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D E S I G N
A N D
P LANN I N G
F O R
A Z O NE
O R I E N T E D
P A I N T I N G
S Y S T E M
July 1984
ADMINISTRATION
IN COOPERATION WITH
AVONDALE SHIPYARDS; NEW ORLEANS, LOUISIANA
Form Approved
OMB No. 0704-0188
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including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington
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1. REPORT DATE
2. REPORT TYPE
JUL 1984
N/A
3. DATES COVERED
6. AUTHOR(S)
8. PERFORMING ORGANIZATION
REPORT NUMBER
b. ABSTRACT
c. THIS PAGE
unclassified
unclassified
unclassified
17. LIMITATION OF
ABSTRACT
18. NUMBER
OF PAGES
SAR
194
19a. NAME OF
RESPONSIBLE PERSON
ACKNOWLEDGEMENTS
FOREWORD
EXECUTIVE SUMMARY
and
planning
structures,
as
related
to
zone
TABLE OF CONTENTS
SECTION
PAGE
i i
LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . .... . ..... .....
2.0 ORGANIZATIONAL STRUCTURE
AND RESPONSIBILITIES . . . . . . . . ....... . . . . . . . . . . . .
2.1 PAINT DESIGN GROUP . . . . . . . . . . . . . . . . . . . . . . . .
1-1
2-1
REFERENCES
2-3
2-5
2-7
3-1
3-2
3-17
3-28
3-28
3-32
3-46
A-1
LIST OF FIGURES
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
2-1
2-2
2-3
2-4
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
3-20
3-21
3-22
3-23
3-24
3-25
3-26
Page
Shipyard Organization.. . . . . . . . . . . . . . . . . . . . . . .
Paint Design and Planning Process Chart . . . . . .
Interdepartmental Relationships . . . . . . . . . . . . . .
Integrated Hull Construction, Outfitting
and Painting (IHOP) Schedule . . . . . . . . . . . . . . . . .
Tentative Paint Scheme. . . . . . . . . . . . . . . . . ......
Standard Paint Scheme. . . . . . . . . . . . . . . . . . . . . . . .
Paint Data Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paint/Shop Primer Table. . . . . . . . . . . . . . . . . . . . . .
2-2
2-6
2-9
2-10
3-3
3-5
3-8
.
.
.
.
3-12
3-13
3-14
3-16
3-21
. . . . . . .
. . . . . . .
. . . . . . .
Chart . . .
3-24
3-26
3-29
3-30
3-31
3-34
3-35
3-36
3-37
3-38
3-39
3-40
3-43
3-45
1.0 INTRODUCTION
(ZPTM) is a cost-effective
The Zone Painting Method
and
productive method of paint application, based on good planning
Integrated with the Hull Block Construction
and scheduling.
and the Zone Outfitting Method (ZOFM ) 2/ ,
ZPTMS purpose is to paint as much as possible prior to launch.
All three methods are based on the Product Work Breakdown
(PWBS)
structure which
sub-divides
Structure
ship
construction into the needed parts and subassemblies.
The Zone Painting Method (ZPTM) is divided into two stages; the
and
the production
The
design stage
stage.
Ship Design
Department has the paint planning responsibility in the design
the
Painting
Department is
stage
while
responsible
for
Coordination is required not only between the Ship
production.
Design Department and the Painting Department (production), but
with the Hull Construction Department, the Outfitting Department,
Purchasing, and any other department which impacts paint design
Figure 2-1, Shipyard Organization, shows the
and production.
placement of these departments within the shipyard structure.
In the design process, these shipyard organizations have certain
responsibilities in accordance with the particular planning
phase. These three phases are contract planning system planning
and zone planning.
In the contract planning phase, the Basic Design Department
prepares a tentative paint scheme and paint
budget estimate.
These preliminary plans are then negotiated with the owner to
better reflect the owners requirements and practices. The paint
scheme and costs are then finalized with the owner.
are defined during the contract
Most paint specifications
planning phase by the Basic Design Department. These people must
know not only the theory of painting, but also painting methods
at the shipyard.
