1. Distribution A – Approved for Public Release
NAVAL SEA SYSTEMS COMMAND Performance Update - High Solids Tank Coatings
Mega Rust – 2015
Norfolk, VA
June 2015
Mr. Mark Ingle, P.E.
SEA 05P2
(202)
Distribution A – Approved for Public Release 1

2. Objectives
• Summarize evolving Naval Sea Systems Command (NAVSEA) organization
and coating requirements:
•• Headquarters NAVSEA Organization & Objectives.
• Summarize history and background for extending tank coating service life through
the use of high-solids, and rapid-cure, single-coat, tank coatings:
•• Business case or motivation for effort.
•• SEA 05 policy & requirements.
• Discuss results to date on high-solids tank coatings.
•• Ballast tanks.
•• Other tanks. 2

3. Naval Systems Engineering Directorate (SEA 05)
Draft: June 2015
Technical Domain Manager (TDM)
Chief Systems Engineer (CSE)
Office of the CHENG
SEA 05B Deputy / COS
(SEA 05B1)
Aircraft Carrier Design & Systems Engineering (SEA 05V)
Chief Finance Office
(SEA 05B3)
Surface Ship Design & Systems Engineering (SEA 05D)
Integrated Warfare Systems Engineering (SEA 05H)
Cost Engineering & Industrial Analysis (SEA 05C)
Ship Integrity & Performance Engineering (SEA 05P)
Chief Workforce Office
(SEA 05B2)
Special Projects
(SEA 00U/05X)
Executive Director / CHENG Deputy / Chief Technology Officer (SEA 05B)
Littoral and Mine Warfare Design & Systems Engineering
(SEA 05L)
Technology Office
(SEA 05T)
Submarine/Submersible Design & Systems Engineering
(SEA 05U)
Technical Policy & Standards (SEA 05S)
Undersea Warfare Systems Engineering (SEA 05N) (NUWCNPT TD)
Surface Warfare Systems Engineering (SEA 05W) (NSWCDD TD)
Marine Engineering (SEA 05Z)
L&MW Warfare Systems Engineering (SEA 05M) (NSWCPC TD)
Explosive Ordnance Engineering
(SEA 05E) (NSWC IH TD)
T&E Technical Advisor
Deputy Commander/CHENG
(SEA 05)
Chief HR & Admin Office
(SEA 05B6)
SEA 05P2

4. Technical Authority Pyramid - Coatings & Corrosion Control - Ships
Draft: June 2015
Code Product Related Specs
All All Technical Products, Managerial All
AF Antifouling Coating Systems MIL-PRF-24647
TNK Tank Coatings, Epoxy Primers MIL-PRF-23236
MIL-DTL-24441
PRM Primers, Single Component TT-P-645
TOP Topside, Alkyds & Polysiloxanes MIL-PRF-24635
INT Interior Coatings (SEA 08) MIL-DTL-24607
MIL-PRF-24596
MIL-DTL-15090
MIL-DTL-1115
HT High Temp Coatings, Metallic TT-P-28
PWD Powder, Interior, Cosmetic MIL-PRF-24712
NSK Nonskid MIL-PRF-24667
DCK Deck Coverings MIL-D-3134
MIL-PRF-3135
MIL-PRF-24613
MIL-PRF-32171
SUR Abrasive blasting, surface prep MIL-A-22262
SEL Sealants & Preservatives MIL-PRF-16173
NAVSEAINST
DOC Policy Documents NSTM 631, NSTM 634
Standard Item
Standard Item
COR Corrosion/PCOE Policy/Design DODI
RSH Research & Development To be determined
UNDS Regulations, Underwater hull TBD
SEA 08R
NAVAIR
Aircraft Engines
TWH: Underwater Hull Husbandry
TWH
Ingle
all
TWH:
Habitability
SDMs: Surface, Submarine, Carrier
Vacant
(EM)
NSK, All
Castle
(EM)
All, COR
EAs
Duckworth/
Deloach
(EA)
All
Lemieux
(EA)
All, RSH
Melhuish
(EM)
All, NSK
Haslbeck
(EM)
All, AF
Wegand
(EM)
RSH, NSK
J. Martin
(EM)
TOP, TNK
Ranero
(EM)
All, NSK
Lattner
(EM)
COR
Brinckerhoff
(EM)
All
Tagert
(EM)
TNK, NSK
Kenney
(EM)
VA-Class
EMs
Jones
(EM)
NSK, DCK
(EM)
Iezzi
RSH TOP
Smith
(EM)
UNDS
McKelvey
(EM)
COR, DOC
Wigle
(EM)
CCAT
Slebodnick
(EM)
RSH,TNK, NSK
Merlino
(LE)
DOCs
Ehrich
(LE)
COR
Eppard
(LE)
NSK, RSH
Needham
(LE)
COR, All
Steinberg
(LE) AF
Lawrence
(LE) AF
LEs
Miekle
COR
Holm AF
Clayton
(LE)
DOCs
Bergh
TNK, SUR
Chasse
COR
Park
DOCs
Ciscon
All
Langaster
TNK
Foster
All
RSH, All
Stanke
F. Martin HT
Kogler
SUR
Thomas
(LE)
COR
Webb
RSH
COR
Ellor
TNK, RSH
Ault
Delegated signature authority
Intern
All
Navy Employee
Navy Developmental Employee
Contractor 4

