Universal Primer and Surface Preparation Process - …€¦ · Cleared for Public Release – Distribution Unlimited Universal Primer and Surface Preparation Process March 12, 2015

Cleared for Public Release – Distribution Unlimited

Universal Primer and

Surface Preparation

Process

March 12, 2015

All Panel Meeting – SPC Panel

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Cleared for Public Release – Distribution Unlimited 2

Ingalls Shipbuilding

• Building four classes of ships simultaneously—

nine ships now in production

• Building second of a 5 ship contract for Arleigh

Burke-class destroyers

• Builder of record for LPD and LHA classes of

amphibious assault ships

• Builder of National Security Cutter for the U.S.

Coast Guard

DDG 51 Surface Combatants LPD 17 Class Amphibious Transport

USCG National Security Cutter

LHA 6 Amphibious Assault Ship



Outline

• Update on Zinc Rich Epoxy Primer Efforts

• Introduction to: Universal Primer and Surface Preparation Process

• Activities This Quarter

– Task 1: Identify Target Applications, Requirements, Constraints

– Task 2: Select Candidate Materials

– Task 3: Finalize Applications and Test Requirements

– Task 4: Develop Test Plan

– Task 5: Fabricate Test Articles

• Plans for Next Quarter

• Summary & Closing

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Zinc Rich Epoxy Primer

Cost Reduction Initiative

4

Proposal:

“Zinc rich epoxy primer with extended overcoat window may be applied, unless otherwise specifically prohibited, as the first coat of epoxy primer in lieu of other epoxy primers”

Zinc Rich Primer Eliminates Abrading Requirement

Abrade

Blast

Prime

Recoat

Clean

Affordability Factors:

Less labor (abrading)

Less labor (repairs)

Less consumable materials

Fewer coats of paint

Fewer inspections

“Commonality” economies

Proven on LPD 18, 20, 21,

23, 25, 26, all USCG and

MSC ships, and used on many

commercial ships

Use same language as LPD Contract Specification on LHA and DDG



Universal Primer and Surface Preparation Method

This project will reduce paint costs by qualifying a primer

with an extended overcoat window (EOW) that eliminates

the need for mechanical abrasion when over-coating the

primer during construction.

Assemble a multifunctional project team to define

requirements and identify potential coating candidates.

Conduct testing, analyze results, and deliver a report

showing whether the candidate coatings meet the

requirements for general use in new build construction of

Navy ships

5



Project Goals and Objectives

Additional Project Goals:

1. Define the process and inspection standards for abrading

epoxy that has exceeded its overcoat window.

2. Draft a specification for qualifying zinc rich epoxy

coatings with EOW.

6



Team Members

• Elzly Technology – Pete Ault

• Ingalls Shipbuilding – Project Lead – John Gunn, Mark Losset, Jay Pertuit, Ronnie Romero, John Walks

• NAVSEA 05 – Mark Ingle, Allyson Jones

• Newport News Shipbuilding – Charles Harvilicz, Arcino Quiero, John Skeldon, Joyce Wright

• SCRA – Frances Pearce

7



Team Member Roles

Ingalls Elzly

Project Initiation Lead Support

Identify Target Applications, Requirements, Constraints Lead Support

Select Candidate Materials Lead Support

Finalize Applications and Test Requirements Lead Support

Develop Validation Test Plans Co-Lead Co-Lead

Fabricate Test Article(s) Lead Support

Perform Validation Testing Lead Support

Issue Test Reports Co-Lead Co-Lead

Issue Final Report Support Lead

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Project Work Breakdown Structure (WBS)

Task 1: Identify Target Applications, Requirements, Constraints

Task 2: Select Candidate Materials

Task 3: Finalize Applications and Test Requirements

Task 4: Develop Validation Test Plans

Task 5: Fabricate Test Articles

Task 6: Perform Validation Testing

Task 7: Issue Test Reports

Task 8: Issue Final Report

9



Project Schedule

10



Project Reports and Deliverables

• Quarterly Status Reports: December 2014, March, June, September,

December 2015

• Test Plan – March 2015

• Test Reports – October 2015

• Final Project Report – November 2015

11



Task 1. Identify Target Applications,

Requirements, and Constraints

• Kickoff Meeting

• Additional meetings to identify applications, requirements, and

constraints

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Applications, Requirements, and Constraints

