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Smoothing the flow for ships and cargoThe profitability of a bulk carrier is as dependant on the durability of thecoating used in its cargo hold as it is on the effectiveness of its hullantifouling treatment. A number of specialist manufacturers havedeveloped coatings to meet all the requirements of bulk carrier operators

Hempadur Ultra-Strength 47500 is the newestand most advanced cargo hold coating to beproduced by Hempel. It is tough enough towithstand the impact and abrasive effects ofthe most punishing cargoes and the most

demanding working conditions. Designed for outstandingdurability, the coating delivers excellent abrasion and impactresistance, excellent application properties all year aroundand an unrivalled time to first hard cargo.

. Independent coal cargo testing at STS in the UK,ranks Hempadur Ultra-Strength 47500 the best performingepoxy coating in the market. It also boasts an industry-leading lO-year repair interval. Suitable for cargo holds,decks, the outer hull and other exposed areas, it is asversatile as it is durable.

Hempadur Ultra-Strength Multi-Strength 45751145753 is a self-priming two-component highly abrasionresistant epoxy coating with excellent resistance to a broadrange of chemically aggressive dry cargoes. It has beendeveloped to meet these needs for protection againstcorrosion and abrasion in cargo holds, tanks and exposedareas on ships.

.•_Years of proven performance, extensive in-houseand eXternal testing confirms the coatings excellentprotective properties.

Coating of tanks used for the transportation ofchemical cargoes serves two purposes: protecting the cargoagainst contamination from previous cargoes, and protectingthe tank against corrosive chemicals. These two purposesgo hand in hand, and both require that the tank lining mustbe resistant to the cargoes and sequences of cargoes tobe carried.

Hempadur1550 is a phenolic epoxy which isresistant to the major part of cargoes carried in chemicaltankers. Having demonstrated through excellentperformance results that it is among the best tank linings onthe market, Hempadur 15500 is the natural choice wherethe highest possible resistance and a close sequence ofcargoes are required. It is also extensively used by operatorsopting for the flexibility to carry a wide number of cargoesoffered by the very broad resistance provided.

Hempel's Galvosil 1570 is a zinc silicate basedtank lining where the cured film is purely inorganic and fullyresistant to most organic solvents and generally allows aclose sequence of cargoes. Hempadur 1540 is an amineepoxy, and is the typical choice in connection with cargoes ofoil and oil products, fats, certain fertilisers and caustic soda.

Hempel's cargo tank coatings have beenformulated to meet the individual demands associated with

various transportation patterns or various needs for storage.The selection of the right coating system must be based onan analysis of the cargoes intended to be carried, and of thetypically occurring cargo sequences.

Hempel is a responsible partner in providingtrustworthy fouling control solutions to shipowners, shipmanagement and shipyards. Hempel's solutions offer anattractive operating economy and a fast workflow to suitindividual customer needs .

MAIN TECHNOLOGIESThe two main technologies to prevent fouling

today are antifouling and fouling release coatings. Theprinciple behind antifouling coatings has been know foryears: Active ingredients incorporated in the paint film aremade accessible via a combination of chemical and physicalaction from the surrounding water.

The principle behind fouling release coatingshas also been known for years. However, exploitation asfouling prevention has only started recently.

The working mechanism is purely physical wherea very smooth and flexible coating with low surface ten-sion simply releases the fouling organisms with help fromthe motion of the water once the vessel is sailing.

Hempel offers a wide range of antifouling andfouling release products of different qualities and fordifferent service intervals.

INTERNATIONAL PAINTSAccording to data collected by International

Paints (IP), if ships didn't use fouling control coatings, fuelconsumption of the world's merchant fleet would beincreased by as much as 40%, with current fuel useconsequently rising by 140 million tonnes per year to atotal of almost 500 million tonnes per year.

The world's fleet uses 350 million tonnes of fuelannually, emitting some 1.1 billion tonnes of C02 and over10 million tonnes of S02. '

Fouling control coatings have an important role inreducing fuel consumption and greenhouse gas emissions,maintaining smooth, clean hulls, achieving energy efficiencyand speed improvements, while reducing operational,commercial and environmental costs.

An increase in hull roughness can be attributableto plate waviness, plate laps, welds and weld quality,mechanical damage and corrosion. It can also be attributableto steel profile, minor corrosion and the condition of thecoatings. Biological factors include animal, weed and slimefouling.

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IP has a Hull Roughness Penalty Calculator thathows in detail how hull roughness affects vessels. This is aoftware programme that predicts the inevitable increase innderwater hull roughness during the specified in-serviceeriod and combines this with the risk of fouling associated.th different antifouling types.

