NACE_ IMCS2008

Establishment of Soluble Salt Criterion &

Salt Measurement Method for Coating Performance

Oct. 30, 2008

M.K Chung*, C.H. Lee, Y.H. Baek, B.D. Heo, and K. S. Kim

Hyundai Heavy Industries Co. Ltd.

Protective Coatings & Corrosion Dep’t

 Major Concerns on Salt Contamination

1. Reestablishment of Criterion of Soluble Salt

2. Development of Cost-effective Soluble Salt

Measurement Method

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 Salt-induced Blistering

Osmotic Blistering

• Premature Coating Failure

• Underfilm Corrosion

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 General Painting & Inspection Practice

1. Welding beads, burnt and rusted areas shall be blasted or

power tool cleaned to the specified grade.

2. The contamination such as zinc salt, etc. shall be removed

with appropriate method like power tooling or sweep
blasting, etc.
Source : KoShipA

Surface Salt Control

⇒ Follow Owner Spec.
⇒ Test Kit : SCM400TM & Others

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 Salt Control in Shipyards

Steel Storage
Salt Measurement

Primary surface preparation

* Washing, if necessary
Sub Assembly
Unit Assembly Salt Measurement

Secondary surface preparation

* Washing, if necessary

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 Criterion of Salt Level

‰ Shipyard : HHI (after blasting)

Area Criterion

Immersion
70mg/m2
(WBT)

Non-immersion
160mg/m2
(Deck)

* Measurement Method SCM400

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 Criteria of Salt Level

‰ Coating Manufacturer (after blasting)

Criterion(mg/m2)
Manufacturer Remark
Immersion Non-immersion

A 70 160

B 100 100

C 50 100 *

D 50 80

E 50 320

* Measurement Equipment : SCM400

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 Literature Survey

‰ DNV Technical Report

Manufacturer Expected Criterion

A 100*< value <200** mg/m2

C 100*< value <200** mg/m2

D Search or Request

*: no blistering, **: blistering

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 Claim Analysis

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 Claim Analysis

• The number of construction ships : 1300 (2008 year : 100)

• Ship construction experiences : abt. 30 years
• Market share : about 14%

Receiving A/S claim

↓
Analysis

Æ No Salt-induced Failure (Blistering)

• HHI’s criterion of soluble salt before IMO PSPC regulation
: 70mg/m2 using SCM400

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 Experience

Early 1990s

Pure
Tar Epoxy Epoxy
Modified

• No Claim
• Relatively weaker • No Claim

to blistering • No problem due to salt

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 IMO’s PSPC

Water Ballast TK

Epoxy HB (160 µm)

Epoxy HB (160 µm)

I.O.Z. (15 µm) Performance Standard

Steel for Protective Coating
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 IMO’s PSPC Regulation

Primary/Secondary Surface Condition

4.4 Basic coating requirements

Table 1 - 3.1 Secondary surface preparation

Water soluble salts limit equivalent to NaCl after

blasting/grinding shall be ≤ 50 mg/m2 of
sodium chloride (NaCl).

Conductivity measured in accordance with

ISO 8502-9 :1998.

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 Salt Requirement Change

PSPC 1st Draft : 30mg/m2

PSPC Final Version (MSC 82) : 50mg/m2

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 Issue of Sur. Salt Criterion

Surface Preparation
(Work Period, Cost, Productivity, Environment, Safety, …)

IMO PSPC : HHI Technical Data

• NaCl 50 mg/m2
• NaCl 70 mg/m2
• Bresle Method (CORR06, 06014)
• No Tech. Data
Insufficient
Tech. Data

Surface Salt Con. Criteria for Coatings of Ship’s WBTk

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 Measurement Times

‰ PSPC_6.2 Inspection Items

large block : 6000m2 105m X 68m = 7140m2

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 Research Activity

‰ Composition Analysis of Surface Soluble Salt on the Ship’s

Surface (Corrosion 2008, No. 08020)

‰ Coating Performance with Soluble Salt

(In process, be presented, min. NaCl 70 ~100 mg/m2)

‰ Development of Soluble Salt Measurement Equipment

‰ Estimation of Atmospheric Environment in the Shipyard

(2007)

Technical data to obtain reliable soluble salt criterion

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 HHI’s Opinion

HHI’s salt criterion more higher than that of IMO PSPC

Æ No problem about 20 yrs

Æ IMO PSPC has much higher safety margin, more than 40%.

Æ Salt criterion in IMO PSPC

The better, the best? Æ High cost, Low efficiency

Æ More understanding real ship yard situation.

Soluble salt criterion in IMO PSPC should be revised.

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 Major Concerns of Salt

1. Reestablishment of Criterion of Soluble Salt

2. Development of Cost-effective Soluble Salt

Measurement Method

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 IMO’s PSPC Regulation

Primary/Secondary Surface Condition

4.4 Basic coating requirements

Table 1 - 3.1 Secondary surface preparation

Water soluble salts limit equivalent to NaCl after

blasting/grinding shall be ≤ 50 mg/m2 of
sodium chloride (NaCl).

Conductivity measured in accordance with

ISO 8502-9 :1998.

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 Measurement Equipment

‰ Bresle Method (Bresle Patch)

‰ SCM 400

‰ Chlor*rid Test (sleeve, Kitagawa Titrator tube)

‰ SSM (Surface
( Salinity Meter, Soluble Salt Meter)

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 Shortcomings of Bresle Patch

Foam
Residue

‰ Shopprimed Surface Removal work

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 Needs for Improvement Bresle Patch

‰ Bresle Patch

- High price
- Residual form Æ removal work by power tool
- Poor durability of film

Improving performance of bresle patch

‰ Development of Color Patch

- Easier, faster, more convenient, practical method
- Color indicating patch

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 Salt Patch Design

Component Requirement Material

Foam Adequate Strength (soft/hard) Polyethylene(PE)
Film (vinyl) Elongation Latex
Adhesive No Leakage, No VOC Arcryl
Inner/outer Liner Easy detachment Glassine, kraft, PE film

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 Performance Test Results

- No Residue after foam removal

- Cost down up to 1/3

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 Color Patch

- Color indicating patch

- Easy, fast, comfortable, field oriented method
- Not the exact salt value but the value range

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 Summary and Future works

1. Reestablishment of soluble salt criterion

- Evaluation of coating performance with salt level.

- Addition of salt criterion test item in coating performance test

of IMO PSPC .

2. Development of cost-effectively practical salt test method

- Field application of advanced Bresle patch and color indicating patch

- Color indicating patch : salt value ranges

- Development of more reliable and practical equipment/kit needed

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 Thank you !

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