PME Cea PUY gO Ma ADIT 5 1995MISSION. Thersson of the American Bureanof Shipping | isto serve the public interest as vel as te neds of our cents by promoting the security of fe, property aad the natural encirronent primarily ough the devdopment and. erfcation of standard forthe design, construction ad operniona maintenance of marine elated faites. QUALITY POLICY Ihisthe policy ofthe American Bure of Shipping to provide quality services in support of our mission cand to Be response tote individual cane clectve reed of our ents aswel. those ofthe publ at lage. Abof our cent comaitments, supporting actions, anc sercicesdticered ust be meogrized as expressions of quality, ‘Wk pledge to monitor our performance ass orig activity ad to ste for continuous improvement COATING SYSTEMS A GUIDANCE MANUAL FOR FIELD SURVEYORS 1995INTRODUCTION Many areas of steel structure of any vessel will be prone to corrosion throughout its service life, and, therefore, 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, it is felt more than ever that the field surveyors should have some basic factual information on coating systems. It is the intent of this guide to meet this need in a straight forward and practical manner, avoiding unnecessary rhetoric. While technically not a coating system, we have included a brief chapter on cathodic protection in order to give the surveyor a more complete picture of corrosion protection systems.ACKNOWLEDGMENTS: 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 of the ABS Ad Hoc Panel on Coatings: Bernard Appleman Steel Structures Painting Council Michael Bentkjaer Hempel Paints Phil Birleson JRS Ship & Offshore Ron Briggs Matson Navigation Dennis Bufo ‘Sabine Transportation Co Helena —_Buist NACE im Denny Courtaulds (Intemational Paints) Rong Huang Chevron Shipping Owen Jones Royal Chemical Joseph — Madden Arco Transportation Tom Meintyre Marine Transport Lines Tom Mulligan Devoe Coatings Ramesh — Raghavan ‘Sigma Coatings Bruce Sawel Esgard Bob Stanley Maritime Overseas Carriers Charles Stuckey Drew Ameroid / Ashland Richard Whiteside BP Oil Shipping Co. Dave Whitmer BP Oil Shipping Co, Chairman NACE TC-14B Frank Windler Scherwin Williams Len Zagrzecki Unitor -Sudheer Chand Part 1: General Resume of Paints and CHAPTER ONE: WHAT IS PAINT?.... PAINT TECHNOLOGY, Binders ‘TuERMoseT Coarines. "TerMoPLasric Coarisas Chlorinated Rubber Resins. Vinyl Resins. Bituminous Binders. PIGMENTS & EXTENDERS Anticorrosive Pigments. Barrier Pigments Coloring Pigments. Extending Pigments Solvents... (Orne Parr ADDITIVES, so ‘Tppieal Groups of Paint Additives: CHAPTER TWO: PAINTS FOR PURPOSE! ANTICORROSIVES. Corrosion. Corrosion in humid environment Corrosion In an acidic environment Bi-metallie corrosion . Galvanic Corrosion. ANTICORROSIVE PAINTS. Barrier effect. Inhibitor Effect. Galvanic effect. ‘SHOPPRIMERS. Demands. Properties ANTIFOULINGS. Fouling. Distribution. Antifouling Paints. CHAPTER THREE: SURFACE PREPARATIO! SOLVENT CLEANING (SSPC-SP-1). HAND Tool, CLEANING (SSPC-SP-2) POWER TooL CLEANING (SSPC-SP-3), Rotary Wire Brushing. Mechanical Descaling Rotary Power Discing ABRASIVE BLAST CLEANING (SSPC-SP-5.6.7.10). ‘SSPC-SP-5, NACE No. I, Swedish Sa 3 ‘SSPC-SP-10, NA SSPC-SP-6, NACE No. 3, Swedish 'SSPC-SP-7, NACE No. 4, Swedish Sa 1 CHAPTER FOUR: METHODS OF PAINT APPLICATION BBSE 1 1 1 L M L 1 1 1 Li ‘METHODS oF APPLICATION Brush Application Roller Application, Conventional Spray.42 Airless Spray. CHAPTER FIVE: ALTERNATIVES TO “HARD” COATINGS. CutenastRy. Sl METHOD OF PROTECTION 51 ‘THICKNESS 5-2 Oractry 5-2 APPLICATION METHOD, CHAPTER SIX: CORROSION AND CATHODIC PROTECTION wissen INTRODUCTION STEEL AND THE CORROSION REACTION Uniform Corrosion. Pitting Corrosion Crevice Corrosion. Deposition Corrosion ‘THe GALVANIC SERIES IN SEA WATER AND CATHFODIC PROTECTION CHAPTER SEVEN: GLOSSARY OF FREQUENTLY USED COATING TERMS. CHAPTER EIGHT: ASSESSMENT SCALE FOR BREAKDOWN... ASSESSMENT OF EXISTING SURFACE COATING SYSTEMS 82 CHAPTER NINE: HOW TO USE THIS GUIDE. (CHAPTER TEN: EXAMPLES. Part! COATING ASSESSMENT GUIDE. RESUME OF PAINTS AND INGREDIENTS‘American Bureau Of Shipping Coating Systems: A Guidance Manual for Field Surveyors Chapter Oni What is Paint? ‘surface on which it subsequently dries or hardens to form a continuous adherent, obliterating. film, In the past, paint technology and paint making were arts or crafts developed over many years and supported by results of practical experience. ‘The performance limitations of the paints produced were basically attributable to the available raw materials, These were predominantly of natural origin. For example, oxides of iron were used as pigments and various blends of vegetable oils and natural resins used as binders, These traditional coatings however, did generally fulfil the accepted demands of the time. P= ‘can be described as a liquid material capable of being applied or spread over a solid Significant advances in paint technology came about with the demand for higher performance, longer Fife coatings, ‘These were eventually realized by the progressive introduction and development of synthetic raw materials and intermediates helping not