© - copyright bureau veritas coating systems - bvn tm coat 01 head office – v0 – june 2014

© - Copyright Bureau Veritas

Coating systems - BVN TM COAT 01

Head Office – V0 – June 2014

2© - Copyright Bureau Veritas Bureau Veritas S.A. internal use only – Coating system s - BVN TM COAT01 – V0 – June 2014

CONTENT

► 1 – Objectives

► 2 – Coating Basic Knowledge

► 3 – Review of Applicable Regulations

► 4 – Typical Tasks for Survey


1- Objectives


• To be familiar with the coating systems

• Study the requirements related to approval of Coating systems for IMO PSPC

1 - Objectives


2 – Coating Basic Knowledge


Coatings Families

Coatings by Physical drying

(Chlorinated rubber, Vinyl Paint )

Hard Coatings

« Chemical » drying

Dry by oxidation (Oil, Alkyd, epoxy-

ester Paints)

Epoxy base Coating

Others systems ( Polyurethane,

Polyester, siloxane etc.)

PSPC

► Coatings families overview



• Curing is obtained by mixing the Base and the Hardener in clearly defined proportions. A chemical reaction then occurs, causing cross linking of the molecular chains. After curing, these paints provide a hard film.

Crosslink reaction (T, Ratio Base/Hardener)

Base (epoxy) +

Hardener

Crosslink Network (Hard film)

► Paint which dry by chemical reaction: Epoxy coatings

solvent

Residual solvent

Initial mixing (Base + Hardener + Solvents)


Coating Manufacturer’s curing time and mix ratio of epoxy coatings shall be carefully respected.


• Coatings have two major components: Binder & Pigments/Extenders

Binder

(Base + Hardener)

► Coating Main components/Formulation

Pigments

is part of nonvolatile film-forming components. It provide internal cohesion,

flexibility and adhesion with substrate and gives the chemical resistance

provide protective properties or decorative properties (color, opacity and gloss)

Fillers or Extenders are organic/inorganic particulates which:•improve coating impermeability,•adjust rheological, gloss and mechanical properties,• reduce cost formulation



Solvents + Additives

Long Hydrocarbonate

chains

(binder)

Vehicle Scheme

• Vehicle is the liquid part of the coating. It consists of the binder, solvent and Additives.




• Additives which confer special properties to the coating product:

Anti-settling agent, Plasticizer, Thickeners etc.

UV absorber

Rheological agent

Polymeric chains

Anchor group

Polymeric chains

Anchor group

Polymeric chains

Anchor group

Anti-skinning

agentAnti-foaming agent




Raw materials Storage

Solvents, Binders, Pigments, Extenders, Additives

Agglomerates be divided into primary particles

Balance/ Mass Flow-meter/ Dissolver

Pre mix solution

Part of Vehicle (Solvent +Binder), Pigments, Extenders and additives

are mixed

Grinding

Pigments, Extenders are filtered

Milling

Machine

Let down / Adjusting

Addition of Pigments/ Extenders, Vehicle ,additives

with test of fines of grind, fineness and Viscosity and

Sag meter

Balance/ Mass Flow-meter/ Dissolver

Final Mix

Paint component are mixed and final tested ,color adjusted

COV tested / Drying time

Filtering / Packing

Paint is filteredFilter

Storage / Delivery

► Coating Formulation Production



► Shop primers families overview

*Silicate and Epoxy Shop primer : A review : JPLC July 2006

• Shop primers shall be distinguished from coating:

- Shop primer provide temporary protection against corrosion

compare to coating.

- Steel plate shop primed can be welded, not the coated steel plates



• Ethyl Zinc Silicate based shop primer is used for marine applications. Pigment is Zinc and Binder is Ethyl Silicate base.

Zinc is sacrificing under atmospheric conditions and creating Zn salts. Then these salts fill the voids in the film and the primer provides a barrier against the contaminants.