They maintain communications with members of
the Paint Design Group, the Painting Department and paint
manufacturers representatives in order to remain aware of all the
latest data on paint materials and application methods.
Once the contract is signed, the Key Planning Section within the
Paint Design Group develops the system planning.
This phase
2-2
discuss
the
the Painting
Department as well as the interaction and coordination of these
and other related shipyard departments.
2-3
the
4.
the
4.
5.
fittings) (MLF).
Update the Budget Control List for the required volume
of paint material according to the MLF.
schedule.
How to organize the painting by pallets according to
the pallet list.
The functions of these sections within the Paint Design Group are
indicated in Figure 2-2, Paint Design and Planning Process Chart.
2.2 Painting Department
Department (production), like the Paint Design
the
Construction
than
Hull
smaller
relatively
Group, is
Some shipyards may
Department or the Outfitting Department.
combine painting with one of these other departments due to the
The
Painting
2-5
ORGANIZATION
SHIPS
. . DESIGN
. . . - . - . DEPARTMENT PAINT DESIGN GROUP
ORIENTATIION
CONTRACT
PLANNING
SYSTEM
PLANNING
PLANNING
PHASES
ZONE
PLANNING
5
FUNCTIONAL
DESIGN
ON-BLOCK PAINT
PAINT SCHEME
OUTPUT
TRANSITION
WORK INSTRUCTION
D E S
I
G N DES I GN
o PAINT SPEC,
PA INT TRANSITION
TABLE
BUDGET CONTROL
LIST
WORK TABLE
ONBOARD PAINT
WORK TABLE
OUTFIT COMPONENT
PAINT SPEC.
0
TIMING
PRE-CONTRACT
OUTPUT .
1ST PHASE
2ND PHASE
3RD PHASE
4TH PHASE
.PAINT MASTER
PLAN
O N- B L O C K
SCHEDULE
PAINT MASTER
.ONBOARD PAINT
SCHEDULE
SCHEDULE
PAINT
.MONTHLY SCHEDULE
PALLET LIST
WEEKLY SCHEDUE
PLANNING
PLANNING
(PRELIM.)
PLANNING
AND
PAINTING DEPARTMENT
ORGANIZATION
Figure 2-2
SCHEDULING
SCHEDULING
( P R E LI M . )
SCHEDULING
Paint
Design
and
Planning
Process
Chart.
4.
5.
6.
7.
8.
9.
10.
Produce
schedules for
and monthly,
painting,
detailed
on-block
painting,
and daily
weekly
on-board
schedules.
Determine labor requirements.
Determine material requirements.
Determine paint quality.
Determine safety requirements.
Determine paint work to be subcontracted.
Work with paint manufacturer to determine painting
and improvement of paint
application requirements
materials.
Figure 2-2, Paint Design and Planning Process Chart, shows the
timing of the first five activities listed above.
2.3 Coordination
The Paint Design Group must communicate with and coordinate its
The Paint Design
activities with other shipyard organizations.
Group provides the following information.
1.
Paint specifications and work instruction drawings to
the Painting Department.
A materials list to Purchasing.
2.
Paint specifications to other design groups.
3.
paint. specifications
(type of paint, number of
coats, color scheme and so on) for pipes and
individual outfit components, including auxiliary
machinery, from the outfitting design groups; and
b.
3-1
PAINTING
Surface preparation
Surfaces of steel plates and structurals shall be coated with one (1)
coat of inorganic zinc primer after shot blasting.
Coating
Bottom shell
CR =
AC =
AF=
BT =
TS =
RP=
DP =
HP=
TE =
PE =
coats
Chlorinated Rubber
Anti-Corrosive
Anti-Fouling
Boot Top Paint
Top Side Paint
Primer Paint
Deck Paint
Hold Paint
Tar Epoxy Paint
Pure Epoxy Paint
Figure 3-1
3-3
II II II II II 11 II
S!$if%i!!%sl
II II II II II II II
WEATHER- WATERPROOF
PROOF
MEDICINE
-PROOF
EASE
OF WORK
DRYNESS
OIL PAINT
CHLORINATED
RUBBER PAINT
Figure 3-3 :
3-5
engineer
phase.
and paint
manufacturer
during
the
contract
planning
negotiations.
