6 PAINTING 2016 Unlocked

19.02.
2016
GEM 418E Corrosion and Fouling Protective Coatings

in Marine Environment
Satisfactory installation of protective
PAINTS & PAINT APPLICATION coatings require 4 basic steps :
1. Surface preparation.
2. Surface pretreatment.
3. Anticorrosive or barrier coating
application.
Prof. Metin TAYLAN 4. Antifouling coating application.
http://www.gidb.itu.edu.tr/staff/taylan/corr/corr.html
© Metin Taylan, 2016
Paints and Coatings Corrosion Protection by Paints
For corrosion prevention with paints, three
main principles are employed:
• Barrier effect
• Inhibitor effect
• Galvanic effect
© Metin Taylan, 2016 © Metin Taylan, 2016
© Metin Taylan, 2016 1

19.02.2016
Paint Consists of: Composition of Paints
• Liquid: Vehicle / Varnish Paints
– Binders
Binder Pigments Extenders Solvents Additives
– Thinners (solvents)
• Dry: Powders / Pigments Natural Resin Colouring Fillers Hydro carbons Wetting agent
– Colour pigments •Drying oil
•Coal Tar Inhibitive pigm. Stress reducing Ketones Anti-settling
– Active / Reactive pigments •Nitrocellulose
– Extenders Esters Drier
Cathodically
– Barrier pigments Synthetic Resin protective
•Alkyd Ethers Anti-skinner
• Chemicals: Additives •CR
•Epoxy Biocides Alcohols Plasticiser
– Production enhancers •Polyester
– Storage facilitators •Polyurethane Water
•Silicate
– Application aids •Vinyl
•Polysiloxane
– Appearance improvers
– Service life strengtheners
The Properties of a Paint Will Drying / Curing Mechanism

be Decided by the Binder
• The properties of a paint film is closely
• Describes the type of paint/coating related to how the binder dries or cures.
• Bind pigments and
extenders to a solid film • The three most common drying / curing
• Provides the adhesion to the substrate mechanisms are:
and cohesion, flexibility in the film
1. Physically Drying (solvent evaporation)
• Provides the water, chemical, solvent and
2. Oxidatively Curing (reaction with oxygen in the air)
UV resistance 3. Chemically Curing (chemical reaction between base
and hardener)

19.02.2016
What Factors May Influence the Drying Process ? Volatile / Non‐volatile
• A paint’s “Solid Content” means the part which does
• Relative humidity, % R.H. not evaporate, commonly quoted as %volume.
• Ventilation
• Temperature • A paint’s “VOC” (Volatile Organic Compound) tells us
how many grams of solvents there are in one litre of
• Film thickness
paint.
• Number of coats
• Evaporation rate of the solvents
Solid Content
Solid Content: WFT vs. DFT
Solvents,
20%
When applied in the same WFT, the paint with the higher
Solvents, solid content will result in a higher DFT (and thus need fewer
50% Additives, 8%
coats or gives better protection)
Pigments,
24%
Additives, 5% 100
100
50microns wet
microns dry film
film 80microns wet
microns dry film
film
Pigments,
15%
Binder,
48%
Binder,
30%
50% SOLID CONTENT
80% SOLID CONTENT
Solid content: 50% Solid content: 80%

19.02.2016
Shopprimers Shopprimers
Definition:
• Protection of steel during the construction process
A quick drying material applied as a thin film to a • Usually designated to last 6‐9 months
metal surface after cleaning, e.g. by a blast cleaning
process, to give protection during the period before • Anticorrosive pigments are used
and during fabrication.
• Quick drying, applied automatically
Requirement: • Damage resistant
Must not interfere with the speed or quality of
• Must not affect welding or weld quality
cutting and welding of the steel during fabrication,
so DFT must be limited to: • No toxic fumes during welding
Iron oxide: 15 – 20 micr.
• Easy to overcoat, without “secondary” preparation
Zinc‐rich: 10 – 15 micr.
Activities Involved in Shop Priming Shoppriming Factory
• Cleaning
• Blasting
• Application
• Handling

19.02.2016
Automatic Spray Boot Application Zinc Silicate Shopprimer During Construction
Shopprimers Topsides and Decks
• Applied at low film thickness – typically
15m (microns).
• Low solids – typically 20‐30 % volume
solids.
• High volatile organic content (VOC) –
typically 650 g/liter.
• Inorganic zinc silicates‐the most common.