Air gaps

Zinc dust (5-10 m) Silicate binder

Shopprimer thickness between 15 m / 60 m 15 m / 25 m

► Shop primers families overview



► Coating System definition:

Steel Substrate

Primer coat: Adhesion and/or active corrosion protection

Intermediate coat: barrier effect, build-up thickness, compatibility

Finish coat: Surface aspect, gloss, color, functionality

• Total number of coats• Chemical nature, color definition / coat• Individual coat and total dry film thickness (DFT)



► Coating System vs Ship Areas*

Hull & Bootop

Top Coat PMA-BiocideTBT free/1 Coat

Intermediate Coat Pure Epoxy / 1 Coat

Primer Coat Tar free Epoxy / 1 Coat

Average Total DFT(m)

325 – 625

FunctionalityAnti-fouling, Abrasion, Anticorrosion

*Coating manufacturer data – ISO 12944-5



► Coating System vs Ship Areas*

Cargo & Grey water Tanks

Top Coat N.A.

Intermediate CoatPhenolic or Pure Epoxy / 1 or 2 Coats

Primer Coat Phenolic or Pure Epoxy / 1 Coat

Average Total DFT(m)

250 - 300

FunctionalityAnticorrosion, Chemical resistant

*Coating manufacturer data – ISO 12944-5



3 – Review of Applicable Regulations



• IMO MSC.215 (82) – PSPC WBT for dedicated seawater ballast tank

• IMO MSC.288(87) – PSPC COT for cargo oil tanks of crude oil tankers

• IMO MSC.244(83) – PSPC VSP for void spaces on bulk carriers and oil tankers

• IACS UI SC 223 for PSPC WBT

• IACS UI SC 259 for PSPC COT

• IACS UR Z 17 Procedural requirements for service suppliers

• Bureau Veritas NR 530 Coating performance standard

► Specification & Testing requirements to be studied related to the

Performance Standard for Protective Coating (PSPC):

Overview of applicable regulations


SOLAS Reg. II-1 / 3-2 amended by MSC.216(82)

WBT All Ships ≥ 500 G.T. , DSSS Bulk Carriers ≥ 150 M

Dec. 2006

- MSC.215 (82)

- MSC.216 (82)

Adoption of PSPC - WBT

1st July 2008

Keel laying*

Delivery

* In absence of a building contract

Building contract

IACS UI SC 223

1st Jan. 2009 1st July 2012

Contract for construction of CSR ships

IACS PR 34

NR 530 Notation CPS (WBT)

► PSPC WBT – Key dates



May 2010

- MSC.288 (87)

- MSC.291 (87)

Adoption of PSPC - COT

1st Jan. 2013

Keel laying*

Delivery

* In absence of a building contract

Building contract

1st July 2013 1st Jan. 2016

SOLAS Chap. II-1 / Reg. 3-11 as amended by MSC.291 (87)

Crude oil tankers ≥ 5.000 Tonnes Dwt. MARPOL 73/78 Reg.1 Annex1

► PSPC COT – Key dates



► Bureau Veritas NR 530



3 – Applicable Regulations

► Bureau Veritas NR 530


Coating Technical File (CTF)

Primary Surface preparation (Shop primer application )

After the Blocks Construction

After the Blocks Assembly (Erection)

Tri-Partite Agreement (TPA) Approved Coating system, Surface preparation, Coating

application inspections

Coating System ApprovalStatement of Compliance Certificate or Type Approval

Certificate

Shipyard, Shipowner, Coating Manufacturer

Administration or Recognized Organization

Shipyard / Coating Inspector

Administration or

Recognized Organization

Coating Manufacturers

Third Party

► IMO PSPC – General Principles



• The coating system is to be type approved as per IMO PSPC Tab.1-1.3 procedures

• Compatibility between coating system and shop primer (SP) tested as per

IMO PSPC Tab.1-3.2 (Cross over test)

≈ 20 m

1st coat

2nd coat

≈ 160 m

Steel

≈ 160 m

SP - Intermediate protection is to be compatible with the approved CS,

if not is to be removed≈ 20 m

1st coat

2nd coat

≈ 160 m

Steel

≈ 160 m

SP - Intermediate protection is to be compatible with the approved CS,

if not is to be removed

► PSPC – Coating system approval

Instructions TTE 3040 Type Approval of Coating Systems



► Coating system approval procedure - BV NR 530 Sec 5



Epoxy-based system

PSPC Tab.1-1.3

Outline of company

List of production facilities

QMS certificate

Technical Data Sheet(s) (TDS)

Material Safety Data Sheet (MSDS)

Infrared and Specific gravity data,

(for each manufacturing sites)

Test report(s)

PSPC Annex 1 Sec.2, as per PSPC Tab.1

Type of coating

Inspection (Surface preparation, application procedure)