The programme then compares vessel fuel usaged cost to the installation cost of different TBT free

ntifoulings and foul release systems and calculates thexhaust emissions (C02, SOx) associated with additionalel consumption. IP has introduced Intersmooth7465Si

PC and Interswift6900Si silyl acrylate antifouling coatings.g to improve and enhance customer choice, the

mpany claims to be the first and only global manufacturero offer both copper acrylate and silyl acrylate antifoulingoatings within a comprehensive range of fouling controlechnologies.

In 2006, IP successfully patented silyl acrylateechnology for use with products of <400gll VOC (volatilerganic compounds). This technology is incorporated intotersmooth7465Si SPC and Interswift6900Si and allows

elivery of the same high levels of proven in-serviceerformance as our current Intersmooth7460/5HS SPC andterswift6800HS copper acrylate antifouling coatings.

Both new silyl products have solvent emissionevels of less than 400gll VOC. This means that they areome of the lowest silyl acrylate solvent emission levels ine industry. Designed for deep sea vessels at newbuildingd maintenance and repair, Intersmooth7465Si SPC

eatures 55% volume solids. Compared to lower volumeolids products, this results in shipyard benefits of fasterpplication, reduced wastage and pail consumption andower solvent emissions to the atmosphere.

Reduced overspray leads to lower contaminationevels in dock and reduced applicator exposure. For theessel operator, the product delivers predictable, higherformance fouling control for up to 90 months and its

erent self-smoothing action potentially reduces fuel usey 4%, cutting operational costs, lowering carbon dioxide

emissions and improving vessel operating image.Interswift6900Si incorporates patented silyl

acrylate polymer technology. Also designed for vessels atewbuilding and maintenance and repair, the product offers

61% volume solids, surface tolerance and in-service periodsof up to 60 months with potential fuel savings of 1.5%.

Mr Mike Hindmarsh, lP's Business DevelopmentManager said, "We recognise that our customers havedifferent requirements and operational preferences, which is

hy we offer a broad choice of fouling control products andtechnologies in our high performance range. Customerssimply choose which technology option best meets theirneeds and we deliver the performance."

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The company's Intergard7020 is a new dedicatedcargo hold coating for all bulk carrier types. Speciallydesigned for operators who don't need or cannot justify theinvestment in the highest performing cargo hold coatings,Intergard7020 offers good abrasion resistance and long termcorrosion protection combined with many of the featuresnormally associated with more expensive products.

Available in the popular and practical red and greycolours, Intergard7020 is an aluminium containing, lowVOC, pure epoxy coating which can be applied to surfacesprepared to a minimum of Sa2. Applicable at temperaturesbetween -SOC and +3s0C the product has a smooth, glossy,easy clean surface, is grain certified and is ready to carryeven the harshest cargoes after only 10 days cure.

Mr Rob Taylor, Market Manager Bulk Carriersfor IP said, "Whilst cargo holds are the important revenueearning spaces of bulk carriers and the areas that can besubject to the severest of operating environments, weunderstand that our customers have different needs and notall require the protection afforded by the very best technol-ogy. Intergard7020 complements and improves our existingcargo hold coatings product range whilst adding to customerchoice.

"The product is particularly suitable for upgradingfrom modified epoxy cargo hold coatings and offersimproved performance with excellent value for money.We now offer a complete range of products fully capable ofmeeting all operator requirements in the very demandingand competitive cargo hold coatings market."

The product range now includes Interbond201, asurface tolerant, modified epoxy, cargo hold coating with along in service history, new Intergard7020, Intershield803,an abrasion resistant pure epoxy coating with an excellenttrack record and Intershield803Plus, its toughest evercargo hold coating with exceptional impact and abrasionresistance, which was introduced last year.

Cargo holds, as well as being the revenue earningspaces of the vessel, are also the areas subject to the harshestof operating environments. Various forms of impact,abrasion and mechanical damage occur from the loadingand carriage of dry cargoes.

Without excellent coating protection, thestructural integrity of holds can be compromised,jeopardising continuing vessel profitability and safeoperation. Faster loading techniques are increasingly beingemployed by ports, which in turn place new demands oncargo hold coatings.

CARGO HOLD DAMAGEKey modes of damage in cargo holds are impact

and gouging. Impact damage can occur when cargoesare loaded into holds through various mechanisms. Highspeed belt conveyors can rapidly break down coatings, aphenomenon known as 'shooting' damage. Gouging is aresult of cargo settlement during sailing and this form ofabrasion can cause severe damage at the cargo/coatinginterface.

