1. Coating systems - BVN TM COAT 01
24/03/2006
Coating systems - BVN TM COAT 01
Head Office – V0 – June 2014
Development Department

2. CONTENT 1 – Objectives 2 – Coating Basic Knowledge
24/03/2006
CONTENT
1 – Objectives
2 – Coating Basic Knowledge
3 – Review of Applicable Regulations
4 – Typical Tasks for Survey
Development Department

3. 24/03/2006
1- Objectives
Development Department

4. 1 - Objectives To be familiar with the coating systems
24/03/2006
1 - Objectives
To be familiar with the coating systems
Study the requirements related to approval of Coating systems for IMO PSPC
Development Department

5. 2 – Coating Basic Knowledge
24/03/2006
2 – Coating Basic Knowledge
Development Department

6. 2 – Coating Basic Knowledge
24/03/2006
2 – Coating Basic Knowledge
Coatings families overview
Coatings Families
Coatings by Physical drying (Chlorinated rubber, Vinyl Paint )
Hard Coatings
« Chemical » drying
PSPC
Dry by oxidation (Oil, Alkyd, epoxy-ester Paints)
Epoxy base Coating
Others systems ( Polyurethane, Polyester, siloxane etc.)
Development Department

7. 2 – Coating Basic Knowledge
24/03/2006
2 – Coating Basic Knowledge
Paint which dry by chemical reaction: Epoxy coatings
Curing is obtained by mixing the Base and the Hardener in clearly defined proportions. A chemical reaction then occurs, causing cross linking of the molecular chains. After curing, these paints provide a hard film.
Initial mixing (Base + Hardener + Solvents)
Crosslink reaction (T, Ratio Base/Hardener)
Crosslink Network (Hard film)
Base (epoxy)
solvent
+ Hardener
Residual solvent
Coating Manufacturer’s curing time and mix ratio of epoxy coatings shall be carefully respected.
Development Department

8. 2 – Coating Basic Knowledge
24/03/2006
2 – Coating Basic Knowledge
Coating Main components/Formulation
Coatings have two major components: Binder & Pigments/Extenders
is part of nonvolatile film-forming components. It provide internal cohesion, flexibility and adhesion with substrate and gives the chemical resistance
Binder
(Base + Hardener)
Pigments
provide protective properties or decorative properties (color, opacity and gloss)
Fillers or Extenders are organic/inorganic particulates which:
improve coating impermeability,
adjust rheological, gloss and mechanical properties,
reduce cost formulation
Development Department

9. Long Hydrocarbonate chains
24/03/2006
2 – Coating Basic Knowledge
Coating Main components/Formulation
Vehicle Scheme
Vehicle is the liquid part of the coating. It consists of the binder, solvent and Additives.
Solvents + Additives
Long Hydrocarbonate chains
(binder)
Development Department

10. 2 – Coating Basic Knowledge
24/03/2006
2 – Coating Basic Knowledge
Coating Main components/Formulation
Additives which confer special properties to the coating product:
Rheological agent
Anti-skinning
agent
UV absorber
Anti-foaming agent
Anti-settling agent, Plasticizer, Thickeners etc.
Development Department

11. 2 – Coating Basic Knowledge
24/03/2006
2 – Coating Basic Knowledge
Coating Formulation Production
Raw materials Storage
Solvents, Binders, Pigments, Extenders, Additives
Pre mix solution
Part of Vehicle (Solvent +Binder), Pigments, Extenders and additives are mixed
Balance/ Mass Flow-meter/ Dissolver
Milling
Machine
Let down / Adjusting
Addition of Pigments/ Extenders, Vehicle ,additives with test of fines of grind, fineness and Viscosity and Sag meter
Grinding
Pigments, Extenders are filtered
Balance/ Mass Flow-meter/ Dissolver
Agglomerates be divided into primary particles
COV tested / Drying time
Final Mix
Paint component are mixed and final tested ,color adjusted
Filtering / Packing
Paint is filtered
Storage / Delivery
Filter
Development Department

12. 2 – Coating Basic Knowledge
24/03/2006
2 – Coating Basic Knowledge
Shop primers families overview
Shop primers shall be distinguished from coating:
- Shop primer provide temporary protection against corrosion compare to coating.
- Steel plate shop primed can be welded, not the coated steel plates
*Silicate and Epoxy Shop primer : A review : JPLC July 2006
Development Department