only to alleviate the restrictions imposed on the paint chemist by traditional technology but also to establish a much more scientifically based industry, Reproducible products with predictable performance 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 from conventional liquid paints applicd 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 principal compon they impart (o the finished product s of paints, their functions and the properties PAINT TECHNOLOGY Paints are mixtures of many raw materials, each of which in turn has been manufactured to give certain specific properties. Basically, however, paints consist of three major components and many additives which are included in minor proportions. ‘The major components are: ‘© Binder (other terms used include: vehicle, medium, resin, film, polymer) ‘© Pigment and extender © Solvent Page 1-1‘American Bureau Of Shipping Binders Coating Systems: A Guidance Manual for Field Surveyors Of these, only the first wo form the final dry paint film, Solvent is necessary purely to facilitate application and initial film formation, it leaves the film by evaporation and can therefore be considered an expensive waste product. Binders are the film forming components of paint, They are predominant in determining the principal characteristics of the coating, both physical and chemical, Paints are generally named after their binder component (e.g. epoxy paints, chlorinated rubber paints, alkyd paints, etc.). ‘The function of the binder is to give a 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 fall into tvo classes, Thermoset and Thermoplastic, This dis should general limite localize a = the cng tl general belied lead ean fay sere coon haw Normally silicon carbide SSPC-SP-5, NACE No. 1, Swedish Sa 3 Ite Meta lt Cee Suse Fish, This as snd died asa ui witha gay. shite uniform mt cotr, sigh roughened fom a sutale pole costnes i sce at oil ress, di, vsbe ml sale, rus corrosion pace oan jer fregn mater. this surface shall havea color characterise the abnor pede Page 3-2 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 oil, ‘grease, dirt, mill scale, rust, corrosion products, oxides, paint or other foreign matter have been removed except for very light shadows, very light streaks or slight discoloration’s. At least 95% of a surface shall have the appearance of a surface blast cleaned to a white metal surface finish, and the remainder shall be limited to the light discoloration mentioned above. h Sa2 , NACE No. 3, Swe ‘Commercial Blast Cleaned Surface Finish. This finish is defined as one from which all oil, grease, dirt, rust scale and foreign matter have been completely removed from the surface and all (Sa 2 provides for almost all) rust, mill scale and old paint have been completely removed except for slight shadows, streaks or discoloration’s, Ifthe surface is pitted slight residues of rust or paint may be found in the bottom of pits. At least 67% of the surface area shall be free of all visible residues and the remainder shall be limited to light discoloration, slight staining or light residues mentioned above. SSPC-SP-7, NACE No. 4, Swedish Sa 1 NOTE: Brush Off Blast Cleaned Surface. This finish is defined as one from which oil, 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 are permitted to remain, provided they have been exposed to the abrasive blast pattern sufficiently to expose numerous flecks of the underlying metal fairly ‘uniformly distributed over the emtire surface. Water Blasting has not been included as a normal method of surface preparation. While itis effective it must be done under very controlled conditions and high pressure. The use of water blasting is increasing in the marine industry Page 3-3‘American Bureau Of Shipping Coating Systems: A Guidance Manual for Field Surveyors Chapter Four: METHODS OF PAINT APPLICATION T: ‘objects in applying paint coatings are to provide films which will give protection and, ‘normally to a lesser extent, decoration to the structure being painted. The variables which ‘govern the success of any application are: Surface preparation Film build and total thickness of system ‘Method of application Atmospheric conditions during application. Methods of Application ‘The normal methods of application of paint coatings are by: Brush Roller Conventional spray Airless spray Other methods may also be encountered, such as dipping and pouring, and more sophisticated adaptations of spraying such as electrostatic, powder coatings application, and automatic plants, but in this paper we will concentrate on the four basic methods detailed. Brush Application ‘The ‘historical’ method of paint application, it is not as fast as spraying or rolling 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 itis important to dip the brush in paint frequently and not to ‘over-brush’ the surface as this will result in large variations in film thickness, the inherent problem with brush application Choice of brush, both size, length and type of bristle, and shape, are important, and the type of paint being applied will modify the selection, “Thus large flat brushes are normally used for the majority of