1. NPCA Virginia Beach June 08
Implementing The Paint Specification in the Performance Standard for Protective Coatings
NPCA
Virginia Beach
June 08
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

2.
Objective
To provide a review of the requirements as laid out in the IMO PSPC and highlight important aspects
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

3. The Parties Involved at present
The Parties Involved at present
Shipyard
Ship-owner
Productivity/
Environment
Performance
Coating supplier
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

4.
The Parties Involved
A paint specification is in many ways a compromise:
It has to meet with the yards building procedures, environmental and productivity requirements
The shipyard is the customer of the coating manufacturers and they have to be competitive on standards as well as price
It has to match the paint suppliers product range.
The PSPC is in effect making the compromise redundant
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

5. Coating Performance Standard Review
The Performance Standard for Protective Coatings (PSPC) provides the technical requirements for protective coatings in dedicated sea water ballast tanks of all types of ships of 500 gt and greater and double sided skin spaces on bulk carriers of 150m and greater in length.
It will be mandatory and is intended to be included as amendments to SOLAS regs II-1/3-2 and XII/6
It is also recommended to be applied where possible to items, not integral to the structure e.g. ladders, platforms – Permanent means of access
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

6. Tip of the iceberg A family of regulations
Tip of the iceberg
A family of regulations
PSPC
Permanent means of access
Cargo tanks
Maintenance
These will change the current compromise solutions
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

7. Coating Performance Standard Review
Aims of the PSPC
to provide a 15 year life for ballast tank coatings over which it is defined as in being ‘good’ condition.
‘Good’ condition is defined in resolution A.744(18) and is “ condition with only minor rust spotting”
( Note: this is different to IACS definition)
Better coating systems with reduced maintenance
Improved safety at sea
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

8. Coating Performance Standard Review
Coating Performance Standard Review
Aims of the PSPC
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

9. Coating Performance Standard Review
Coating Performance Standard Review
Aims of the PSPC
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

10. Coating Performance Standard Review
Entry into force
The proposals will apply to the aforementioned types of vessels:
For which the building contract is placed on or after 1st July 2008, or
In the absence of a building contract, the keels of which are laid or which are at a similar stage of construction on or after 1st January 2009, or
The delivery of which is on or after 1st July 2012
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

11. Coating Performance Standard Review
Entry into force
However IACS are applying the proposals on ratification to tankers ( L > 150m) and bulkers (L > 90m) under the Common Structural Rules (CSR) for contracts signed from December 8th 2006
It is expected that the first new building classed under the above rules will begin building in the second half of 2007
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

12. ? The Parties Involved Shipyard Ship-owner Classification Soc.
The Parties Involved
Shipyard
Ship-owner
Classification Soc. ?
Productivity
Performance
Coating supplier
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

13. Coating Performance Standard Review
Main Elements of the PSPC:
Design of a specification and coating system
Coating System approval
Definition of inspection procedures
Production of a Coating Technical File (CTF) which records all aspects of the process
Verification of compliance
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

14. The Paint Specification
The Paint Specification
The paint specification is at the heart of the PSPC and covers:
Primary and Secondary surface preparation standards
Steel profile range
Cleanliness of surfaces prior to coating
Soluble salt limits
Steel condition
Thickness and number of coats
Environmental conditions allowed
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

15. The Paint Specification
The Paint Specification
The paint specification applies to the coating system that has been selected
Selection of the coating system takes into account the service conditions and planned maintenance
All coatings to be epoxy based or equivalent and consist of multi-coat systems of contrasting colour
The top coat to be a light colour
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

16. The Paint Specification
The Paint Specification
All coatings to be pre-qualified by:
A method corresponding to a specified test procedure or equivalent ( now Annex 1), cross test with shop primer or…
Documented field exposure with a final condition of “GOOD” after 5 years
Non Annex 1 test must show equivalent testing procedures and needs.
A Statement of Compliance or Type Approval Certificate to be issued by a third party - independent of the coating manufacturer
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

17. The Paint Specification
The Paint Specification
The paint specification covers all the processes and defines the standards from:
Shop Primer Application
Block Painting
Post Erection Repairs
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