5. Tank Coating History
• There are ≈ 9,400 tanks on Navy ships that contain:
- Fuel (ships & aircraft) - Ballast water - Cooling Water
- Potable water - Wastewater
1997, tank recoating was largest cost item (~25%) in availability work packages
with annual cost estimate of ~$244M to re-preserve tanks/voids.
• Modern ballast tank coating era began on 27 Sept with implementation of
MIL-P-24441, “Mare Island” Formula 150 epoxy.
•• Polyamide epoxy formulation that contains <340 gm/l volatile organic
compounds (VOC), (still in service in U.S. Navy).
•• Product was intended for “universal” service including potable water.
•• System effectively supports 3 to 5 year docking cycles. .
Poor performance on welds,
corners, and edges –
Not edge-retentive.
Mare Island epoxy is a good coating with long history of service on Navy ships. 5

6. What is Edge Retention? Edge Retention Evaluation of
MIL-DTL-24441
Edge retention of high-solids,
rapid-cure, single-coat paint
New solvent-free,
edge retentive epoxy
Old solvent-based
epoxy pulls away from
the edge.
Paint Spray
MIL-PRF Appendix A requires measurement of coating thickness on aluminum extrusion with 1/32-inch or 0.8mm corner radius
Edge-retentive coatings must have >70% of the coating thickness on the flat surfaces retained on the edge 6

7. High-solids, Edge-retentive Coatings
1997 Business Plan for
High-solids, Edge-retentive Coatings
● plan to shift from a 3-5 year tank recoating periodicity for Mare Island to
a 20 year service life (i.e., 80% of the population being in a EXCELLENT or GOOD
condition at end of service period) by:
- Qualifying ultra-high solids, edge-retentive paints.
- Improving coating application process (e.g., surface cleanliness, profile,
environment, and oversight). 7

8. 1997 Business Case Proving Accurate for Seawater Ballast Tanks
∙ Business case predicated on avoiding need to repaint tanks.
- 60% to 80% Job cost associated with opening and preparing tank.
- Labor and QA required to spray paint, inspect paint, and touch-up regardless of type.
- Higher priced high-solids paint cures more rapidly, saves time.
* 15 UHS tanks are blistered and are rated CCIMS 3 or 4
(Coated) NUMBER OF TANKS (Not Coated)
Avoiding Tank Repaint Work Using High Solids is Lowering Total Ownership Costs 8

9. Ballast Tank Coating Performance on LHD 2
• LHD 2 seawater ballast tanks coated in 1998/1999 to
support twelve year docking.
- Larger tanks, more challenging access.
- One platform, one contractor, one system.
• Tank coating assessment by Naval Research Laboratory using camera and
visual inspections in 2012/ Total of 35 ballast tanks assessed as follows: `
Number of Ballast Tanks
Tanks in POOR Cond.
All Inspected Legacy
UHS coatings can support 12-year docking with minimal risk to material condition 9