purposes, but round brushes are better for painting bolt-heads and “difficult” areas. Special brushes are available with offset heads and long handles to facilitate painting the “backs' of structures and. inaccessible areas, Brush application is most suited to the slower drying, normal build type of coatings, and will not always be suitable for the more sophisticated ‘fast-drying’ or *hi-build’ materials. It 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. Page 4-1American Bureau Of Shipping Coating Systems: A Guidance Manual for Field Surveyors Roller Application Roller application is faster than brush on large, flat surfaces, such as tank sides and tops and ‘walkways and deck areas, but is not so good for “difficult” areas. It is hard to control film thickness, however, and care must always be taken that the coating is not ‘over-rolled’ in the same manner that it can be ‘over-brushed’. Choice of roller pile - short or long hair, sponge or lambs wool - is dependent on type of coating and roughness and irregularity of surface being coated. Conventional Spray This is widely accepted, rapid method of applying paint to large surfaces. The equipment is relatively simple and is usually confined to fairly low-viscosity paints, although newer techniques using. “pressure-pot’ or “hot spray’ apparatus allow application of some of the ‘higher build” type coatings. ‘whatever type of equipment is used, the mechanism is the same, Paint and air are fed separately 10 the spray gun and mixed at the nozzle, where the paint is atomized and air is mixed with these droplets forming a fine mist of paint which is carried by the air pressure to the work surface (soe below). The pattern of the ‘fan’ so produced is controlied by adjusting the air and fluid pressures, and ‘major change sin paint type can be accommodated by different sizes of nozzle. is important to have only sulicient air to provide good atomization, as excess air gives tise 10 overspray and ‘rebound’ from the work surface. The gun should be held at right-angles to the work ‘surface with the nozzle some 6-8” (15-20 cms) away. Normal air pressure is from 40-80 psi (2.8-5.6 kgiem’) Airless Spray BBy far the most important and efficient method for the application of heavy duty marine coatings. ‘As the name implies, it sa technique of spray application which does not rely onthe mixing of the paint with air to provide atomization, which is achieved by forcing the paint through a specially designed nozzle or ‘tip’ at very high pressures, as compared with air pressure associated with conventional spray, (2500-3500 psi; 176-246 kg/cm?) ‘This very high pressure is provided by a hydraulic pump driven by an air motor, which explains why the pump unit requires a supply of compressed air, a fact which often confuses the newcomer to the industry when told itis ‘airless spray" Pumps are available with compression ratios from 20:1 up to 60:1, which means that with an input air pressure to the motor of 80 psi (5.6 kg/cm), the maximum paint pressure at the gun would be 1600 psi, for a 20:1 Pump Page 42 ‘American Bureau Of Shipping fc aa Coating Systems: A Guidance Manual for Field Surveyors Chapter Five: ALTERNATIVES TO “HARD” COATINGS Chemistry ym other than “hard,” These here are several different alternate coating systems to choose from ot s coatings can be broken down into categories: semi-hard and soft. Semi-hard coatings dry in a few days or less to form a flexible film hard enough to touch and walk upon and will not wear off or erode by ballast water movement, Soft coating always remain soft and can be removed or damaged by walking or touching. ably dry surface before appltion Allcatings onthe marketplace oui a clean ight reasonably dy : Surfaes shouldbe ccun ta SSPC SP. or Swedish ST-2 Standard pio fo ABS inspection "aplication Itis important to note that alternative coating products are very diverse and can vary by: Chemistry Method of Protection Thickness Opacity Application method Follow-up service Products can be one or a combination of the following: Lanolin/wool grease-based Petroteum-based Vegetable oil-based Organic/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 (interact with oxides to prevent further oxidation) © Corrosion barrier (prevents oxygen from reaching metal surface) It should be noted that a pure corrosion barrier product will still allow a corrosion cell to be active underneath the product, while a corrosion inhibitor stops this activity. Page 5-1Coating Systems: A Guidance Manual for Field Surveyors. ‘American Bureau Of Shipping Coating Systems: A Guidance Manual for Field Surveyors ‘American Bureau Of Shipping Thickness Product film thickness can vary from a thin film of 3 mils up to a thick film of 80 mils. This is an important feature to consider when inspecting a tank, since a thicker product may be a safety hazard and require spot removal in order to see the steel surface underneath, ‘The products are ether: * Opaque © Transparent Again, this feature will have an impact on the inspection of the tank. The opaque products will require spot removal to see the steel surface underneath, whereas the transparent products could