U.S. Navy Tank and Void Maintenance and Lifecycle Cost Reduction - PowerPoint PPT Presentation

Materials Engineering Office, O5P23 U.S. Navy Tank and Void Maintenance and Lifecycle Cost Reduction Initiatives Arthur A. Webb Head, Marine Coatings Section Naval Research Laboratory Paul Slebodnick Corrosion Engineering Section Naval Research Laboratory Beau Brinckerhoff Corrosion Control Division Naval Sea Systems Command Presented to The International Symposium on Shipbuilding Technology (ISST 2007) September 6-7 2007 1 Osaka University, Japan

Materials Engineering Office, O5P23 Tank and Void Corrosion • Progression of Corrosion Control Coatings Traditional Solvent Based System 1991 1997 Reduction in VOC and HAPS 1994: Initial implementation of improved QA High Solids Systems 1996 1995: Use of edge retentive coatings 1996: Initial implementation of plural component for handling solvent-free coatings 1997: Institutionalization of enhanced QA! Solvent Free Rapid Cure System 2001 Present 2001 : Improved application equipment 2002: Development of specialized resin materials 2004: First rapid cure product placed on Navy QPL 2

Materials Engineering Office, O5P23 Application Condition Drivers Problem Short Term Solution Risk Long Term Solution Risk Low Environmental Employ localized and or Employ cold cure with Temperature space heating High plural component Low Low Material Employ localized Employ heated plural Temperature heating High component Low High Environmental Employ plural Temperature Work Rapidly High component Low Employ rapid cure Rapid Turn-around Employ post application coating with plural Required heating High component Low Surface Preparation Requirements (Navy SI 009-32) Relative Humidity <50% Surface Profile 75-125um Condition SSPC SP-10 (Sa 2 1/2) Chloride <3ug/cm^2 3 Required for all Critical Areas to include Tanks and Voids

Materials Engineering Office, O5P23 Current Coating Scheme Current U.S. Navy Shipboard Tank Coatings Systems at a Glance (All thicknesses in microns) System Primer Stripe Coat Mid Coat Stripe Coat Topcoat Total Solvent based 125-175 125-175 125-175 125-175 125-175 625-875 High Solids 200-250 200-250 200-250 200-250 200-250 1000-1,250 Solvent Free 375-450 375-450 375-450 1,125-1,350 Moving toward solvent free, direct-to-metal, fast-cure in all applicable areas Maintain Present Quality Assurance Requirements Reduce Maintenance Costs Rapid Turn-Around 4 Reduce overall Asset Protection and Maintenance Costs

Rapid Cure Coatings • Sponsored under Office of Naval Research, Code 332 (S&T Manager) – 7 year program aimed at employing latest state of the art in solvent free coatings for reduction in maintenance costs and for life cycle extension – Program management and technology identification and insertion through demonstrations – Materials identification and performance/process development by the Naval Research Laboratory code 6138. • Shipboard demonstration and validation of performance • Transition managed by NAVSEA 05P2 (Materials Warrant Holder) – Acceptance documents and placement on Qualified Products List (QPL) – Revisions to standard maintenance procedures and fleet directives 5

Rapid Cure Coatings Sponsorship Transition Office of Naval Research Code 332 Naval Research Laboratory Code 6130 Naval Sea Systems Command 05P23 Materials and Process Development Design and Acquisition Managers Product Demonstration Naval Research Laboratory Performance Review Naval Surface Warfare Center Instituted Fleet Implementation 6 Regional Maintenance Centers

Rapid Cure Ship Tank Coatings Technology Perspective Traditional Solvent Based System Theoretical Required Time for Application/Cure-out and QA (Hours) 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 Five-coat Traditional Cure 10 30 40 20 5-7 Years Service Life High Solids/Solvent Free System Required Time for Application/Cure-out and QA (Hours) 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 Three-coat Traditional Cure 10 30 40 20 15-20 Years Service Life Solvent Free Rapid Cure Systems Required Time for Application/Cure-out and QA (Hours) 5 10 15 20 25 30 35 70 80 100 105 110 115 40 45 50 55 60 65 75 85 90 95 Three-coat Rapid Cure Single-coat (Multipass) Rapid Cure 10 30 40 20 7 15-20 Years Service Life

Materials Engineering Office, Tank and Void Coatings O5P23 Cure Speed Classification General classification of coatings based on cure times Cure Class Coating Chemistry Standard Cure Traditional solvent free epoxy Rapid Cure Solvent free epoxy using enhanced curing agents Single Coat Polyurethane and Polyurea with low catalyst levels Typical cure times at various temperatures for coating types Coating Type Time to Cure 0C 4C 15C 24C 32C 43C Standard Cure Epoxy No curing No curing 12-24 hrs 8-12 hrs 6-8 hrs 4-6 hrs Cold Cure Epoxy 18-24 hrs 12-18 hrs 8-12 hrs 6-8 hrs 4-6 hrs <4 hrs Rapid Cure Epoxy No curing 8 hrs 5-7 hrs 3-4 hrs 2-3 hrs 1-2 hrs Rapid Cure Polyurethane 60-90 min* 40-60 min* 20-30 min 10-20 min 5-10 min <1 min 8 Polyurea 3-5 min 2-3 min 1-3 min 30-45 sec 5-10 sec < 5 sec * High catalyst levels required