The following surface preparation standards are
most commonly used in the shipbuilding industry:
Swedish Standards Institution, "SIS 05 59 00 - 1967:
items.
Ishikawajima-Harima
published steel
items.
Heavy
Industries
Co.,
Ltd. has a
surface preparation standard which cover these
Trouble
sometimes
in
painting
performance
during
occurs
construction and/or after delivery of a ship, and the cost of
Damage is rarely limited to
repair can become quite expensive.
one spot but usually extends to a large area, so the repair can
require dry-docking, scaffolding, abrasive blasting and so on.
Coating re-work has an extreme negative impact on production,
schedule and cost as well as guarantee costs. Therefore, careful
attention to painting is essential in the planning phase.
The final paint scheme should be reviewed in detail with the
paint
material
Design
Department,
Painting
Department
and
manufacturer in the planning phase.
All material and application specification documentation is
Therefore, the basic
maintained by the Basic Design Department.
designer must communicate with the detail design engineers,
Painting Department and paint manufacturer. Many times, a Paint
Technical Committee is established for information exchange.
This committee is composed of people from the Basic Design
Department, the Paint Design Group, the Paint Department and
A manager is generally
paint manufacturers representatives.
appointed chairman and he will call meetings on subjects such as
the following:
Standardization of drawings for paint schemes and
o
specifications.
Standardization of painting practices and procedures.
o
Technical study of new types of paint for ship
applications.
Failure investigation and analysis of damaged and
defective
paint
materials
from
reports
3-10
on
delivered
o
o
are
K:
A:
material
volume
is
S H E L L
L : LENGTH OF SHIP ( M )
3-13
this .
TRANSVERSE
BULKHEAD,
B X D
Figure 3-10
3-15
FUEL
OIL
TANK
refined to
consumption.
provide
sound
basis
for
estimating
paint
3-17
3-18
General requirements:
Paint work to be accomplished according to
o
o
o
b.
co
d.
e.
Surface preparation:
o
Surface preparation by abrasive blasting,
power tool or pickling.
o
Grade of surface preparation to be shown in
table.
Inspection:
Dry film thickness measurement instrument.
o
Method of inspection.
o
Inspection schedule.
o
Painting methods:
Paint method to be carried out by airless
o
spray, roller, brush or other.
o
When and if thinner is to be used.
Method of touch-up.
o
Miscellaneous:
3-19
o
o
o
o
While the design engineering groups are responsible for the above
activities, the Painting Department is involved as well during
the system planning
Their responsibilities
phase.
are to
develop:
3-20
GRADE OF SURFACE
PREPARATION
P A I N T I N G
BEFORE
SHOP
PRIMER
AREA
BEFORE
LAUNCHING
SP-10
BEFORE
PRIMER
FIRST
COAT I NG
SP-3
I ZP
COLOUR
OF COATS 3
1
REMARKS
MUNSELLS
NOTATION
CRAC
KEEL
AT DOCKING
RED
.
BOTTOM
EXCEPT
BEFORE
LAUNCHING
ABOVE
AT DOCKING
s P -l0
SP-3
12P
d
BOOT
TOP
BEFORE
LAUNCHING
SP-10
SP-3
12P
AT DOCKING
BEFORE
LAUNCHING
TOP
RED
CRAC :
CRBT
SP-10
SP-3
IZP
CRAC CRACCRTS
BLACK
CRAC
SIDE
AT DOCKING
BOW
CHOCK
AND
TOP
CRTS
(N-1.O)
BLACK
(N- 1.0)
OUT
SIDE
S P -10
SP-3
I ZP
I N
SIDE
S P -10
SP-3
I ZP
RUDDER AND
OUT
SIDE
SP-10
SP-3
1 ZP
BILGE KEEL
IN
SIDE
s P -10
SP-3
I ZP
Figure 3-12:
LIGHT GREEN
BS
SP-3
GRADE OF SURFACE
PREPARATION
P A I N T I N G
BEFORE
SHOP
PRIMER
AREA
BEFORE
LAUNCHING
SP-10
BEFORE
PRIMER
FIRST
COAT I NG
SP-3
I ZP
COLOUR
OF COATS 3
1
REMARKS
MUNSELLS
NOTATION
CRAC
KEEL
AT DOCKING
RED
.