allow the inspector to see most ofthe steet surface. Application method Products can be applied by either of the following methods: “Spray ‘Float Jn fact some products can be applied by both methods. It should be noted that the float method will, require more product, but no staging. Care must be taken to adhere to pollution prevention procedures when using this method. Page 5-2 Chapter Six: CORROSION AND CATHODIC PROTECTION Introduction environment which results in the degradation of that material. To be more specific, metallic corrosion with which we are particularly concerned, is the oxidation of the metal at the etal/environment interface. This subsequently results in a deterioration in the mechanical properties of the metal. I: ‘general terms corrosion can be defined as the spontaneous reaction between a material and its ‘Mild steet remains the number one metal for constructional purposes by virtue of its relatively low cost, mechanical strength and ease of fabrication, Its main drawback is that it corrodes easily, and unless adequately protected rapidly loses strength resulting in structural failures. “The majority of metals ae found in nature in the mineral state, that is in ther stable oxidized condition as oxides, chlorides, carbonates, sulfates, sulfides, ete. The extraction of a metal from the appropriate mineral involves a reduction process in which a great deal of energy is absorbed. Asa consequence of this large energy input the metal is in a high energy condition and will endeavor to return to its former stable oxidized low energy state as quickly as environmental conditions will allow. I is this energy difference between the pure metal and its oxidized forms which is the driving force for corrosion of the metal. Many corrosion products show a chemical similarity to the corresponding minerals. Iron, for example, is extracted form its ores, mainly oxide and carbonate by ‘eduction with carbon in a blast furnace. In the presence of moisture the iron metal so obtained is. ‘oxidized to rust, which if analyzed is found to have a composition similar to the mineral ore. See Figure 6-1 IRON ORE, HEAT IRON METAL, _————— Iron Oxide WATER OxYGI [REVERSION RUST IRON OXIDE REACTION Chemically similar to original ore Figure 6-1: ‘The Reversion Reaction Steel and the Corrosion Reaction Mild steel is an impure non-uniform material, This heterogeneity is a major factor contributing to its poor resistance to corrosion, Page 6-1‘American Bureau Of Shipping Coating Systems: A Guidance Manual for Field Surveyors ‘The important step in the corrosion of stec| is the transformation of a metal atom to a metal ion by the loss of two electrons. This is the anodic reaction: (Fe > Fe + 2% IRON ATOM > IRONION ELECTRONS (FERROUS) This reaction can only occur if there isa suitable electron acceptor to combine with the electrons released by the iron atom, Freshwater or seawater contains dissolved atmospheric oxygen which readily serves this purpose, The oxygen i electrochemically reduced to hydroxy ions in the cathodic (2)0? +2H"0 + de > 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, Figure 6-2 shows the progress of corrosion where metal is lost from the anode, causing it to progressively become thinner, accompanied by a flow of electrons from the anode to the cathode which in (urn react with both oxygen and water to form hydroxyl ions, Mild Steel Water The products of reaction (1) and (2) the ferrous ions and hyaroxy! fons combine 10 form iron (errous) hydroxide ‘orrosion of Steel Page 6-2 American Bureau Of Shipping Coating Systems: A Guidance Manual for Field Surveyors @yFe" + 20 2 Fe (OH): FERROUS IONS +HYDROXYLIONS > FERROUS HYDROXIDE Ferrous hydroxide in the presence of an abundant supply of oxygen is oxidized to the familiar reddish brown rust (4)2Fe(OH) + Oz 2 Fe;0:2H20 FERROUS HYDROXIDE + OXYGEN jf nust ‘The above reactions (1) (2) (3) 4) are the basic reactions which occur when iron or stee! transforms to rust or more specifically to iron oxide, In practical situations however, the process not so simple. For instance, corrosion of stecl in seawater or in polluted atmospheres results in more rapid and. ‘complicated reactions producing corrosion products in association with iron oxide. ‘Some of these iron salts for example chlorides and sulfates are water soluble and can cause major problems to paint coatings if not removed beforehand, ‘There are several particular forms of corrosion of which the following are the most common, some ‘much more serious than others. Uniform Corrosion ‘The most common type of corrosion encountered is general attack of a more or less uniform nature. Although the loss of metal is concentrated at the anode sites there is a 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 is thus a continuous interchange between the anodic and cathodic areas, such that over a period of time the loss of metal over the entire surface is fairly uniform. This is the easiest form of corrosion to combat or allow for because structural life times can be predicted, a feature which 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 deep in relation to the area attacked. Pitting is one of the most dangerous forms of corrosion and often occurs in places where it cannot be readily seen, in crevices for example. Pitting corrosion can be extremely intense on millscaled steel left outside, as shown in Figure 6-3: Pitting Corrosion. Figure 6. 