19.02.2016
Accomodation and Engine Room Bottom Area and Bootop
Cargo Areas Tank Coatings

19.02.2016
Painting Does it Good
Ballast Tank Coatings
Summary Paint Application
Cleanliness and good housekeeping before, during
• The direct cost of coatings is ~2% of a new
and after application are most important factors to
vessel. have a good result
• With the surface preparation and coating
application costs this increases to 8‐10%.
• The time for the whole painting process is 15‐
20% of the overall time to complete the
vessel. Delays can be costly.
• Protection of a ship’s hull by coatings is a
complex business, with different coatings for
different areas.

19.02.2016
Atmospheric Conditions Estimating Probability of Condensation
Requirement During Blasting and Painting
• Cold liquid inside hull and warm air outside causes condensation
Surface temperature of the • See how frames inside keeps the cold longer
structure must be minimum
3 °C above the dew point B-24/2-4
4847-693
of the surrounding atmosphere
Why Temperature & Humidity are Important Purpose of Climatic Evaluation
Condensation follows the
contours of the double‐bottom
tank 
Evaluate the likelihood of the
moisture in the air to form
condensation on a substrate
 Frozen overnight
condensation, follows
the frames of the ship

19.02.2016
Moisture / Absolute Humidity Absolute Humidity
• When water evaporates, it forms water vapour or
moisture in the air
• We may measure this moisture as gram water per DEFINITION:
cubic meter air (g/m3)
• The maximum amount of moisture that can be
contained in the air depends on the temperature of • The maximum content of water vapour in the
the air air at a given temperature
• Warm air can contain larger amounts of moisture
than cold air
• The maximum moisture that can be contained in air • The content will vary with temperature
at the various temperatures is called the Absolute
Humidity
Absolute Humidity Moisture / Relative Humidity
• The Relative Humidity is a measure of how much of the
Absolute Humidity (maximum moisture) that the air
contains, expressed as percent.
At 8o C, the • If the air contains the maximum amount of moisture, it will
maximum have a Relative Humidity of 100%
moisture content At 20o C, the • If the air contains half of the maximum amount of moisture,
in the air is 8.28 maximum it will have a Relative Humidity (RH) of 50%
g/m3 moisture content • If the air contains a quarter of the maximum amount of
in the air is 17.31 moisture, it will have a Relative Humidity of 25%
g/m3
• Question: Will air with RH=50% at 8o C have the same
moisture content as air with RH=50% at 20o C?

19.02.2016
Relative Humidity, RH
Relative Humidity
% RH:
DEFINITION: Water vapour in the air as percentage of the total
amount water vapour the air can contain at the same
• The ratio of
temperature.
– The amount of water vapour present in a given
volume of air at a given temperature
and Example
– The maximum amount of water vapour which this
Air at 20o C can contain 17.31 g. water/m3, but the
volume of air can hold at that temperature
actual content is measured to 15 g/m3. What is the
• RH is expressed as a percentage R.H. ?
15g x 100%
• RH outdoors will vary R.H. = = 86.65%
17.31g
Humidity / Dew Point Dew Point
• Air at 20o C and 73% RH contains 12.64 g/m3 water (12.64 as
percentage of Absolute Humidity 17.31) DEFINITION:
• If the temperature drops to 16o C, it will still contain 12.64
g/m3, but the RH will increase to 92.69% (12.64 as percentage
of Absolute Humidity 13.65) • The temperature at which the air becomes
• If the temperature drops further to 12o C, what will happen? saturated with water vapour
• At 12o C the maximum moisture content (Absolute Humidity)
is 10.62 g/m3. This means the moisture content of 12.64 g/m3 • At this temperature the RH = 100% and water
is 2.02 g/m3 more than it can hold at this temperature
will condense
• The consequence is that the excessive moisture will leave the
air through condensation, ending up as dew on available
surfaces or as rain or fog • The chance of condensation is high when the
• The temperature at which a given moisture content will start weather is changeable
to condensate is called Dew Point.

