Cleared for Public Release – Distribution Unlimited Universal Primer and Surface Preparation Process March 12, 2015 All Panel Meeting – SPC Panel
Cleared for Public Release – Distribution Unlimited
Universal Primer and
Surface Preparation
Process
March 12, 2015
All Panel Meeting – SPC Panel
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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
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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
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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
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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
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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.
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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
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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
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Project Schedule
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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
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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
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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
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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
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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
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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
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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
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Task 5. Fabricate Test Articles
• Ingalls will fabricate and coat the test articles as required by the Test
Plan
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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)
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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)
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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?
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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.
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Requirements for Opening Epoxies (NSI 009-32)
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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.
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Requirements for Opening Epoxies (NSI 009-32)
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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.
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Requirements for Opening Epoxies
EXAMPLE (MFR’s ASTM F-718)
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• 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.
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Requirements for Opening Epoxies (MFR’s Info)
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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.”
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Requirements for Opening Epoxies (MFR’s Info)
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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?
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Qualification of Zinc Rich Epoxy Primers
Draft Army Specification: Metal Rich Primer
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Definition and
validation of
extended overcoat
window is
essential to
the specification.
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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.
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Universal Primer and Surface Preparation Process
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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Universal Primer and Surface Preparation Process
• Questions?
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