12 Corrosion Page 63sills. f no ‘American Bureau Of Shipping Coating Systems: A Guidance Manual for Field Surveyors American Bureau Of Shipping Coating Systems: A Guidance Manual for Field Surveyors | ‘When two dissimitar metals become electrically connected and are exposed tothe same solution (seawater ther individual corrosion behavior can become significantly altered particularly if the ; , difference in their corrosion potentials is large. When mild stel and copper ar in contact for Intense localized coroson, ranging frm small pits o extensive attack over the whole surface, can ere ef eelt ie ee ty ‘occur within narrow crevices formed by the geometry of a structure, for example riveted plates or ‘than it would if the two metals were isolated. ‘The corrosion of the more noble copper is reduced. threaded joins, Crevice corrosion is characterized bya geomcrical configuration in which the cathode reactant (i.e. oxygen) can readily gain acess to the metal surface outside the eevice and less acess to the cove. The metal within the crevice is therefore anodic othe surrounding stel and suffers preferential corrosion Crevice Corrosion Deposition Corrosion This is a similar type of attack to that occurring in crevices. wherever loose debris collect there will bbe a depletion of oxygen beneath the deposit in the same way that there is depletion in a crevice. Consequently attack is localized beneath the loose debris. See Figure 6-4 : Deposition Corrosion. HIGH COPPER MILO STEEL ~ peorecreD Aetatekaren ACCUMULATED eee comRostow ‘DEBRIS Na Anode Cathode LOW O2 ‘STEEL SEAWATER Figure 6-4 : Deposition Corrosion The Galvanic Series in Sea Water and Cathodic Protection Figure 6-5 Inthe same way that the corrosion of copper is reduced as shown above the corrosion rate of mild steel can be significantly lowered by connecting it to zine, which is near the base end ofthe galvanic Metallic corrosions an electrochemical phenomenon, metal degradation being accompanied by the SesU Tie Tins ie ered ess evinaal sande eal i neoena eroeaiae seks Td ea passage of electrons. Consequently as a metal corrodes it lakes up its own electrical potential known is by cathodic protection as the corrosion potential with respect toa fixed reference. Table 6-1 gives the relative tendencies of ‘commercially available metals to corrode in sea water. METAL ELECTRODE POTENTIAL (VOLTS Versus: STANDARD CALOMEL ELECTRODE) ELECTRON FLOW MAGNESIUM -1.50 BASE zis “ios CORRODED END ALUMINA “a9 Cast non oat MID STEEL fet teAD 80 zine wo sre. TIN 0.2 Avobe) (caTuone) BRASS. 0.30 ACCELERATED COPPER. 0.28 CORROSION CUPRO Nicks ox Browz an Meee ou seavaren Steven on TiTaNitNt oto STAINLESS STEEL “308 NosLE CORROSION RESISTANT END Table 6-1: Galvanic Series Page 6-4 Page 65American Bureau Of Shipping Coating Systems: A Guidance Manual for Field Surveyors As an alternative to sacrificial cathodic corrosion protection itis also possible to suppress the corrosion of mild stee! in seawater by using impressed current cathodic protection. In the same way that coupling mild stee! to zinc results in a flow of electrons are supplied to the mild steel so that the anodic reaction (metal loss) is checked. An auxiliary anode made from a non-consumable ‘material, platinised niobium for example replaces the anode of the sacrificial system, ‘The arrangement is shown schematically in Figure 6-7 below + < ANODE DC POWER SOURCE < jp CURRENT REF 1y1FLOW ELECTRODE ayn * PROTECTED : \ \ ‘ ‘STRUCTURE. \ \ \ Figure 6-7 Generally the structure would be coated, otherwise the current requirement for protection would be to0 high economically. Cathodic protection systems therefore, are gencrally used in conjunction with painted stecl, protection being afforded to gaps or breaks in the coating. Page 66 ‘American Bureau Of Shipping Coating Systems: A Guidance Manual for Field Surveyors Chapter Seven: GLOSSARY OF FREQUENTLY USED COATING TERMS Air drying paints: are paints which dry and form a film when exposed to air, without any external heat ‘being applied. Oil and alkyd paints are usually air drying, [Airless spray: is a method of paint spraying which does not use compressed air to atomize the paint. In this method, the paint put under great pressure (up to 5000 p.s.i. — 360 kg/sq.cm.) and is atomized by being forced through a small nozzle, Airless spray is a very fast and efficient method of application since the paint is forced into the surface at very high speed, which assists in wetting the surface. Alkyd: is a synthetic resin made by reacting wo chemicals in the presence of a natural or processed oil ‘Because of the wide variety of possible constituents, alkyds can be ‘tailor-made’ to meet ‘conditions found in practice. Anode: a piece of metal fixed to steel to provide cathodic protection. Anodes must be fixed so that they are in electrical contact with the steel they have to protect, and must not be greased