BOTTOM
EXCEPT
BEFORE
LAUNCHING
ABOVE
AT DOCKING
s P -l0
SP-3
12P
d
BOOT
TOP
BEFORE
LAUNCHING
SP-10
SP-3
12P
AT DOCKING
BEFORE
LAUNCHING
TOP
RED
CRAC :
CRBT
SP-10
SP-3
IZP
CRAC CRACCRTS
BLACK
CRAC
SIDE
AT DOCKING
BOW
CHOCK
AND
TOP
CRTS
(N-1.O)
BLACK
(N- 1.0)
OUT
SIDE
S P -10
SP-3
I ZP
I N
SIDE
S P -10
SP-3
I ZP
RUDDER AND
OUT
SIDE
SP-10
SP-3
1 ZP
BILGE KEEL
IN
SIDE
s P -10
SP-3
I ZP
Figure 3-12:
LIGHT GREEN
BS
SP-3
o
o
o
o
o
The
paint
master plan
Decisions
effectively.
describes
how to
made on
paint
each
ship
must
be
what
should be
to erection at what location.
Items to be
accomplished prior
considered are:
reduce painting positions by shifting blocks so that
o
down hand or vertical painting may be maximized and
reducing the necessity of painting in high places that
require the use of scaffolding to readily accessible
o
o
o
o
o
places.
the
facilitate
use
of
temperature
and
humidity
controlled buildings, especially for sophisticated and
less forgiving coatings,
provide safer environments without implementing devices
that would encumber workers,
prevent in-process rust and associated re-work,
minimize the use of scaffolds needed only for surface
preparation and painting, and
maintain an even work load throughout the entire
shipbuilding process in order to avoid large work
volumes in the final stages that could jeopardize
scheduled delivery.
3-23
BEFORE
ON-BLOCK PAINTING
FINAL PAINTING
CRAC X 2
CRAFX 1
ON-BLOCK PAINTING
CRAF X 2
O N- - 6 L C C K P A I N T I N G
Figure 3-14
LAuNCHING
3-24
The
paint master
with the
above paint master plan to increase paint work efficiency.
This
paint master schedule is coordinated with the hull construction
and
outfitting
master
schedule
master schedule;
and when
integrated, become the IHOP schedule (discussed in Section 2).
In order to
3-25
STAGE
S E C T I O N
AT FABRICATION
STAGE OR
MANUFACTURER
AUX .
NACHINERY
AND
EQUIPMENT
EXTERIOR
TO BE COATED
PART
INTERIOR
PART
TO BE COATED INCLUDING
FINAL COAT
(COVERED WITH VINYL)
OTHER COMPONENTS
ON-BLOCK
TO BE COATED
ONLY WITH ANTICORROSIVE PAINT
ON-BOARD
FINAL COAT
UNDER COAT
AND FINAL C O A T
N O T E S : 1 . OTHER COMPONENTS ARE LADDERS, VENTILATION TRUNKS, PIPES, PIPE SUPPORTS, ETC.
2. THE MAST, POST, CRANE, FUNNEL, ETC. ARE PAINTED THROUGH THE FINAL COAT AT THE
FABRICATION STAGE (BEFORE ERECTION) For SAFETY PURPOSES.
3. THE HATCH COVER IS PAINTED EXCEPT THE FINAL COAT, WHICH IS APPLIED BEFORE
DELIVERY IN ORDER TO COVER THE AREA DIRTIED BY WORK4. EXTERIOR AUXILIARY MACHINERY AND EQUIPMENT IS THE SAME AS (3).
