Inspection, Maintenance and Application of Marine Coating - ABS

192 Pages·2007·9.08 MB·English

our
M I S S I O N
The mission of the American Bureau of Shipping is to serve the public
interest as well as the needs of our clients by promoting the security
of life, property and the natural environment primarily through the
development and verification of standards for the design, construction
and operational maintenance of marine-related facilities.
quality & environmental
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GUIDANCE NOTES ON
The Inspection,
Maintenance and
Application of
Marine Coating Systems
THIRD EDITION
Copyright © 2007
American Bureau of Shipping
ABSPlaza
16855 Northchase Drive
Houston, TX 77060 USA
www.eagle.org
Acknowledgement
This document is the result of a joint research project between ABS and International Paint Ltd. extending over several
years. ABS would like to thank International Paint Ltd. for its material contributions to the project and support with
the document review. ABS is also grateful to the following contributors for their dedication to this project:
Peter Contraros, Consultant to ABS
Dr. Les Callow, AMTEC Corrosion Ltd.
Dr. Jane Lomas, AMTEC Corrosion Ltd.
The ABSGuidance Notes are recognized by NACEInternational. NACE International is
a professional technical association dedicated to promoting public safety, protecting the
environment and reducing the economic impact of corrosion. Established in 1943, NACE International has more
than 17,000 members worldwide and offers technical training and certification programs, sponsors conferences,
and produces industry standards, reports, publications and software.
Disclaimer
The information contained in this publication is non-binding guidance and not Rules. Users of these Guidance Notes are
encouraged to employ or to require other approaches that meet the requirements of the applicable statutory or regulatory
requirements in individual circumstances. ABS, its subsidiaries, affiliates, agents and employees shall not be liable for any
loss or damage arising directly or indirectly from the possession, publication, use of, or reliance on, any information
whatsoever contained in these Guidance Notes and howsoever accessed.
Executive summary
The steel structure of a vessel is prone to corrosion throughout its service life. Due allowance should be made at the new
building stage and by periodic maintenance, to provide effective corrosion protection that contributes to the continued
structural integrity of the vessel.
Given the emphasis on coatings in the various mandated Rules and Regulations and the unprecedented acceleration of
coating technology, personnel involved with assessing coatings should have factual knowledge of coating systems and the
applicable standards. It is the intent of these Guidance Notes to meet this need in a straight-forward and practical
manner.
ABS GUIDANCE NOTES ON THE INSPECTION, MAINTENANCE AND THE APPLICATION OF MARINE COATINGS SYSTEMS i

