State of NAVSEA Coatings

Andrew Seelinger
CORROSION CONTROL DIVISION
NAVSEA 05M1
JULY 2003

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 U. S. Navy Directions for Coatings

Š Reliability and Extended Performance

Š Faster Painting Schedules

Š Compliance with Environmental Laws/Regulations for Air

and Water Quality

Š Establishment of Standards and Specification Common to

World Navies, e.g. NATO and others

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 Market Summary

Š World Naval Fleets

„ USA 300/100
„ UK 149
„ France 169
„ Italy 85
„ Canada 38 1100+
„ Australia 43
„ New Zealand 7
„ Sweden 89
„ Netherlands 60
„ Others (German, Norway, Spain…) 100+
Š High Value Commercial Ships
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 Coating Reliability & Extended Performance

„ Drivers of Change
z Extended Docking Cycle up to 12 Years

z Reduction of Maintenance Costs

„ Targets
z Ballast Tanks 20 Years
z Fuel Tanks (including compensated) 20
z Potable Water Tanks 20
z Sewage Tanks 8
z Well Deck Overheads 15-20
z Antifouling Paint 7-12
z Topside 5-10
z Free board 10-15
z Non-skid Ext. Durability (2+ year)

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 Coating Reliability & Extended Performance (cont.)

Š Development of Standards/Instructions
„ Paint Application Procedures
„ Quality Control
„ Quality Assurance
Š Development of Certification for Quality Inspectors and
Applicators
Š Development of Performance Warranties comparable to
commercial standards

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 Faster Painting Schedules

Š Needs
„ Shortening of Maintenance Cycles
„ Faster Repairs on Ships at Sea
„ Need exists in Military and Commercial Ship Building/Repair
Š Present Limitations of Paint Setting & Cure Time (5-7 days) are too long
Š 24 Hour cure time is target
Š Need to look broadly into Epoxy, Polyurethane & Polyurea Technologies
Š Need to emphasize volatile organic limits approaching 0-20 g/l to
accommodate future trends in the world (e.g. USA & Western Europe)
Š U. S. Navy Program exists for Qualification of “Fast-cure Paints” with
interested Paint Companies
Š U. S. Navy R&D resulted in Patent Applications on New Technology “Fast-
Cure” paint systems suitable for Interior/exterior application as well as all
Navy Tanks (does not include anti-fouling paint application) Patent
licensing open to private sector companies.
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 Compliance with Environmental Regulation & Laws

Air Regulations
Š Existing Federal Regulation expected to produce 33% or greater
reduction in Volatile Organic Content (VOC) of paints in state
implementation plans (SIP) for 2004.
Š State of California plans reductions of VOC 100-200 g/l within 2-3 years
for Paints currently limited to 340 g/l California leads the United States
in air control limits. Extrapolated long-term VOC limit is ZERO VOC.
Š Today technologies exist for zero VOC paints e.g. Polyurethanes &
Polyureas, as well as the new technical systems developed recently by
the Navy.
Š CONCLUSION: It will be difficult or impossible to argue that
technology does not exist to approach VOC levels of 0 g/l. Limiting
factor is paint formulation which is not major barrier. Since most
technologies cited are “Fast-cure” there is an economic incentive for
users.
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 Compliance with Environmental Regulation &
Laws (cont.)

Water Regulations
Š Ban of Tri-butyl Tin Anti-fouling has no effect on U.S. Navy. Usage
of TBT ended over 10 years ago.
Š U. S. Navy challenge is to lower or eliminate Copper emissions.
Priority one is elimination of copper.
Š The Need to reduce copper emissions is based on the co-operative
finding between the Navy and the Environmental Protection Agency
(EPA) working to develop the Uniform National Discharge Standards
(UNDS) for the Department of Defense.
Š The Lead Paint Company in the Navy Program to eliminate Copper in
AF paint is SIGMA-KALON.
Š The success of the Sigma-Kalon Copper-free product is vital to World
& U.S. Navy needs.

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 Establishment of Specifications &
Standards

Š The U.S. Navy maintains specifications, standards and process

instructions for paints and their applications.
Š Discussions with other nations and especially France led to the
realization that NATO standards would be useful to all Navies.
Š Under the leadership of France-USA, work on standards has begun in
2002 to produce NATO standards covering initially 3 areas:
„ Best Practices for Paint Application
„ Topside Exterior Paints
„ Anti-fouling Paints
Completion for above is June 2004, other topics will be covered later.
Š USA, France, UK, Canada, Australia, New Zealand, Holland, Italy and
Sweden are active participants in this effort.

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 Development of Certification for Quality Inspectors
and Applicators

• NAVSEA Basic Paint Inspector Course

• Contractor Certification
• Plural Component Equipment Certification
• Abrasive Blasting Certification

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 NAVSEA Basic Paint Inspector Course

What does NBPI teach?

Familiarization with policy documents.
Corrosion basics & common types.
Cleaning & surface prep. methods.
Hydroblasting and alternate blasting/paint stripping methods.
Coating types and curing mechanisms.
Safety: MSDS, NFPA, PPE.
Coating storage, mixing, application.
Coating failures and causes.
Specialty surfaces & coatings: non-skid, anti-fouling,
PCMS topcoats, powder coating, metal spray coatings.
Several team exercises.
Hands-on “practical day”. 11
 NAVSEA Basic Paint Inspector Course

Developed in 1995 to train and certify coating inspectors for Navy ship
& submarine preservation work
80% passing grade, based on quizzes, final exam, oral exam, log book.
Four-year certification granted.
Re-certification program in place.
Approximately 1400 students have taken NBPI course, representing
diverse range of activities involved in Navy preservation. ~93% pass.
Over 1000 currently NBPI certified.

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 NAVSEA Basic Paint Inspector Course

Points of Contact

Š SSPC: Web Site - http://www.sspc.org/

„ Phone: 412-281-2331

„ Course Scheduling: Heidi Borter x215

„ Recertification: Calvin Brown x201

Š NAVSEA 05M1
„ Andrew Seelinger: 202-781-3670

Š NSWCCD Code 624

„ Jeff Duckworth: 215-897-7486

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 Contractor Certification

Š Implementation of Non-Skid Contractor certification requirements to SSPC

QP-1.
„ Certification is an industry standard program administered by SSPC.
„ Guidelines are based on consensus standards created by a cross
section of industry professionals
Š Other Programs under consideration:
„ QP-1 – Certification for companies providing surface preparation and
coatings application for steel structures on-site
„ QP-3 – Certification for companies involved in surface preparation
and coatings application in a fixed facility (similar to QP-1)
„ QP-5 – Certification for coating & lining INSPECTION companies
Note: The certification programs are for the company, not the individual

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 Plural Component Equipment Certification

Plural Component Equipment Applicator Training

Course Objectives

• Provide basic anatomy of high-solids plural component paint

systems operation
• Problem recognition
• Key setup, use, and lessons learned when using plural component
spray equipment
• Hands-on competency assessment

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 Abrasive Blasting Certification

Fundamentals of Dry Abrasive Blast Cleaning

Course Objectives
• Identify Basic Principles of Surface Preparation
• Describe the “how” and “why” of blast cleaning
• Identify types of equipment
• Describe equipment setup
• Describe abrasives
• Describe equipment operation
Course Outline
• Principles of Surface Preparation
• Primary Components of an Abrasive Blasting System
• Equipment Setup Hands-On Session
• Abrasives
• Equipment Operation Hands-On
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