or painted for underwater use on hulls. Contains agents which prevent the adhesion and growth of organisms on the hull. Antifoulings 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, most manufacturers use binders based on alkyds, chlorinated rubbers, epoxies ete. Cathodic protection: a method of altering the electrical characteristics of stcel so that itis less liable to rust in water. Steel protected in this way has to be painted with particularly resistant paint systems, Chlorinated rubberiviny! resins: High molecular weight polymers which are used as binders in some thermoplastic paints. The drying of these paints is not very temperature sensitive. Coal tar epoxy: a combination of epoxy resins and tar which, in a 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 react with air to dry and cure, Emulsion paints: paints in which the binder is dispersed in water (emulsified) e.g, polyvinyl acetate (PVA), acrylics ete, ‘The paints dry as soon as the water evaporates and the emulsified droplets of resin join together to form a solid film, Epoxy: Epoxide 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. Film thickness: is 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 and specialized equipment is available to measure the film thickness. Flashpoint: the temperature at which the vapor of a material will be ignited by a spark or open flame. It is measured under standardized conditions. Hard Coatings: is a coating which chemically converts during its curing process, normally used for new constructions, or non-convertible air drying coating which may be used for maintenance Antifout Page 7-1American Bureau Of Shipping Coating Systems: A Guidance Manual for Field Surveyors, Purposes. Hard coating can be either inorganic ot organic, + IMO MSC 63/23/Add.1/Annex 22 Latex: a resin used in emulsion paints. Pigments: powders, insoluble in resins, which give the paint its color, finish, and protective properties. Polymer:’ a high molecular weight material created from lower molecular weight constituents by cchemical reaction. Polymers with resinous characteristics are frequently used in paints. Polyurethane: a resin with special characteristics. Paints based on polyurethanes are either one or two pack, are 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 paint will not behave in the normal manner, Paint must never be allowed to remain in spray equipment after the expiry of its potlife. PVA paint: see Emulsion paints Resin: a material used as a binder constituent which forms a noncrystalline film when dried, ‘Semi-Hard Coating: Coating which dries in such a way that it stays flexible although hard enough to touch and walk upon. These coatings do not appreciably erode with the usual ballast water movement. Such coatings provide temporary protection of existing structures. ‘Shopprimer: a rust preventing paint for temporary protection of blasted stce] immediately after blasting. Shopprimers will protect the surface from corrosion during construction and until the final paint system is applied, Soft Coatings: Coating that remains soft so that it wears off at low mechanical impact or when touched bby hand; often based on oils (vegetable or petroleum) or lanolin (sheeps wool grease), these coatings are gencrally used to give temporary protection to existing structures. Sophisticated paints: are paints which are based on unconventional binders, such as epoxies, chlorinated rubbers, vinyls etc. Generally, sophisticated paints give a higher level of protection than Conventional paints, but are not so simple to handle. Spreading rate: the area which is covered by one liter of paint, Tar epoxy: sce Coal Tar Epoxy ‘Thermoplastic paints: are paints which dry by evaporation of solvent only, The binder is unreactive. ‘Thixotropic paints: have a semi-solid or gel consistency when undisturbed, but flow readily when stirred ‘or shaken, or when being applied. The process is reversible, and a fluid paint reverts to a gel consistency when the disturbance ceases. when applied, thixo-tropic paints will flow easily as long as they are being worked, but quickly regain a gel consistency which assists in preventing runs and sags. used to describe paints which are supplied in two separate containers and which have 10 be mixed together before use, Vinyl resins: see Chlorinated rubber resins, Zine phosphate: a pigment with corrosion preventing properties, ‘ine silicate paints: zinc-filled paints based on an inorganic binder, Zine silicates ‘Zinc-rich paints: zinc filled paints based on a large proportion of metallic zinc in powder form, ‘They usually contain more than 85% zinc in the dry film and provide give very hard films, and are resistant to solvents, Potli ‘Two pack pai Page 7-2 Part II Condition Assessment of Existing “Hard” Coatings‘American Bureau Of Shipping Coating Systems: _A Gui Chapter Eight: ASSESSMENT SCALE FOR BREAKDOWN ASSESSMENT OF TISTING SURFACE COATING SYSTEMS For the purpose of consistent assessments of the “degree of effectiveness’ of an cxisting surface coating system, itis 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 anor light rustling over 20% or more of areas under