CONTENTS
CHAPTER 1: Corrosion
1 General..........................................................................................................................................................................1
2 Uncoated steel and the corrosion reaction...................................................................................................................1
3 Factors influencing corrosion rates..............................................................................................................................3
4 Types of corrosion.........................................................................................................................................................4
CHAPTER 2: Coatings and corrosion
1 General........................................................................................................................................................................11
2 Factors affecting coating lifetime...............................................................................................................................11
3 Types of coating breakdown.......................................................................................................................................13
4 Anti-corrosion protection by coatings........................................................................................................................15
5 Coating compatibility.................................................................................................................................................16
6 Stripe coats.................................................................................................................................................................17
CHAPTER 3: Coating types and their uses
1 General........................................................................................................................................................................19
2 Paint composition.......................................................................................................................................................20
3 Binders........................................................................................................................................................................20
4 Cross-linked (thermoset) coatings.............................................................................................................................20
5 Thermoplastic coatings...............................................................................................................................................21
6 Pigments and extenders..............................................................................................................................................22
7 Solvents.......................................................................................................................................................................20
8 Anti-corrosion paints..................................................................................................................................................23
9 Impact and abrasion-resistant coatings......................................................................................................................24
10 Shop primers...............................................................................................................................................................25
CHAPTER 4: Surface preparation
1 General........................................................................................................................................................................27
2 Surface cleanliness......................................................................................................................................................27
3 Surface cleaning and conditioning.............................................................................................................................28
4 Solvent cleaning..........................................................................................................................................................28
5 Abrasive blasting.........................................................................................................................................................29
6 Spot blasting...............................................................................................................................................................31
7 Sweep blasting............................................................................................................................................................32
8 Hydro blasting/water jetting.......................................................................................................................................32
9 Power tool cleaning....................................................................................................................................................33
10 Pickling.......................................................................................................................................................................35
11 Preparation of non-ferrous metals..............................................................................................................................35
12 Edge and weld preparation at new building..............................................................................................................35
13 Surface preparation standards....................................................................................................................................38
CHAPTER 5: Paint Application
1 General........................................................................................................................................................................43
2 Surface preparation.....................................................................................................................................................43
3 Film thickness measurement......................................................................................................................................43
4 Methods of paint application......................................................................................................................................43
5 Curing conditions.......................................................................................................................................................46
CHAPTER 6: Cathodic protection in ballast tanks and cargo holds
1 General........................................................................................................................................................................49
2 Sacrificial anodes........................................................................................................................................................49
3 Impressed current cathodic protection.......................................................................................................................52
ABS GUIDANCE NOTES ON THE INSPECTION, MAINTENANCE AND THE APPLICATION OF MARINE COATINGS SYSTEMS iii
CONTENTS
CHAPTER 7: Anti-Fouling
1 General........................................................................................................................................................................55
2 Fouling........................................................................................................................................................................55
3 Anti-fouling system (AFS)..........................................................................................................................................56
4 Self-polishing anti-fouling coatings............................................................................................................................58
5 Insoluble matrix (controlled depletion) coatings......................................................................................................58
6 Foul release coatings..................................................................................................................................................58
7 Coating compatibility.................................................................................................................................................58
CHAPTER 8: Performance Standards for Protective Coatings
1 Introduction................................................................................................................................................................59
2 Scope and application.................................................................................................................................................60
3 Review of the inspection agreement...........................................................................................................................60
4 Primary surface preparation.......................................................................................................................................60
5 Secondary surface preparation....................................................................................................................................62
6 Coating application....................................................................................................................................................64
7 Coating inspection requirements...............................................................................................................................65
8 Verification requirements...........................................................................................................................................67
9 Coating film thickness measurements........................................................................................................................67
10 Coating system approval............................................................................................................................................68
11 ABSCPSGuide...........................................................................................................................................................70
CHAPTER 9: Coating requirements for void spaces...............................................................................73
CHAPTER 10: Coating requirements for cargo spaces
1 Oil tankers..................................................................................................................................................................75
2 Bulk carriers................................................................................................................................................................75
CHAPTER 11: Coating Technical File
1 Statement of Compliance or Type Approval Certificate.............................................................................................77
2 Technical datasheet.....................................................................................................................................................77
3 Shipyard work records................................................................................................................................................78
4 Inspection procedures................................................................................................................................................78
5 Daily logs....................................................................................................................................................................78
6 Shipyard’s verification report......................................................................................................................................79
7 In-service repair procedure.........................................................................................................................................79
CHAPTER 12: Coating failures
1 General........................................................................................................................................................................81
2 Coating defects during application............................................................................................................................81
3 In-service coating failures...........................................................................................................................................85
CHAPTER 13: Assessment of coating breakdown
1 Introduction................................................................................................................................................................97
2 Assessment of existing coating systems for all vessels except tankers......................................................................97
3 Assessment of existing coating systems cargo holds..................................................................................................99
4 Assessment of existing surface coating systems in oil carriers chemical carriers, and double hull oil carriers......101
CHAPTER 14: Examples..................................................................................................................................111
iv ABS GUIDANCE NOTES ON THE INSPECTION, MAINTENANCE AND THE APPLICATION OF MARINE COATINGS SYSTEMS
CONTENTS
CHAPTER 15: Glossary and definitions.....................................................................................................137
CHAPTER 16: Appendices..............................................................................................................................141
Appendix A – IMOPSPCMSC.215 (82)..................................................................................................................142
Appendix B – IACSPR 34........................................................................................................................................161
Appendix C – IACSSC122......................................................................................................................................164
Appendix D – IACSSC 127......................................................................................................................................165
Appendix E – IACSPRZ17......................................................................................................................................166
Appendix F – IACSZ9.............................................................................................................................................177
ABS GUIDANCE NOTES ON THE INSPECTION, MAINTENANCE AND THE APPLICATION OF MARINE COATINGS SYSTEMS v