• Target Applications

– Interior, Non-Critical Spaces

• Requirements

– Longer overcoat windows than MIL-PRF-24441 epoxies

– Less intensive surface prep when overcoat window is exceeded

• Constraints

– VOC compliant

– Compatible with pre-construction primer and topcoats

– Meets NAVSEA health, safety, and toxicity standards

13



Task 2. Select Candidate Materials

• Solicit coating recommendations from manufacturers

• Conduct evaluation of recommended coatings

• Select one or more coatings for tests

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Request Letter to Coatings Manufacturers

Vendor –

As you may be aware, NSRP has funded a project to help identify commercially available primers that offer advantages over MIL-

PRF-24441 for use in shipyards with long build cycles. These primers should be suitable for use on interior spaces of US Navy

ships and have one or both of the following characteristics:

• Longer overcoat windows than MIL-PRF-24441 epoxies

• Less intensive requirements (than are required for MIL-PRF-24441 epoxies) to

prepare primer which has exceeded its overcoat window for subsequent coats

The products do not need to be qualified for use on US Navy Ships but should have the characteristics required for primers in interior

spaces (i.e., it should be highly likely that they could be qualified if necessary). If you have products which you believe should be

considered for this project, could you please provide me with a listing of the products, a brief summary of what advantages they

provide, and current product information (e.g., product data sheet and MSDS).

In addition to product submissions, I welcome any comments you have regarding the project including relevant testing or experience

you may have on the above issues (overcoat windows and preparation methods for primers that have exceeded the overcoat

window).

As always, thank you for your support and feel free to contact me with any questions!

J. Peter Ault, P.E.

Elzly Technology Corporation

15



Response from Coating Manufacturers

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DESCRIPTION ON

PRODUCT DATA

SHEET

MAX VOC

(g/L)

TYPICAL

DFT (mils)

MAXIMUM

OVERCOAT Surface Prep if Window Exceeded Pigments as listed on MSDS

Interzinc 75v Zinc Rich Epoxy 332 3-4 Extended See International MPG Zinc, Talc, Zinc Oxide, Iron Oxide

Intergard 267 Tie Coat 335 5 2 weeks Barium Sulfate, Titanium Dioxide, Talc

Intergard 268 Holding Primer/TC 336 1-2 Extended See International MPG Iron Oxide, Barium Sulfate, Talc

Intergard 269 Holding Primer / TC 450 1.6 Extended See International MPG Iron Oxide, Barium Sulfate, Talc

Intergard 269V Holding Primer / TC 418 1.6 Extended See International MPG Iron Oxide, Barium Sulfate, Talc

Interprime 234 Alkyd A/C Primer 340 1.5-3.5 Extended See International MPG Limestone, Talc, Iron Oxide, Zinc Oxide

Amercoat 68HS Zinc Rich Epoxy 288 2-5 Unlimited Powerwash as needed to remove all surface contaminants including zinc salts. Surface clean and dry. Quartz, Zinc

Amercoat 240 Universal 145 4-12 1 month

Sandpapering with medium or sweep blasting with a very fine abrasive. Use the verbiage in SSPC-SP7

adding that remaining paint is to be sufficiently de-glossed Nepheline Syenite, Mica Group Minerals

Dimetcote 302HReinforced Inorganic Zinc

Primer 284 2-4 3 months Powerwash as needed to remove all surface contaminants including zinc salts. Surface clean and dry. Zinc, Cement, Barium Sulfate

Amercoat 370 Multipurpose 300 4-6 6 months

Sandpapering with medium or sweep blasting with a very fine abrasive. Use the verbiage in SSPC-SP7

adding that remaining paint is to be sufficiently de-glossed

Barium Sulfate, Titanium Dioxide,

Crystalline Silica < & > 10 u

Sigmacover 435 General Purpose 344 3-6 Unlimited Dry and clean Talc, Titanium Dioxide

