surface contaminant pet 3. No corrosion 4. No scale ling TSCF Assessment Scale: less than 19% 19% Coating Condition Example Number 2 Goopans Svsrews: A Guouice Manual For FieLa Sunvevons ABS TSCF Assessment Scale: Notes: : ar I. Minor rusting on weld seams 2 2. Spot rusting 3 3, Filmy deposit much of surface | less than 19% 1% Coating Condition. Bample Number: 3 .- GOOD@ Coarine Systeus: A GUDANCE ManuaL FOR Fie. Sin Notes: 1. Line of sediment 2. Note absence of rust stains Coating Condition Example Numb ‘TSCF Assessment Seale: less than 19%& Quine Svstens: A Gumnance Manual FoR Fiud SURVEYORS Notes: 1. Visible coating repairs 2. Minor rust stains TSCF Assessment Scale: less than 19 Coating Condition Example Number: 5 GoopNotes: 1. Coating discolored from surface contamination 2. Organisms 3. No corrosion 4. No scale Coating Condition Gants Sy ‘TSCF Assessment Scale: us: A Guan Mogwai con Flewo Sunverars less than 19% : eee GOOD 1% Example Number: 6 erCorns Sees: & GvoHee Man fo Feo Sire ABS Notes: 1. Good coating 2. Dirty surface 3. Sediment on structure Coating Condition ... Example Number: 7 TSCF Assessment Scale: | less than 19% 1% 5=e Caste Steen: A GuoaNce Ma ro Fo Sunvevns TSCF Assessment Scale: | Notes: 1, Minor corrosion 2. Surface contamination (oily and sediment) [- | less than 1% 1% Coating Condition . . GOOD Example Number: 8Caannc Sysreus: A GuIDANCE Manual FoR FieLa SURVEvORS ABS — Notes: 1. Dirty coating 2, Discolorations due to oily contaminants and sediments Coating Condition Example Number: 9 ‘TSCF Assessment Seale: less than 19% 1% - GOODMs: A Guioance ManuaL Fon Fieto SURVEYORE TSCF Assessment Scale: Notes: 1. Scattered corrosion 2. Coating repaired less than 19% Coating Condition eteeenesGOOD Example Number: 10Coane Svsrewe: A Gummance Manual FoR FleLo Sunvevoas ABS | TSCF Assessment Scale: | | Notes: s 1. Sediment | ir . | | 2 Drip marks on lower frames | | less than 19% 1% Coating Condition .--- GOOD Example Number: 11Conrins Sysrews: A Guioance ManuaL Fon Fea Suavevens ‘TSCF Assessment Scale: Notes: 1, Rust stains 2. Moist coating or stiffeners less than 1% Coating Condition Example Number: 12 Goop