18. The Paint Specification
The Paint Specification
The painting process at each stage can be separated into the following simple processes:
Cleaning the surface
Preparing the surface
Coating the surface
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

19. The Paint Specification
The Paint Specification
The paint specification covers all the processes and defines the standards from:
Shop Primer Application
Block Painting
Post Erection Repairs
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

20. The Paint Specification
The Paint Specification
Shop Primer
Four items are defined
The standard of surface preparation of the bare steel - determines ‘cleanliness’
The ‘profile’ of the steel - determines adhesion
The maximum level of water soluble salts on the surface prior to application - determines resistance to blistering
The shop primer type (the thickness of shop primer is not specified but will be given on the product technical data sheet)
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

21. The Paint Specification
The Paint Specification
Shop Primer
The standard of surface preparation of the bare steel ex the steel mill is to be Sa2½ as defined in ISO
This process is carried out in an automated plant using, typically, round steel shot
Achieving this standard on a well maintained plant is normally not a problem
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

22. The Paint Specification
The Paint Specification
Shop Primer
Sa2½ as defined in ISO is
“When viewed without magnification, the surface shall be free from visible oil, grease and dirt, and from mill scale, rust, paint coatings and foreign matter. Any remaining traces of contamination shall show only as slight stains in the form of spots or stripes “
All the standards have pictorial references
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

23. The Paint Specification
The Paint Specification
Shop Primer
Surface profile to be between microns and its measurement is defined in the standard ISO /3
The measurement is by a comparator of known roughness and size
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

24. The Paint Specification
The Paint Specification
Shop Primer
Water Soluble Limit on the surface prior to coating to be less than or equal to 50 mg/m² ( or 5µg/cm²)
This is measured by a conductivity method according to ISO
A known volume of water is used to extract any soluble material from a known area and the conductivity of that solution is measured and converted to a mg/m²
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

25. The Paint Specification
The Paint Specification
Shop Primer
Shop Primer is to be a zinc containing inhibitor free zinc silicate or equivalent (its compatibility with the main coating system to be confirmed by the coating manufacturer )
The vast majority of shop primers in use today meet this criteria
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

26. The Paint Specification
The Paint Specification
Shop Primer
There is also statement stating that blasting should not be carried out when:
The relative humidity is > 85%
The surface temperature of the steel is < 3°C (5 °F) above the dew point
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

27. The Paint Specification
The Paint Specification
Shop Primer
The application of shop primer is a carried out in an enclosed automated plant and is a continuous process.
Usually once the plant is set up it is left to run with only spot checks being made
There is no specific mention of any of the shop primer details being required for the CTF …but ‘records of the coating application’ are requested
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

28. The Paint Specification
The Paint Specification
Shop Primer
Also
Depending on ship type as little as 5% of shop primed steel will be in the ballast tanks
In most cases only one side of the plate will be part of the ballast tank surface
Pre-primed plate sourced externally will be subject to the same requirements
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

29. The Paint Specification
The Paint Specification
Shop Primer
It is probable given the practical difficulties outlined of measuring the parameters etc. stated in the PSPC that a procedure for maintaining the standards ( i.e. spot checks) in the shop primer plant will have to be produced, audited and certified
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

30. The Paint Specification
The Paint Specification
The paint specification covers all the processes and defines the standards from:
Shop Primer Application
Block Painting
Post Erection Repairs
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

31. The Paint Specification
The Paint Specification
Block painting is the application of the main coating system. In some yards the coating of ballast tanks is carried out in-situ - after erection - but the vast majority of new building yards coat the ballast tanks at the ‘block stage’
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

32. The Paint Specification
The Paint Specification
The specification at block stage covers:
The condition of the actual steel work
Surface preparation and profile requirements
Thickness of the coating and number of coats
Stripe coats
Cleanliness/contamination
Soluble salt levels
Environmental conditions
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

33. The Paint Specification
The Paint Specification
The specification at block stage covers:
The condition of the actual steel work - to prevent premature breakdown of the coating system
Surface preparation and profile requirements - determines coating life and adhesion
Thickness of the coating and number of coats - determines protective properties
Stripe coats - to prevent premature breakdown
Cleanliness/contamination - to prevent premature breakdown
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