SIGMACOVER 456US General Purpose 324 3-6 Unlimited Dry and clean

Titanium Dioxide, Crystalline Silica < & > 10

u, Talc

Randogrip Metal Primer 253 2-7 2 months

Solvent wipe up to 2 months, after 2 months it is necessary to sweep blast or power tool clean to

roughen the surface.Nepheline Syenite, Talc, Magnesite, TiO2,

Zinc Phosphate

Zinc Clad II PlusInorganic zinc (ethyl

silicate) 320 2-4 Unlimited

requirement for overcoating is to ensure they are clean, dry, sound, and a SSPC-SP1 performed prior to

topcoating Quartz, Amorphous Silica, Mica, Zinc, ZnCl

Zinc Clad IV Zinc Rich Epoxy 340 3-5 Ulimited

requirement for overcoating is to ensure they are clean, dry, sound, and a SSPC-SP1 performed prior to

topcoating Zinc, Quartz

Copoxy Shop Primer 240 3-5 12 months

Past 12 months the epoxy must be cleaned and abraded to promote adhesion. Aggressively and

thoroughly abrade all surfaces with 80 grit sandpaper, or equivalent, to promote adhesion. Barium Sulfate, Quartz, Talc

NAME

International

PPG

Randolph Products

Sherwin Williams



Down Select Candidate Coatings

Down select process:

1. Assemble coating data

2. Team members to evaluate with regard to their shipyard requirements

3. Team members to rank products

4. Tabulate rankings and select top products for tests

Plans are to select up to 6 products to include:

1. All manufacturers, if possible

2. Coatings suitable for each shipyard represented on team

17



Task 3. Finalize Applications and Test

Requirements

• Conduct a review of the results of task 1 and 2 to obtain comments

from NAVSEA

• Finalize the applications and requirements for validation testing

18



Task 4. Develop Validation Test Plan

• Ingalls and Elzly will develop a Test Plan which will be submitted for

review by the Project Team and NAVSEA

• Comments will be incorporated into the plan

19



Task 5. Fabricate Test Articles

• Ingalls will fabricate and coat the test articles as required by the Test

Plan

20



Test Plan Ideas – Test Articles

• Yard Tool Boxes (nominally 6’ by 15’ surface)

– Coat 10-30 sq ft with primer

– Weather for as long as possible at HII

– Perform two different surface preps (water rinse and scuff sand)

– Topcoat (with what coating?)

• 24441, 23236 (which type?), chlorinated alkyd, polysiloxane

– Perform adhesion tests (pull test and X-Cut test)



Test Plan Ideas –Test Coupons

• Nominally 12, 6” by 12” cut from 1/8 to ¼” sheet

– Weather at HII, elsewhere?

– Characterize versus time – Gloss, SEM, profilometer, microhardness, wetting angle?

– Secondary surface prep – what variations?

• None

• Water wash

• Light scuff/solvent wipe

• Heavy scuff/solvent wipe

• Sweep blast

• Other?

– Topcoat (with what coating?)

• 24441, 23236 (which type?), chlorinated alkyd, polysiloxane

– Perform adhesion tests (pull test and X-Cut test)



Test Plan Ideas - Abrading Guide

• Collection of pass/fail abrading pictures from HII, elsewhere?

• Possible use of gloss or surface roughness instruments?

• Assemble into a guide similar to SSPC VIS-1

– Initial condition (various paint colors?, feathering?, various ages?, none of the

above?)

– Acceptable final condition using process A

– Acceptable final condition using process B

–

– Acceptable final condition using process n

• Processes to include pad sander, hand sanding, orbital sander,

various grits of paper (80 & 36?), scotchbrite pad…others?



Additional Project Goals

• Define the process and inspection standards for abrading

epoxy the has exceeded its overcoat window.

• Draft a specification for qualifying zinc rich epoxy

coatings with EOW.