19.02.2016
Dew Point / Substrate Temperature Main Rule for Pre-treatment

• On an early morning inspection we measure the air temperature and Paint Application:
to be 8oC and the RH to be 83%
• Due to cold over‐night temperature, the steel temperature of a
structure to be painted was measure to only 4o C
• Would this cause any problem?
Temperature of substrate should
• At 8oC and RH 83%, the moisture content is 6.87 g/m3 be at a temperature of
• Although the general air temperature is 8o C, the air next to the
steel surface will be cooled by the steel and perhaps only be 4o C min. 3oC
as well
• At 4o C the max moisture content is 6.36 g/m3 above dew point of the air in
• This means that although we may not see it clearly, there will be the vicinity
condensation on the steel
• This is why Steel Temp. must be min. 3o C above the Dew Point!
Measuring Ambient Conditions Electronic Humidity Gauge
• Electronic multi‐function gauge • Needs frequent
• Electronic humidity gauge calibration
• Dependent on batteries
• Sling Psychrometer (Sling Hygrometer,
“Dry and Wet bulb”) • Multi‐function models will
measure air temperature,
(Hair hygrometer, not suitable!)
surface temperature,
• Dew point calculator relative humidity, and
• Steel thermometer calculate dew point and
T(*)
(* ) difference between dew point and surface
temperature)

19.02.2016
Sling Psychrometer Measuring the Relative Humidity
A dry and a wet thermometer put together in • Photo: Sling Psychrometer
for measuring:
one unit.
‐ Dry temperature
‐ Wet temperature
• The difference in the measured temperatures • Measure the temperature
in the vicinity.
indicate the amount of humidity: • Calculate the relative Cd-4932-88
humidity
• Use together with dew
• Large difference = low RH% point calculator
• Small or none = high RH%
Dew Point Calculator Contact Thermometer
• For calculation of dew point • Electronic instrument for measuring the steel temperature
• To be used together with surface • Other types of thermometers are also available. E.g.
temperature thermometer and magnetic thermometers
sling psychrometer.
• Use this frequently during pre‐
treatment, application and
drying of the paint.
• Recommendation: Every 6 hours Cd-4932-89
and when weather conditions
are changing
© Metin Taylan, 2016

19.02.2016
IX ‐ diagram for IX Diagram (MOLLIER Diagram)

determination of relative
humidity (%RH)
Example:
Measured values
Air dry temp. : 14.0 °C
Wet bulb temp. : 10.5 °C
Read
Relative humidity : 65 %
Dew point : 7.0 °C
Air‐water content : 6.3 g/kg
Using the IX Diagram Ambient Conditions (General)

• Draw a horizontal line at the appropriate dry bulb Painting should not be started when:
temperature
• Draw a 45o line at the appropriate wet bulb
• The relative humidity exceeds 85% (unless the paint
temperature
manufacturer consider it safe)
• At the intersection you will determine the RH
• Draw a vertical line from the intersection point all
• The substrate temperature is less than 3oC above the
the way to the 100% line
dew point
• This is the dew point

19.02.2016
Ambient Temperature and Steel Temperature
Ways to Control the Climatic Conditions
Is the temperature important ? YES !
• Dehumidifier, reduces the actual humidity in the
• Ambient temperature will
surroundings influence:
• Steel temperature will
affect:
• Heater, heat the objects (surfaces) prior to – shelf life (storage) – probability for condensation
– potlife (two‐pack paints: time
application in order to reduce the danger for between mixing and no longer
– solvent evaporation
– speed of cure (drying time)
condensation useable)
– degree of cure
– induction time (pre‐reaction
– recoating interval
• Forced ventilation is a must in order to secure a before application)
– service life of the coating
– viscosity/sprayability
proper evaporation of the solvents from the paint – Steel Temperature
film
Hand‐tools for Application of Paint
Paint Application
• Stirrer: Only to be
A temperature of 21°C, humidity of used for small tins
50‐60% and little or no wind would • Round paint brush
be ideal weather condition for • Flat, short paint
brush Cd-4934-04
painting and coating.
• Radiator brush
• Small back roller
• Tape for masking