34. The Paint Specification
The Paint Specification
The specification at block stage covers:
Soluble salt levels - to prevent blistering
Environmental conditions - to prevent premature breakdown
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

35. The Paint Specification
The Paint Specification
Block stage :
The steelwork should be prepared so that the coating can be applied evenly in accordance with ISO grade P2
This involves removing sharp edges, weld spatter etc - most coatings flow away from sharp edges leaving an inadequate thickness for protection
Edges of stiffeners are also to be rounded to a radius of 2mm - or subject to ‘three pass grinding’ or equivalent
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

36. The Paint Specification
The Paint Specification
Block stage :
ISO grade P2 consists of a number of illustrations that are provided covering imperfections such as weld spatter, slag, flame cut edges etc and P2 grade describes the preparation on each imperfection
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

37. The Paint Specification
The Paint Specification
Block stage :
E.g. P2 for weld porosity:
“ Surface pores shall be sufficiently open to allow penetration of paint, or dressed out”
P1 - “as welded”.
P3 - “ surface shall be free from visible pores”
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

38. The Paint Specification
The Paint Specification
Block stage :
Surface Preparation is defined as per the shop primer specification -i.e in accordance with ISO
As the steel is already coated with shop primer the specification calls for:
Sa2½ standard of preparation on welds and damaged shop primer
“Sa2 standard removing at least 70% of intact shop primer” if the shop primer has not passed a pre-qualification test”
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

39. The Paint Specification
The Paint Specification
Block stage :
“Sa2 removing at least 70% of intact shop primer” is not a standard
Sa2 refers to bare steel
Is it 70% removal by area or volume??
If the shop primer has passed a pre-qualification test as part of the epoxy system it may remain but should be cleaned by sweep blasting, high pressure washing or equivalent
A number of yards sweep blast the shop primer anyway when preparing the welds as it is quicker and more productive
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

40. The Paint Specification
The Paint Specification
Block stage :
Steel Profile is specified as microns or that recommended by the coating manufacturer and is according to ISO /3 as per the shop primer specification
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

41. The Paint Specification
The Paint Specification
Block stage :
Paint thickness and number of coats are specified as follows:
Nominal dft microns in total
This is to be achieved in a minimum of 2 coats and 2 stripe coats
Typical specs will be 2 x 160 microns – but coats of differing thicknesses are allowed
Stripe coats by brush or roller to be applied to edges, welds, etc (roller to be used for scallops and rat holes only)
Second stripe coat may be omitted on welds if the ndft can be met by the coats applied
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

42. The Paint Specification
The Paint Specification
Block stage :
The paint thickness specification has upper and lower limits:
NDFT of 320 microns but with a “90/10” rule
At least 90% of all thickness measurements will be greater or equal to the NDFT and none of the remaining percentage (up to10%) to be below 0.9 of the NDFT i.e. a minimum thickness of 288 microns
Upper limit to be defined by the coating manufacturer
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

43. The Paint Specification
The Paint Specification
Block stage :
The PSPC also advises on where to check for dft and the number of readings to be taken (This is in annex 3 and is referenced in the standard SSPC - PA2 – this covers calibration, etc)
Thickness measurements are to be taken after each coat for quality control purposes and the total dft confirmed on completion
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

44. The Paint Specification
The Paint Specification
Block stage :
The PSPC also advises on where to check for dft and the number of readings to be taken (This is in annex 3 and is referenced in the standard SSPC - PA2 – this covers calibration, etc)
Thickness measurements are to be taken after each coat for quality control purposes and the total dft confirmed on completion
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

45. The Paint Specification
The Paint Specification
Block stage :
Cleanliness and contamination on a surface prior to coating are defined in the specification as:
no oil or other visible contamination to be present on the surface
Dust quantity rating “1” for dust size class 3,4 or 5 as stated in ISO Lower particle sizes to be removed if visible without magnification
Any particles embedded in a coating are also to be removed
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