10. Service Life of Fuel and Compensated Fuel Showing Blistering
∙ Compensated fuel, fuel, and JP-5 tanks include wide range of service and in-service history.
- JP-5 sumps and drains (e.g., 36 month inspection).
- Fuel oil storage (e.g., 120 month inspection).
- Corrosion, pitting, and “steel contamination” increase blistering risk.
* 13 UHS tanks are blistered and are rated CCIMS 3 or 4
(Coated) NUMBER OF TANKS (Not Coated)
Extended service life being achieved, but blistering is significant issue. 10

11. What To Do About Blistering?
∙ Paint Center of Excellence funded analysis to determine if blistering is a significant risk issue for
tank service life.
- Do blisters lead to tank corrosion, metal loss, and the repair “hockey stick”?
- Do blisters grow and lead to catastrophic coating failure (e.g., sheets)?
Extended service life being achieved, but blistering may be avoided without appreciable corrosion risk. 11

12. What To Do About Blistering?
∙ Corrosion data indicate blisters are not a risk to structure.
- Blistered panels show similar mass loss in abrasion testing (e.g., foot traffic).
- Tanks inspection could be completed even on blistered tanks.
Blistering would not be a problem with tank inspection and tanks could be placed back in service. 12

13. Business Case for Potable Water Tanks Initiated After Ballast Tanks in 2002
∙ Potable water UHS tank coatings are all qualified to MIL-PRF-23236D “COATING SYSTEMS FOR
SHIP STRUCTURE” that includes all corrosion control performance tests and the following
additional requirements:
3.4.1 Class 9 coatings shall maintain NSF International to NSF Standard 61 for 500-gallon storage tanks.
3.4.2 Color in water. Color units shall not be greater than 10.
3.4.3 Taste in water. Threshold taste values shall not be greater than 2.
3.4.4 Odor in water. Threshold odor values shall not be greater than 2.
3.4.5 Chlorine residual. Chlorine residual shall not decrease in excess of 50 percent of concentration.
3.4.6 Phenol contamination. The cured coating shall not leach phenolic compounds in concentrations greater
than 1 part per million.
High Solids, Type VII
Class 5/18 and 7/18 Single Coat
Ballast & Fuel tanks, chain lockers, voids
Class 18 signifies single-coat Class 9
Potable Water
Class 19 and Class 19/18
Well Deck Overhead `
Qualified a Class 9/18 in 2014.
Adding Class 9/18 to next
Standard Item Update
Potable water system limited to two coat UHS, but shifting to single coat in 2016 14

14. Business Case for Potable Water Tanks Initiated After Ballast Tanks in 2002
∙ Potable water tank performance history limited to thirteen years of data.
- Qualification of coatings to MIL-PRF-23236, Type VII, Class 9 is complex.
- Coating manufacturers must commit to maintain NSF 61 listing.
(Coated) NUMBER OF TANKS (Not Coated)
Potable water system limited to two coat UHS, but shifting to single coat in 2016 13

15. CHT / Sanitary Tanks are Providing Up to 15 Years of Service
∙ NAVSEA never predicted extended service life for CHT/waste tanks.
- Fatty acids actually degrade epoxy coatings.
- Tanks small and difficult to coat.
- Qualified coatings most frequently based on novolac chemistry.
(Coated) NUMBER OF TANKS (Not Coated)
Performance to date suggest qualified novolac epoxy coatings can support 12 year docking 15

16. Tank/Void Coatings in New Ship Acquisition
Added to ship specification
Expanding applications on every hull
Rapid-cure, high-solids,
edge-retentive, single coat
tank coatings
Demonstration testing
Specification Development 16

17. Conclusions
• UHS tank coating technology developed and fielded in late 1990’s
is performing effectively as measured by 1997 NAVSEA Business Case:
- Ballast tanks on track to achieve
15-20 years of service.
- Tank coatings on USS ESSEX (LHD 2)
supported 12-year docking.
- Fuel, CHT, and Potable water tanks
exceeding expectations.
• Key issue is end of life tank performance.
•• Blistering.
•• Schedule driven recoating.
•• Service life beyond 20 years?
• NAVSEA to continue efforts to support extended tank coating service
life. 17

18. Backup slides 18 21