19.02.2016
Good Access is as Important for a Satisfactory
Application as the Quality of the Equipment! Methods of Application
• Brush
• Roller
• Airless spray
Application by Paint Brush
Brush Application
• Suitable for oil‐based coatings Benefits
 Good wetting of the substrate
• Small and intricate areas  Forces the paint into the surface
• Repair of small areas or touch‐up coating  Better than roller on the first coat
 Good on areas with poor accessibility
• Round or oval brushes are suitable for
rivets, bolts and irregular surfaces Limitations
 Gives low film thickness,
• movement of the brush should be back many coats required
and forth in two or more directions  Creates an uneven film
 Application speed is slow

19.02.2016
A Round (or an Oval) Paint Brush is in Many
Angled, Flat Paint Brush (Radiator Brush)
Cases Recommended
• Paint brush “works” the paint well into the substrate • For areas being difficult to access
• Can be used on 1. coat as well as subsequent coats • Long handle is not recommended
• Limitation: The production rate
• With long extension: Not permitted in offshore use
Cd-4934-05
Roller Application Application by Rollers
• The first rule : is never use a roller for the first Benefits
coat of paint on cleaned surfaces
 Application speed is faster than with paint brush
• Rolling is primarily for large flat areas such as  Good on areas with poor accessibility
the exterior of a tank or a flat part of a ship’s
side Limitations
• Rough areas and areas along welds often  Poor wetting of the substrate
create areas where a roller does not  Never use for the first coat
penetrate, thus leaving ‘holidays’  May incorporate air and pinholes in the paint film
 Gives low film thickness, many coats required
Holiday : discontinuity in protective coating such as cracks, porosity etc.

19.02.2016
Roller Types
Application by Rollers
Trabzon’da Bir Futbol Sahası.... Stripe Coating
Doğal defans elemanları
Keşke Fener maçını burada

oynasak.... • Hard to clean
areas
• Hard to paint
Hami Mandıralı
areas
• Often applied
with
contrasting
Cardoza’nın kamyoneti color

19.02.2016
Stripe Coating Prior to Each Full Coat Examples of Good Stripe Coating
Stripe coat with paint brush:
• Where difficult access with spray
• Profiles
• Inside edges
• Holes, notches
• Corners, angles
• Sharp edges
• Manual welding seams
Examples of Bad Stripe Coating Stripe Coating of Superstructure
Between First and Second Full Coat
Note the contrasting colors
• Pipes
Cd-4934-92
• Supports
• Windows
• Reeling

19.02.2016
Airless Spray Application Why Use Airless Spraying ?

• With airless spray there is no air used in the
atomization of the paint.
Applicator saves time: Up to 50 ‐ 75%
• The liquid is forced through a very fine orifice by
hydraulic pressure and forms a spray pattern as it • With paint brush: Four times longer
expands into the atmosphere.
• The spray gun should always be held at right • With roller : Twice as long time
angles to the surface and held no closer than
450mm nor more than 600mm from the surface.
• The nozzle is by far the most expensive and
important component in the airless spray
equipment. It should therefore be treated with
the utmost care.
Main Parts of Airless Spray Equipment Airless Spray Pump: How It Works

Compressed
air
Airless spray equipment consist of three
main parts :
1. Compressed air / electrical motor
Pressurized
2. Paint pump Paint
3. Hose and spray gun

19.02.2016
Atomization of the Paint Formation of a Paint Film

Tip
1. As the coating droplets hit the substrate they will become
High pressure
flat
paint flow
2. Then, they will overlap and form a continuous paint film
Orifice
When the paint is
released from inside
Atomised droplets Fan pattern
the highly pressurised and width
of paint
hose and through the
nozzle to the open air,
it “explodes” or
“atomises” into tiny
droplets
Rules When Spraying Airless Spraying with Overlap
• Correct distance between spray gun and Overlapping ensures
substrate (30‐60 cm) 50 %
an even film thickness
Overlap
• Correct angle (90°)
• Overlapping (50% or cross application)