Materials Engineering Office, O5P23 Tank & Void Coating Cure Speeds Time to Cure at 25C (77F) Average Cure Times of Commercial Products 14 12 10 Cure Time (hrs) 8 6 4 2 20 minutes 0 Standard Epoxy Cold Cure Epoxy Rapid Cure Epoxy Rapid Cure Polyurethane 9 Product Type

Rapid Cure Products Current list of products under evaluation for corrosion control Type Cure to Recoat (hrs) Full Service Equipment Reqt's Handle Epoxy (8) 3 hours 4 to 8 max 7 days PC/single feed gun Polyurethane (2) 20 minutes 4 max 7 days PC/impingment gun System Application Acceptability Solvent Free System Line-up Use Area Standard Cure Epoxy Rapid Cure Epoxy Rapid Cure Polyurethane Dedicated Seawater Freshwater Gray/black water Fuel/compensated fuel Voids Air Plenums Bilges Acceptable Marginal 10 Not Recommended

Rapid Cure and Single Coat • Rapid Cure – Epoxy based systems where coating is applied in separate evolutions, e.g., • Prime (first evolution) • Stripe (second evolution) • Topcoat (third evolution) • Single Coat – Polyurethane systems where: • Prime, Stripe, and Topcoat all applied during ONE evolution. 11

Application Sequence Rapid Cure Epoxy Systems Blast Cleaned 1 st Coat (primer) Stripe Coat 1 st Evolution Wait 3-4 Hours 2nd Evolution Wait 3-4 Hours Inspect and Close Wait 3-4 Hours Topcoat 12 3rd Evolution

Legend Application Sequence First Pass Second Pass Using a Single Coat Multipass System 3 rd Pass (Completed) Sequence Approach: 2-10 minutes between sections Completed 13 All inclusive process, In ONE evolution

Single Coat Multi-Pass Method • Sequencing Process Prepared Structure Primer Coat Application Topcoat applied by First Crew Mid Coat begins as Primer team finishes Final Coat begins as Mid Coat Team finishes Cure to Handle Wet Primer Mid Coat 14 Topcoat

Single Coat Multi-Pass Method • Sequencing Process Typical Painting Sequence Single Coat Multi-pass Sequence Finished!!! 15

Materials Engineering Office, O5P23 Additional New Process U.S. Navy Shipboard Tank Coatings Systems Including Single Coat (All thicknesses in microns) System Primer Stripe Coat Mid Coat Stripe Coat Topcoat Total Solvent based 125-175 125-175 125-175 125-175 125-175 625-875 High Solids 200-250 200-250 200-250 200-250 200-250 1000-1,250 Solvent Free 375-450 375-450 375-450 1,125-1,350 All Inclusive in Application Multipass Single Coat 1,125-1,350 1,125-1,350 A new option for time savings and increased productivity! 16

Rapid Cure Coating Application 8,000ft 2 Seawater Ballast Tank Application of a rapid cure solvent free polyurethane (note that applicator is standing directly on completed and cured deck) 17

Application Comparison 900m 2 (10,000 ft 2 ) Tank Legacy Solvent Free Rapid Cure Rapid Cure Process System System Epoxy Polyurethane Surface preparation Sa 2.5 Sa 2.5 Sa 2.5 Sa 2.5 Required profile 75-125um 75-125um 75-125um 75-125um Time required (hrs) 40 40 40 40 Application Equipment Singe feed Singe feed Plural Feed Plural Feed Training QP-1 QP-1 QP-2 + Vendor QP-2 + Vendor Training Training Cure Temperature, C Minimum 15 15 10 0 Maximum 35 35 35 35 Paint Cure Schedule (hrs) Prime 8 8 3 1 Stripe 8 8 3 1 Mid 8 Stripe 8 Top 8 8 3 1 QA/QC Prime 4 4 4 4 Stripe 4 4 4 4 Mid 4 Stripe 4 Top 4 4 4 4 Overcoat Minimum 12 hrs 12 hrs 12hrs 1 hr Maximum 30 days 30 days 14 days 4 hrs Environmental Control <50 RH <50 RH <50 RH <50 RH 18 Total Time to Completion (hrs) 100 76 61 55

Application Costs Percent Savings Versus During Demonstration Polyurethane Epoxy Initial Subsequent Initial Subsequent Application Application Application Application Space Seawater Ballast -13 49 2 31 Freshwater -16 22 Fuel tanks 27 31 Percent Savings During Production Production Application Savings System Savings Legacy Coating 0 Rapid Cure Epoxy 51 Rapid Cure Polyurethane 30 19 All costs based compared to “legacy (solvent based system)