consideration, but less than as defined for POOR condition, ‘© POOR condition with gencral breakdown of coating over 20% or more of areas or hard scale at 10% or more of areas under consideration. Tanker Structure Co-operative Forum has tabulated the above definitions as follows: Definition of Coating Conditions: Note: The lowest rating within any category shall govern the final rating. Rating /Condition. ‘Good Fair Poor, ‘Spot Rust Minor Light Rust Minor >20% Edges Weld <20% >20% Hard Seale Minor <10% >10% General Breakdown Minor <20% >20% ‘Other References 150, RIS RIS RIS European Rust RES RES RET Scale ‘An ‘Assessment Scale for Breakdown’ of coatings is shown in Examples of coating, system condition categorized under the above rating system are shown on the following, pages. Page 6-1‘American Bureau Of Shipping Coating Systems: A Guidance Manual for Field Surveyors ‘American Bureau Of Shipping Coating Systems: A Guidance Manual for Feld Surveyors ASSESSMENT SCALE FOR BREAKDOWN Chapter Nine: | HOW TO USE THIS GUIDE ‘The coating condition should normally be judged over larger areas, For classification \ Purposes it is normal to judge the complete tank. However, if the conditions vary to a ‘great extent between the various main parts (bottom, deck, longitudinal bulkheads, and transverse, bulkheads) of the tank, then an evaluation of the various parts may be advantageous, ‘Some of the pictures shown in this guide are not from tankers but from ballast tanks of i dry cargo ships. However, since the coating condition is in focus here it was decided to use them in this context. ‘The photographs should be considered a tool to assist the Surveyor in the performance of his duties, and this Guidance Manual is intended to be used as such. It does not set a standard, It is not a part of the Rules for Building and Classing Steel Vessels, Page 8-2 ea Figure 8-1: “Measles Chart"‘American Bureau Of Shipping Coating Systems: A Guidance Manual for Field Surveyors Chapter Ten: EXAMPLES Page 10-1‘American Bureau of Shipping Costing Assessment Guide INates: [ISCF Assessment Scale; 1. Blisters |2. Surface discoloration R lloss than 1% i JExamole Number: 4[STS Bureau of Shipping Costing Assessmont Gui Notas: [TSCF Assessment Scale: 1. Coating intact 2. Filmy surface contaiminant peeling 13. No corrosion 4. No scale less than 1% 1% {Coating Condition: GOOD Example Number: 2‘American Bureau of Shipping Costing Assessment Guide Notes: [TSCE Assessment Scala: H. Minor rusting on on weld seams 2. Spot rusting 3. Filmy deposit much of surface. less than 1%‘American Bureau of Shipping Coating Assessment Guide Notes: [ESCE Assessment Scale: H. Line of sediment | 12. Note absence of fust stains less than 1%iene Bureau oF Shipping SSS Coating Assessment Guide |Notas: |Visable coating repairs Minor rust stains less than 1%‘American Bureau of Shipping Coating Assessment Guide Notas: [TSCE Assessment Scale: }1. Coating discolored from surface contamination 12. Organisms 13. No corrosion 4. No scale ess than 1%‘American Bureau of Shipping Coating Assessment Guide Notes: [SCE Assessment Scale: IGood Coating, Dirty suriace, [Sediment on Structure less than 1% 1% Coating Condition: GOOD‘American Bureau of Shipping Coating Assessment Guide |Examale Number: 8 |Notea: ITSCE Assessment Scala: Minor corrosion ISurface contaimination (oily and sediment) lless than 1% Coating Condition: GOOD‘American Bureau of Shipping Coating Assessment Guide Notes: TISCE Assessment Scale: Dirty coating Discolorations due to oily contaminants and sediments. lessthan1% 1% [Coating Condition: GooD Examole Number: 9‘American Bureau of Shipping Coating Assessment Guide |Notes: Scattered corrosion Coating repaired less than 1%‘American Bureau of Shipping Coating Assessment Gui Notes: Sediment Note: Drip marks Jon lower frames less than 1% 1% Coating Condition: GOOD‘American Bureau of Shipping Coating Assessment Guide Notes: 1. Rust stains 2. Moist coating or stiffeners less than 1%‘American Bureau of Shipping Coating Assossment Guide |Notes:, [ISCE Assessment Scala: 11. Scattered Corrosion“American Bureau of Shipping Coating Assessment Guide }. Marine organisms l2. Dark stripe coat 3. Spots are contaminants lless than 1%Coating Assessment Guide ‘American Bureau of Shipping Notes: 1. No corrosion 2. Significant eurfaca corrosion Example Number: 15 P lless than 1% GOOD 1%“American Bureau of Shipping Coating Assessment Guide |Notes; 1. Top coat failure - see pattem on edges . Blisters Detachment No corrosion 7) Coating Condition: JExampie Number: 16 a less than 1% 1% GOOD‘Amorican Bureau of Shipping Coating Assessment Guide . Filmy surface contamination . Discolored coating - note drip pattem . No corrosion less than 1% Example Number: 17‘American Bureau of Shipping Coating Assessment Guide : ITSCE Assessment Scale: 1. Scattered corrosion on edges and welds 2. Surface discoloration _ less than 1% 1% GOOD‘American Bureau of Shipping Coating Assessment Guide |Notes: H. Staining - scattered ‘over > 20% l2. No edge breakdown 3. Note absence of texture red/orange areas |Coating Condition: Example Number: 19 less than 1%‘American Bureau of Shipping Coating