If the coating becomes damaged, exposed steelwill corrode during the carriage of moist cargoes such ascoal, reducing coating adhesion and leaving the steelvulnerable to further mechanical attack. Selecting thecorrect coating is critical to minimising damage. lP's cargohold range provides the optimum balance of abrasion

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IMarine Coatings

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resistance and corrosion prevention, delivering the ultimateperformance. e

Intershield803Plus, its toughest ever cargo holdcoating that has been specifically designed to withstand theimpacts of modern high speed belt conveyors, frequentlyused at loading. Shooting damage from such mechanismscan have a dramatic effect on coating lifetimes.

Intershield803 is a two-pack, high performance,abrasion resistant pure epoxy coating. Its excellentmechanical properties limit mechanical damage andsubsequent corrosion. With an extensive track record andproven performance it offers outstanding long termprotection. Intergard7020 is an aluminium two-componentpure epoxy coating, offering good corrosion and abrasionresistance, and enhancing vessel earning potential.

Interbond20 1 is a surface tolerant, anticorrosiveprimer, available in two grades: a temperate version for useat temperatures down to 5°C (41°F) and a low temperaturecuring version for use at temperatures down to -5°C (23°F).

IP has achieved full type approval and proven inservice performance for the outstanding anticorrosive coat-ing Intershield300. In 2008, it was awarded the first Lloyd'sRegister IMO PSPC Type Approval Certificate for Cargo OilTanks. Mr Barry Robison, Worldwide Marine MarketManager at IP said, "Type approval in cargo oil tanks is avery important achievement for us. We recognise theimportance of the IMO PSPC in extending the reliabilityand lifetime of cargo oil tanks in crude oil tankers andhave been working hard to ensure our coating systems arecompliant. "We're particularly pleased that the first Lloyd'sRegister Certificate has been awarded to our premiumanticorrosive, Intershield300 and are confident that with anexisting, proven track record, this product will continue toprovide very high levels of newbuilding productivity and inservice performance."

In 2010 the high performance and durability ofIntershield300 was proven in service at the third specialsurvey of the 73,222dwt panamax bulk carrier Eleranta,when a Lloyd's Register surveyor confirmed the doublebottom tanks of the vessel to be in "good condition". ThelS-year-old bulk carrier, built at Samsung in 1995, hadIntershield300 applied to her ballast tanks when shewas built.

With a track record on over 12,000 vessels since1988, the legendary Intershield®300 sets an industrybenchmark in proven anticorrosive performance. Thisunique, abrasion resistant, (>9%) aluminium pure epoxycoating, offers long term asset protection, control of throughlife maintenance costs, excellent application properties andlow temperature workability.

JOTUNThe [otaguard 600 series of optimised cargo hold

coatings from [otun fulfil operational demands, protectstructural integrity and are legislation compliant.

[otaguard 690/Jotaguard 690 S offers ultimatedurability, [otaguard 660 provides exceptional robustness,while [otaguard 630 give effective protection.

The pure epoxy coatings [otaguard 690 and[otaguard 690 S provide ultimate protection of cargo holdsby withstanding abrasion, impact and gouging in toughenvironments. They also provide excellent corrosionresistance and reduce the need for maintenance. The

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coatings are FDA compliant and are certified for the carriageof grain.

[otun has successfully completed testing ofcoating systems consistent with the new IMO PSPC rulesfor cargo oil tanks (COT), scheduled to come into force inJanuary mext year. Focused on maintaining the long-termintegrity of tanks, the new standard requires that all coatingsused in the tanks must provide long-term protection againstthe corrosive effects of crude oil.

[otun has successfully completed testing forcoating systems at one of the IMO-approved test institutes(COT in the Netherlands), passing with several tank coatingsystems. Two test methods are utilised. The first testsimulates the composition of the vapour phase in crude oiltanks both in ballast and in fully loaded condition. Thesecond test simulates immersion in a crude oil tank with amodel liquid developed to replicate some of the mostcorrosive crude oils.

CHUGOKUSeaflo Neo, recently developed by Chugoku

Marine Paints (CMP), is a high performance TBT-freehydrolysis antifouling, utilising a special and uniquepolymer to deliver an ultra smooth surface and excellentself-polishing performance, thus providing long termantifouling protection, low friction resistance and low-fuelconsumption.

Sea£loNeo is the lowest VOC (330gIL) antifoulingin the hydrolysis category.

The key features are: formation of an ultrasmooth paint film, excellent self-levelling characteristics,the lowest VOC in the hydrolysis AF category andexcellent workability. CMPdeveloped the DoubleCylinder Friction ResistanceEquipment to analyse theproduct'S resistance insea-water with Tokyo Univer-sity of Science and theNational Maritime ResearchInstitute.

The test revealedthat Seaflo Neo reducedfrictional resistance by 8%compared to conventionalantifouling paints. This isexpected to translate to a 3%to 5% fuel saving when SeafloNeo is applied to ships inservice. _