19.02.2016
Keep the Gun at a
Thickness of the Paint Applied
Right Angle to the Substrate
The distance should be between 30 and 60 cm. The optimal
distance will vary, depending on other things such as wind, The film thickness is affected
temperature, pressure at the nozzle and viscosity of the paint by:
.
Cd-4934-20
•Distance gun tip ‐ surface
• Speed of gun stroke
• Pump pressure
• Nozzle size
High Pressure, Airless Spray Pump Airless Spray Control Valve for Air Pressure
• A spray pump’s “ratio” relates to the relation
between the pistons in the air‐motor and the • Correct pressure is
paint‐pump
important
• A pump with ratio 1:48 means the air‐
motor’s piston has an surface that is 48
• Typical pressure ratio:
times larger than the surface of the piston in 1:48 or 1:60
the paint‐pump Cd-4934-15 • Recommended pressure at Cd-4934-16
• The consequence is that if the air pressure nozzle: Minimum 15 MPa
into the unit is 5 kp/cm2, the pressure of the (150 kp/cm² or 2.100 psi)
paint going out of the unit is 5 x 48 = 240
kp/cm2 • Small diameter and long
• Typical pressure ratios:
length of spray hose will
lead to loss of pressure
1:48 and 1:60

19.02.2016
Well Protected Applicator Ready to Spray
Airless Spray Painting
• Disposable suit, mask, gloves
and boots covers the entire
body.
• Disposable suits is particularly
recommended when working
with epoxies.

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19.02.

GEM 418E Corrosion and Fouling Protective Coatings

© Metin Taylan, 2016 © Metin Taylan, 2016

© Metin Taylan, 2016 1

© Metin Taylan, 2016 © Metin Taylan, 2009

The Properties of a Paint Will Drying / Curing Mechanism

© Metin Taylan, 2016 © Metin Taylan, 2016

© Metin Taylan, 2016 2

© Metin Taylan, 2016 © Metin Taylan, 2016

Solid content: 50% Solid content: 80%

© Metin Taylan, 2016 © Metin Taylan, 2016

© Metin Taylan, 2016 3

© Metin Taylan, 2009 © Metin Taylan, 2016

© Metin Taylan, 2016 4

© Metin Taylan, 2016 © Metin Taylan, 2016

© Metin Taylan, 2016 © Metin Taylan, 2016

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© Metin Taylan, 2016 © Metin Taylan, 2016

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© Metin Taylan, 2016 9

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© Metin Taylan, 2016 10

Dew Point / Substrate Temperature Main Rule for Pre-treatment

© Metin Taylan, 2016 © Metin Taylan, 2016

© Metin Taylan, 2016 © Metin Taylan, 2016

© Metin Taylan, 2016 11

© Metin Taylan, 2016 12

IX ‐ diagram for IX Diagram (MOLLIER Diagram)

© Metin Taylan, 2016 © Metin Taylan, 2016

Using the IX Diagram Ambient Conditions (General)

© Metin Taylan, 2016 © Metin Taylan, 2016

© Metin Taylan, 2016 13

© Metin Taylan, 2016 © Metin Taylan, 2016

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© Metin Taylan, 2016 © Metin Taylan, 2016

Keşke Fener maçını burada

© Metin Taylan, 2016 17

© Metin Taylan, 2016 © Metin Taylan, 2016

© Metin Taylan, 2016 © Metin Taylan, 2016

© Metin Taylan, 2016 18

Airless Spray Application Why Use Airless Spraying ?

© Metin Taylan, 2016 © Metin Taylan, 2016

Main Parts of Airless Spray Equipment Airless Spray Pump: How It Works

© Metin Taylan, 2016 19

Atomization of the Paint Formation of a Paint Film

© Metin Taylan, 2016 © Metin Taylan, 2016

© Metin Taylan, 2016 © Metin Taylan, 2016

© Metin Taylan, 2016 20

© Metin Taylan, 2016 © Metin Taylan, 2016

© Metin Taylan, 2016 21