Assessment Guide 1. Light rusting > 1% 2. Scattered rusting 3. Extensive rust staing > 20%| less than 1%ET Bureau of Shipping Coating Assessment Gui INates: 1. Coating discolored from surface contamination 2. Organisms [3. No corrosion |4. No scale 1% lless than 1% GooD ing Cancion [Example Number: 21‘American Bureau of Shipping Coating Assessment Guide |Notes: 1. Corrosion on edges and some welds - minor spot rusting {Coating Condition: GOOD Example Number: 22‘American Bureau of Shipping Coating Assessment Guide Notes: H. Corrosion l2. Localized breakdown on edges 3. Intact coatings on welds |4. Extensive staining‘American Bureau of Shipping Coating Assessment Guide Notes: 1. Light rusting > 20% 2. Touch-up repainting ‘(ight areas) 3, Isolated breakdown at comer [Coating Condition: Examola Number: 24 [TSCE Assessment Scale: loss than 20% FAIR‘American Sureau of Shipping Coating Assessment Guide Notes: 1. Anode working .. White deposits 3% 3. Corrosion on edges 4. Top coat loss‘American Bureau of Shipping Coating Assessment Guide ITSCE Assessment Scala: Active corrosin on pipe Discoloration on . Deposits on vertical structura . Scattered corrosion - blishers on BSNS less than 10% {Coating Condition: FAIR |Example Number: 26‘American Bureau of Shipping Coating Assessment Guide [Notes: H. Edge corrosion 2. White deposits [3 General corrosion 10-20%rary . Localized heavy corrosion . White deposits ‘American Bureau of Shipping Coating Assessment Guide TISGE Assessment Scale: beside anode - > 50% on upper part of tank Dark scale | less than 50%“American Bureau of Shipping Coating Assessment Gui¢e: Notes: 1. Edge corrosion 2. Light rusting > 20% less than 20% FAIR‘American Bureau of Shipping Coating Assessment Guide Notas: H. Coating breakdown on welds 12. Spot rusting‘American Bureau of Shipping Coating Assessment Guide flotas: ISCE Assessment Scale: 1. Edge corrosion 2. Anode working | 3. Coating generally inact |‘American Bureau of Shipping Coating Assessment Guide 1. Edge corrosion l2. White deposits lower areas |3. Red rust on overheads‘American Bureau of Shipping Costing Assessment Guide |Notes: H. Significant edge breakdown I2. Discoloration FAIR‘American Bureau of Shipping Costing Assessment Guide i. Edge corrosion . Corrosion on welds 3. Generalized breakdown 10-20% l4. No hard scale‘American Bureau of Shipping Costing Assessment Guide Notes: 1. Edge breakdown > 20% 2. General breakdown less than 20% ion: FAIR mber: 35"American Bureau of Shipping Coating Assessment Guide jNotas: Edge breakdown . Hard scale > 10% . Light corrosion > 20% . Absence of red rust due to white deposits from Anode action.‘American Bureau of Shipping Coating Assessment Guide |Notas: |TSCE Assessmant Scale: - Light rusting - 20% 12. Staining at waterline 3. Rust stains less than 20%“American Bureau of Shipping Costing Assessment iNotes: 1. Edge breakdown 2. White deposits > 5% 3. Red rust noticable less than 20%‘American Bureau of Shipping Coating Assessment Guide |ESCE Assessment Scale: }1. Local corrosion on edges of stiffeneers and drain holes.‘American Bureau of Shipping Costing Assessment Guide \TSCF Assessment Scale: 1. Edge breakdown White deposits > 5% 3. Red rustmerican Bureau of Shipping Costing Assessment Guide |Notes: _ Edge breakdown on vertical stiffeners . White deposits . Absence of red rust . Surface contamination below weep holes lless than 20%‘American Bureau of Shipping Coating Assessment Guide Notes: 1. Edge breakdown Corrosion on horizontal surfaces [3. Hard scale on horizontal surfaces: |4. Discoloration [TSC Assessment Scala:‘American Bureau of Shipping Coating Assessment Guide Notes: H. General breakdown > 20% 2. Topcoat detachment f | less than 20% Coating Condition: POOR |Examole Number: 43‘American Bureau of Shipping Costing Assessment Guide Notes: 1. Corrosion > 20% 12. Hard scale > 10% 13. Deformed stitfener edges“American Bureau of Shipping Coating Assessment Guide Notas: ‘i. Corrosion 20% l2. Scale not visable 3. Discoloration lless than 20%‘American Bureau of Shipping Coating Assessment Guide INotes: ITSCE Assessment Scala: 11. Corrosion > 20% l2. Discolorations lless than 20% [Coating Condition:‘American Bureau of Shipping Costing Assessment Guide 1. Locolazied corrosion > 20% |2. Steel cross section loss ]merican Bureau of Shipping Coating Assessment Guide J2. Hard scala > 10%‘American Bureau of Shipping Coating Assessment Gui¢e Notes: [TSCE Assessment Scale: H. General breakdown onoverhead > 20% 2. Edge breakdown [3. Rust staining less than 20% |Coating Condition: [Example Number: 49 POOR‘American Bureau of Shipping Coating Assessment Guide Notes: 11. Corrosion > 20% 2. Scale > 5% 3. Topcoat detachment /4. Black staining‘Tmerican Bureau of Shipping | Natesx 4. Anode working 12. White deposits IS. Top coat delamination l4. Edge breakdown IS. Coating loss on vertical bulkhead on right lies than 10% Coating Condition: POOR Example Number: 51|Nates: 1. Corrosion 20% 12. Hard scale > 10% 13. Delamination ot scale on bracket‘American Bureau of Shipping Coating Assessment Guide Hard scale . Rust stains . Surface discolorations Note top surface of lower longitudinal FERS lless than 10%