46. The Paint Specification
The Paint Specification
Block stage :
ISO uses clear adhesive tape that is pressed onto a surface and after removal is placed on a ‘display board’ of contrasting colour to the dust. The tape is then compared against standards – 1 ( minimum ) to 5 (maximum) for volume of dust
The dust is also classified by size :
Class 0 particles (not visible under 10x magnification) and class 5 ( particles clearly visible in normal vision of up to 5 mm in diameter.)
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

47. The Paint Specification
The Paint Specification
Block stage :
Soluble salt levels on the steel after surface preparation but before painting are specified to be less than or equal to 50 mg/m².
This is to be measured according to ISO as per shop primer application and in at least one location per block
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

48. The Paint Specification
The Paint Specification
Block stage :
The environmental conditions under which the coating may be applied are to be in accordance with the manufacturer’s recommendations but the specification states that coatings shall not be applied:
If the relative humidity is > 85% or
The surface temperature is < 3ºC ( 5 ºF) above the dew point
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

49. The Paint Specification
The Paint Specification
Block stage :
Other parameters such as the drying, curing and over coating times are to be given by the manufacturer and will be found on the data sheet
The method of application will also be specified by the manufacturer as will any repairs of defective areas
Appropriate ventilation is also required as recommended the manufacturer
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

50. The Paint Specification
The Paint Specification
The paint specification covers all the processes and defines the standards from:
Shop Primer Application
Block Painting
Post Erection Repairs
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

51. The Paint Specification
The Paint Specification
Post Erection surface preparation and repairs are specified as follows:
Butts (‘join ups’) to be prepared prior to coating to ‘St3 or better or Sa2½ where practical’ as per ISO
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

52. The Paint Specification
The Paint Specification
Small damages - up to 2% of the total area are to be prepared to St3 standard prior to coating.
Contiguous damage over 25 m² or over 2% of the total area of the tank should be prepared to Sa2½ (note that open blasting in a confined space can lead to over-blast damage)
All coating repairs to be feathered in the overlap
Note: There is no profile requirement in St3 standard – this may be an issue!!
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

53. The Paint Specification
The Paint Specification
The main elements of the specification in the PSPC are already being carried out in many shipyards and have been for a number of years
The main items that are new are :
A Coating Technical File has to be produced by the shipyard
All inspectors are to be qualified to a recognised standard
Increased inspection and prescriptive inspection and data collection
Audit by class
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

54. Suggested table of contents and responsibilities for New build
06/04/2017
Suggested table of contents and responsibilities for New build
Copy of type approval certificate or statement of compliance
Yard procedures (for inspection and repair) audit certificate from class (includes application ).
Paint Company
Planned maintenance procedures for in service
Class Soc.
Sign off as approved
YARD
A statement of agreement between Owner/yard and paint company for this contract
Paint specification as issued by yard including key criteria and data sheets
A summary or full log of work carried out by yard/coating inspector - one for each tank and Non-conformity/repair summary log for each tank - including verified inspection reports
Statement of conformance
NPCA08 54
Copyright Safinah LTd Jan 2007
Day 1 Session 7 146CLRS CPS Course Paint Specification 54

55. Suggested table of contents and responsibilities for in service
Suggested table of contents and responsibilities for in service
Ship owner
Maintenance log
Inspection log
Condition log
Class inspection log
NPCA08 55
Day 1 Session 7 146CLRS CPS Course Paint Specification

56. Ambiguities There are many ambiguities in the standard:
Ambiguities
There are many ambiguities in the standard:
Salt measurement
90:10 rule
Area judgement and other subjective elements
CTF detail and content
Products approved through testing – will they last 15 years target life
What happens if they do not
There are some guidelines
PR34 from IACS
IACS guidance notes
Maintenance requirements
Costs of implementation
IACS members not acting in harmony – adding costs
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification

57. Conclusions Needs a bedding in period
Conclusions
Needs a bedding in period
Needs a cool and calm interpretation
In the wrong hands can considerably add to costs.
Places a clear increased burden on yards
It is going to get worse before it gets better.
NPCA08
Day 1 Session 7 146CLRS CPS Course Paint Specification