5. ON-BLOCK PAINTING FOR OUTFIT COMPONENTS IS SELDOM DONE.
Figure 3-15 :
3-26
3-27
3-28
Figure 3-16 :
3-29
3-30
3-31
3-13.
3-32
it is first
area to be
the paint area must be
painted. In this design phase,
re-calculated by using detailed drawings such as the hull block
structure drawings, fitting arrangements, and detailed component
drawings.
Some areas can be obtained from the data prepared by
other design groups for other purposes.
For instance, the steel
surface area is shown in the calculation sheets of hull block
weight and pipe lengths (from which the pipe area is calculated)
and are shown in the summary table of pipe piece drawings per
pallet.
The determined paint area must be indicated in the work
instruction drawings as shown in Figures 3-19, 3-20 and 3-21.
These tables provide the data for the material lists.
The
material lists per pallet (MLF) are prepared and issued to the
and Painting Department
Purchasing Department
for material
requisitioning, as shown in Figure 3-23. The Painting Department
then informs the Purchasing Department of the quantity of
material and delivery time required.
After completion of the MLF, the budget control list (previously
based on the MLS) must be updated using the new data.
In order to prepare the paint schedule, a design engineer should
know the production procedure and the schedule for painting, hull
construction, and outfitting because the painting is integrated
into the hull construction and outfitting schedules, as shown in
Figures 3-24 and 3-25.
3-33
LIST
MATERIAL
SURFACE
AREA
(SQ.M.)
PAINT
AREA
( SO. M.)
PAINT
SCHEME
NNORMAL
FILM THK
(MI CR/
COAT) GRAM/SOM
PAINT
SYMBOL
KG
786
708
TEx1
180
810
672
300
270
CRRPX2
30
240
130
269
2'33
CRRPX2
684
626
TEx1
31
20
SIDE SHELL
180l
UPPER DECK
Ma 6 HOLD
30
240
112
180
810
426
CRRPX2
30
240
14
170
CRRPX2
76
480
163
CRRPX2
30
240
62
47
180
810
38
MATERIAL
MANUFAC.
REQ D
BRAND/COLOUR OUANTITY
xxx
PAINT CO.
BISCON HB
BLACK
KG
1,036
CRRP
xxx
PAINT CO.
RAVAX A/C HB
BROWN
260
CRAG
xxx
PAINT CO.
RAVAX RED
LEAD PRIMER
GRAY
TE
UPPER DECK
(MLF)
163
Figure 3-23 :
PALLET NO
TExt
x x xxx x
BLOCK NAME
UT.1,
US1,SU1
CRAC = C h l o r i n a t e d
CRRP = C h l o r i n a t e d
TE
=Tar
Epoxy
25 microns =
Rubber
Anti-Corrosive
Rubber
Primer
Paint
Paint
mil
paint
film
thickness
3 41
The shop primer may be applied either by the steel mill or the
shipyard.
Therefore, the decision whether to buy the steel
primed or unprimed must be made before material purchase.
An outline of outfitting components painting requirements is
provided in the paint master plan issued by the Painting
Department at an early date, namely, at the same time the system
planning is done, as shown in Figure 3-15. Painting requirements
for outfitting components is developed step by step at each
planning
phase
and is
finalized
components, as shown in Figure 3-26.
on
detailed
drawings
of
Since
outfitting
painting
to
easily
define
the
paint
on-board
paint
work
is
specified
by
zones,
as
shown
in
o
o
o
and
drawings
work
the
instruction
on-board
work
instruction drawings may be developed directly,
Material lists (MLS, MLF) may be omitted and replaced
by the on-block/on-board paint work table,
The
lists
pallet
may
be
replaced by
the
on-block/on-board work instruction drawings, and
The paint master plan and paint master schedule may be
integrated into a single document.
3-44
3.4
FEED-BACK SYSTEM
3-46
REFERENCES
1.
2.
3.
4.
Outfitting
and Painting
Integrated Hull Construction,
(IHOP)", L.D Chirillo and Y. Okayama, National Shipbuilding
Research Program, May 1983.
5.
6.
A-1