13. 2 – Coating Basic Knowledge
24/03/2006
2 – Coating Basic Knowledge
Shop primers families overview
Ethyl Zinc Silicate based shop primer is used for marine applications. Pigment is Zinc and Binder is Ethyl Silicate base.
Zinc is sacrificing under atmospheric conditions and creating Zn salts. Then these salts fill the voids in the film and the primer provides a barrier against the contaminants.
15 mm / 25 mm
Development Department

14. 2 – Coating Basic Knowledge
24/03/2006
2 – Coating Basic Knowledge
Coating System definition:
Steel Substrate
Primer coat: Adhesion and/or active corrosion protection
Intermediate coat: barrier effect, build-up thickness, compatibility
Finish coat: Surface aspect, gloss, color, functionality
Total number of coats
Chemical nature, color definition / coat
Individual coat and total dry film thickness (DFT)
Development Department

15. 2 – Coating Basic Knowledge
24/03/2006
2 – Coating Basic Knowledge
Coating System vs Ship Areas*
Hull & Bootop
Top Coat
PMA-Biocide
TBT free/1 Coat
Intermediate Coat
Pure Epoxy / 1 Coat
Primer Coat
Tar free Epoxy / 1 Coat
Average Total DFT(mm)
325 – 625
Functionality
Anti-fouling, Abrasion, Anticorrosion
*Coating manufacturer data – ISO
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16. Cargo & Grey water Tanks
24/03/2006
2 – Coating Basic Knowledge
Coating System vs Ship Areas*
Cargo & Grey water Tanks
Top Coat
N.A.
Intermediate Coat
Phenolic or Pure Epoxy / 1 or 2 Coats
Primer Coat
Phenolic or Pure Epoxy / 1 Coat
Average Total DFT(mm)
Functionality
Anticorrosion, Chemical resistant
*Coating manufacturer data – ISO
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17. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
Development Department

18. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
Specification & Testing requirements to be studied related to the Performance Standard for Protective Coating (PSPC):
IMO MSC.215 (82) – PSPC WBT for dedicated seawater ballast tank
IMO MSC.288(87) – PSPC COT for cargo oil tanks of crude oil tankers
IMO MSC.244(83) – PSPC VSP for void spaces on bulk carriers and oil tankers
IACS UI SC 223 for PSPC WBT
IACS UI SC 259 for PSPC COT
IACS UR Z 17 Procedural requirements for service suppliers
Bureau Veritas NR 530 Coating performance standard
Overview of applicable regulations
Development Department

19. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
PSPC WBT – Key dates
SOLAS Reg. II-1 / 3-2 amended by MSC.216(82)
WBT All Ships ≥ 500 G.T. , DSSS Bulk Carriers ≥ 150 M
Dec. 2006
- MSC.215 (82)
- MSC.216 (82)
Adoption of PSPC - WBT
1st July 2008
Keel laying*
Delivery
* In absence of a building contract
Building contract
IACS UI SC 223
1st Jan. 2009
1st July 2012
Contract for construction of CSR ships
IACS PR 34
NR 530 Notation CPS (WBT)
Development Department

20. SOLAS Chap. II-1 / Reg. 3-11 as amended by MSC.291 (87)
24/03/2006
3 – Review of Applicable Regulations
PSPC COT – Key dates
May 2010
- MSC.288 (87)
- MSC.291 (87)
Adoption of PSPC - COT
1st Jan. 2013
Keel laying*
Delivery
* In absence of a building contract
Building contract
1st July 2013
1st Jan. 2016
SOLAS Chap. II-1 / Reg as amended by MSC.291 (87)
Crude oil tankers ≥ Tonnes Dwt. MARPOL 73/78 Reg.1 Annex1
Development Department

21. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
Bureau Veritas NR 530
Development Department

22. 3 – Applicable Regulations
24/03/2006
3 – Applicable Regulations
Bureau Veritas NR 530
Development Department

23. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
IMO PSPC – General Principles
Coating Technical File (CTF)
Primary Surface preparation (Shop primer application )
After the Blocks Construction
After the Blocks Assembly (Erection)
Tri-Partite Agreement (TPA)
Approved Coating system, Surface preparation, Coating
application inspections
Coating System Approval
Statement of Compliance Certificate or Type Approval Certificate
Shipyard, Shipowner, Coating Manufacturer
Administration or Recognized Organization
Shipyard / Coating Inspector
Administration or
Recognized Organization
Coating Manufacturers
Third Party
Development Department

24. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
PSPC – Coating system approval
The coating system is to be type approved as per IMO PSPC Tab procedures
Compatibility between coating system and shop primer (SP) tested as per
IMO PSPC Tab (Cross over test)
Instructions TTE Type Approval of Coating Systems
Development Department

25. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
Coating system approval procedure - BV NR 530 Sec 5
Development Department

26. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
Epoxy-based system
PSPC Tab.1-1.3
Coating manufacturer
Coating specification
(TDS)
PSPC Annex 1 Sec.2, as per PSPC Tab.1
Type of coating
Inspection (Surface preparation, application procedure)
Audit
IACS UR Z17
Classification Society
Testing
coating sys.
Laboratory
IMO PSPC - IACS UI SC 223/259 - NR 530
Method A (Laboratory tests of PSPC App.1 and App.2)
Method C (Marintek test level B1)
Method B (5 years field exposure)
Documentation Compilation
Coating manufacturer
Outline of company
List of production facilities
QMS certificate
Technical Data Sheet(s) (TDS)
Material Safety Data Sheet (MSDS)
Infrared and Specific gravity data,
(for each manufacturing sites)
Test report(s)
Approval request
AdE. 616
BVN Local office
Transmit TAC request
(MPA) 1
Development Department

27. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations 1
IMO PSPC Tab.1–1.3 / NR 530
Review of coating specification / TDS
(PSPC Tab.1 and Sec )
Review of Test report, IR/SG data
(PSPC Annex 1, UI SC 223/259 Method A)
Review
Documentation
Audit of production site(s)
BVN Local office(s)
Draft
TAC(s)
BV HO DO/EMC
IMO PSPC - UI SC 223/259 Method D - NR 530 – NR320
Documentation (raw material suppliers, quality control etc.)
Production units and testing
Formulations, Raw material supply
Batch records, Marking
Assessment report_Recognition (App.A01 – TTE 3002)
Checklist_Recognition (App.01 – TTE 3040)
Manufacturer site(s)
BV HO DO/EMC
Recognition
Certificates
Audit report
Check list
Completion and Check of TAC(s)
BVN Local office
Coating manufacturer
Signed
TAC(s)
Development Department

28. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
Overview Testing procedure (Method A) - PSPC WBT
Testing laboratory is to apply following standards:
For surface preparation of test specimens:
ISO : 1988/Suppl.1994 – Visual assessment of surface cleanliness
ISO /2: 1988 – Surface roughness characteristics of blast cleaned steel
ISO /9: 1988 – Test for assessment of surface cleanliness Bresle test
For testing methods:
ISO /4: 1997 – Determination of density
ISO /3: 2003 – Assessment of degree of blistering / rusting
ISO 4624:2002 – Pull-off test for adhesion
ASTM D4145:1998 – Standard test method for Coating Flexibility
ISO :1988 – Continuous condensation
Solas II-1 Reg 3.2: Amendments 1996
Development Department

29. Simulated Water Ballast Tank Test (6 months)
24/03/2006
3 – Review of Applicable Regulations
Overview Testing procedure (Method A) - PSPC WBT
Simulated Water Ballast Tank Test (6 months) 1 2 3 5 4
N°1 (Upper Deck)
N°5 (Bottom heated)
N°3 (Side cooled)
N°4(Side not cooled)
N°2 (Bottom)
Cross over test
Thickness steel plate 3 mm
Development Department

30. Condensation Chamber Test (6 months)
24/03/2006
3 – Review of Applicable Regulations
Overview Testing procedure (Method A) - PSPC WBT
Condensation Chamber Test (6 months)
150 mm
Two panels to be tested
Thickness steel plate 3 mm
Development Department

31. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
Development Department

32. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
Overview Testing procedure (Method A) - PSPC WBT
1mm
10mm
5mm
150
5mm
3mm
10mm
400
Development Department

33. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
Overview Testing procedure (Method A) - PSPC WBT
400
Development Department

34. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
Overview Testing procedure (Method A) - PSPC WBT
Development Department

35. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
Overview Testing procedure (Method A) - PSPC COT
Testing laboratory is to apply following standards:
For surface preparation of test specimens:
ISO : 1988/Suppl.1994 – Visual assessment of surface cleanliness
ISO /2: 1988 – Surface roughness characteristics of blast cleaned steel
ISO /9: 1988 – Test for assessment of surface cleanliness Bresle test
For testing methods:
ISO /4: 1997 – Determination of density
ISO : 2007 – Immersion in liquids other than water
ISO /3: 2003 – Assessment of degree of blistering / rusting
ISO 8217:2005 – Specification of marine fuels
ISO 6618:1997– Determination of acid or base number
ASTM D :2008 – Standard Practice for preparation of substitute ocean water
Solas II-1 Reg 3.2: Amendments 1996
Development Department

36. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
IMO MSC.288 (87) – Appendix 1 Gas-Tight Cabinet Test
Duration: 3 months
Test gas composition as per PSPC (COT) Annex 1 – Sec.5
Test temp 60°C, RH 95%, Monitoring for test gas refreshed
IMO MSC.288 (87) – Appendix 2 Immersion Test
150 mm
100 mm
Duration: 6 months
Test liquid composition as per PSPC (COT) Annex 1 – Sec.6
Test temp 60°C
Two panels to be tested for each test
Test reports shall include information as per PSPC COT Annex 1 Sec.4:
Coating identification: IR, SG, Batch No.
Test panel preparation and Tests conditions
Test results: No blisters and No rusting
Development Department

37. 3 – Review of Applicable Regulations
24/03/2006
3 – Review of Applicable Regulations
Cross over test - IMO MSC.215(82) Table 1 § 3.2
Demand for type test SP2
Pass
Cross over test
Issued Type Approval for Coating System EBS1 + SP2; SP3 etc.
Epoxy Based System (EBS2) +
Shop Primer (SP2)
Epoxy Based System (EBS1)
Shop Primer (SP1)
Demand for type test EBS1
Epoxy Based System (EBS3)
Shop Primer (SP3)
Demand for type test SP3
Type approved Coating System + Shop primer as per PSPC Annex 1 (Method A)
Tested Shop Primer compatibility as per PSPC Appendix 1 § 1.7 (Panel no.2)
Development Department

38. Cross over Test (6 months)
24/03/2006
3 – Review of Applicable Regulations
Cross over test - IMO MSC.215(82) Table 1 § 3.2
Cross over Test (6 months) 2
N°2 (Bottom)
Cross over test
Static immersion
Development Department

39. 4 – Typical Tasks for Survey
24/03/2006
4 – Typical Tasks for Survey
Development Department

40. 4 – Typical Tasks for Survey
24/03/2006
4 – Typical Tasks for Survey
Recognition of testing laboratory – BV NR 530 / IACS UR Z 17
Instructions TTE Recognition of testing laboratory as per NR 320
Instructions TTE Type approval of coating system as per IMO PSPC
Check documentation requested in NR 530, Sec 5 [2.2]
Development Department

41. 4 – Typical Tasks for Survey
24/03/2006
4 – Typical Tasks for Survey
Recognition of testing laboratory – BV NR 530 / IACS UR Z 17
Instructions TTE Recognition of testing laboratory as per NR 320
Instructions TTE Type approval of coating system as per IMO PSPC
Assessment to check Audit requirements as per NR 530, Sec 5 [2.3]:
Training of personnel & Personnel records
Supervision
Equipment and facilities (look for test standard methods)
Procedures covering testing activities (look for IMO PSPC testing procedures)
Subcontractors
Verification
Reporting
Development Department

42. 4 – Typical Tasks for Survey
24/03/2006
4 – Typical Tasks for Survey
Coating Manufacturer Assessment – BV NR IACS UI SC 223/259
Instructions TTE BV Mode II Recognition
Instructions TTE Type approval of coating system as per IMO PSPC
Check documentation requested in NR 530, Sec 5 [3.5.2]
Development Department

43. 4 – Typical Tasks for Survey
24/03/2006
4 – Typical Tasks for Survey
Recognition of testing laboratory – BV NR 530 / IACS UR Z 17
Instructions TTE BV Mode II Recognition
Instructions TTE Type approval of coating system as per IMO PSPC
Assessment to check Audit requirements as per NR 530, Sec 5 [3.5.3]:
Management of type approval with the Society
Training & qualification of personnel
Traceability of products
Management of equipment including maintenance and calibration
Testing standards and procedures (look for IMO PSPC testing requirements)
Management of complaints and non-conform products
Verify items of Checklist recognition coating manufacturer (App.01 – TTE 3040)
Development Department

44. 4 – Typical Tasks for Survey
24/03/2006
4 – Typical Tasks for Survey
Recognition of testing laboratory – BV NR 530 / IACS UR Z 17
Main items of Checklist recognition coating manufacturer (App.01 – TTE 3040)
Formulation adjustment clearly state in the Quality control procedures
Manufacturer ‘s quality control system ensures that all current production is the same formulation as that supplied for type approval certificate
Traceability and Quality control records of raw material and coating batch production
Records of Coating Quality control tests (i.e. viscosity, specific gravity, airless spray characteristics)
Technical Data Sheets up to date and Quality control procedure of technical centre
Development Department

45. 24/03/2006
Development Department