24



Requirements for Opening Epoxies (NSI 009-32)

25

3.11.8 Nonskid application

– 3.11.8.2 If nonskid application begins within 3 to 7 days after completion of final full

primer coat application, the primer coat shall be solvent wiped with solvent

required by the NAVSEA-reviewed ASTM F718, then lightly abraded, solvent

wiped again, and a tack coat (one to 2 mils) of primer shall be applied.

3.1.18 Anti-fouling Application

– Apply the first coat of MIL-PRF-24647 anti-fouling paint when the last coat of epoxy

paint is still slightly tacky (as defined in 3.6.4) (approximately 4 to 6 hours after

paint application) and in accordance with applicable NAVSEA-reviewed ASTM

F718. If the maximum recoat time for the epoxy is exceeded, accomplish the

overcoat window requirements of 3.5, then apply a tack coat (explained in 3.6.1) of

epoxy paint one to 2 mils wet film thickness (WFT) over previously painted

surfaces. The epoxy tack coat shall be allowed to cure until tacky, and then

the first full coat of anti-fouling paint shall be applied.



Requirements for Opening Epoxies (NSI 009-32)

26

3.5 Overcoating of Non-MIL-DTL-24441 Epoxy Paints:

– 3.5.1.1 If either the manufacturer's instructions or the 30-day window (or a

specific extension approved by NAVSEA) has been exceeded, the paint

shall be reactivated by following the manufacturer's instructions for

reactivating the surface.

3.4 Overcoating of MIL-DTL-24441 with MIL-DTL-24441:

– 3.4.3 If more than 30 days has elapsed since the application of the prior

coat, the entire surface shall be cleaned in accordance with SSPC-SP 1 of

2.5. After allowing the surface to dry, the surface shall be lightly abraded

to degloss the epoxy, using a brush-off abrasive blast (preferred), power

sanding, or hand sanding using 80-120 grit, then apply the next full coat of

the system.



Requirements for Opening Epoxies

EXAMPLE (MFR’s ASTM F-718)

27

• PROVIDE INFORMATION FOR REPAIR PROCEDURES IF

THE OVERCOAT WINDOW HAS BEEN EXCEEDED: Please refer to NAVSEA Standard Item 009-32 and contact the International Paint Representative for specific guidance.



Requirements for Opening Epoxies (MFR’s Info)

28

International Marine Paint Guide:

(iv) coatings having a glossy surface which could have a detrimental effect on the

adhesion of subsequent coats should be treated by light surface abrasion, sweep

blasting, or other suitable processes which will not cut through or detract from

the performance of the underlying coating.

“631-5.2.3.3 Preparing Old Paint in Good Condition. Old paint in good

condition provides an excellent base for repainting. When a surface is

to be repainted and the old paint is not to be removed, the surface

shall be roughened with an abrasive and cleaned and dried before a

new paint is applied.”



Requirements for Opening Epoxies (MFR’s Info)

29

International Marine Paint Sweep Blast (Visual) Standards:


Typical appearance when specifications call

for “mechanically abrade coatings”

In this case abraded with grinder and 36 grit disc

Not acceptable

Over / under abraded?


Qualification of Zinc Rich Epoxy Primers

Draft Army Specification: Metal Rich Primer

31

Definition and

validation of

extended overcoat

window is

essential to

the specification.



Universal Primer and Surface Preparation Process

Plans for next quarter:

• Coat test articles and begin primer aging.

• Continue efforts to define abrading requirements and develop draft

specification for coatings with extended overcoat window.

32




Summary:

• The Team has finalized target application and requirements

• Manufacturers have recommended alternate primers

• The team has selected candidate coatings

• Ingalls and Elzly are developing a draft test plan for review

• The team expects to complete tasks 1-5 by March 30

• Coatings tests will begin early April.

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• Questions?

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Documents

Universal Primer and Surface Preparation Process - …€¦ · Cleared for Public Release – Distribution Unlimited Universal Primer and Surface Preparation Process March 12, 2015