Coating manufacturerCoating

specification

(TDS)

IMO PSPC - IACS UI SC 223/259 - NR 530

Method A (Laboratory tests of PSPC App.1 and App.2)

Method C (Marintek test level B1)

Method B (5 years field exposure)

Audit

IACS UR Z17 Classification Society

Testing

coating sys. Laboratory

Documentation Compilation

Coating manufacturerApproval request

AdE. 616

BVN Local office Transmit TAC request

(MPA)

1



1IMO PSPC Tab.1–1.3 / NR 530

Review of coating specification / TDS

(PSPC Tab.1 and Sec. 3.4.2.2)

Review of Test report, IR/SG data

(PSPC Annex 1, UI SC 223/259 Method A)

Review

Documentation BV HO DO/EMC

Audit of production

site(s)BVN Local office(s)

Draft TAC(s)

IMO PSPC - UI SC 223/259 Method D - NR 530 – NR320

Documentation (raw material suppliers, quality control etc.)

Production units and testing

Formulations, Raw material supply

Batch records, Marking

Assessment report_Recognition (App.A01 – TTE 3002)

Checklist_Recognition (App.01 – TTE 3040)

Completion and Check of

TAC(s)

BVN Local office Coating manufacturerSigned

TAC(s)

Manufacturer site(s)

BV HO DO/EMC

Recognition Certificates

Audit report

Check list



► Overview Testing procedure (Method A) - PSPC WBT

Testing laboratory is to apply following standards:

For surface preparation of test specimens:

•ISO 8501-1: 1988/Suppl.1994 – Visual assessment of surface cleanliness

•ISO 8503-1/2: 1988 – Surface roughness characteristics of blast cleaned steel

•ISO 8502- 6/9: 1988 – Test for assessment of surface cleanliness Bresle test

For testing methods:

• ISO 2811-1/4: 1997 – Determination of density

• ISO 4628-2/3: 2003 – Assessment of degree of blistering / rusting

• ISO 4624:2002 – Pull-off test for adhesion

• ASTM D4145:1998 – Standard test method for Coating Flexibility

• ISO 6270-1:1988 – Continuous condensation



Thickness steel plate 3 mm

N°1 (Upper Deck)

N°5 (Bottom heated)

N°2 (Bottom)

Cross over test

N°3 (Side cooled)

N°4(Side not cooled)

1

2

3

5

4

Simulated Water Ballast Tank Test (6 months)

40 mm

25 mm

200 mm

400 mm

Zinc anode

Ø 8 mm

100 mm

40 mm

25 mm 40 mm

25 mm

200 mm

400 mm

200 mm

400 mm

Zinc anode

Ø 8 mm

100 mm

Zinc anode

Ø 8 mm

Zinc anode

Ø 8 mm

100 mm

40 mm

25 mm

200 mm

400 mm

Zinc anode

Ø 8 mm

100 mm

40 mm

25 mm 40 mm

25 mm

200 mm

400 mm

200 mm

400 mm

Zinc anode

Ø 8 mm

100 mm

Zinc anode

Ø 8 mm

Zinc anode

Ø 8 mm

100 mm

40 mm

25 mm

200 mm

400 mm

Zinc anode

Ø 8 mm

100 mm

40 mm

25 mm 40 mm

25 mm

200 mm

400 mm

200 mm

400 mm

Zinc anode

Ø 8 mm

100 mm

Zinc anode

Ø 8 mm

Zinc anode

Ø 8 mm

100 mm




Thickness steel plate 3 mm

150 mm

150 mm

Two panels to be tested

Condensation Chamber Test (6 months)




400

5mm5mm

150

5mm5mm

1mm1mm1mm1mm10mm10mm

3mm3mm 10mm10mm




400




► Overview Testing procedure (Method A) - PSPC COT

Testing laboratory is to apply following standards:

For surface preparation of test specimens:

•ISO 8501-1: 1988/Suppl.1994 – Visual assessment of surface cleanliness

•ISO 8503-1/2: 1988 – Surface roughness characteristics of blast cleaned steel

•ISO 8502- 6/9: 1988 – Test for assessment of surface cleanliness Bresle test

For testing methods:

• ISO 2811-1/4: 1997 – Determination of density

• ISO 2812-1: 2007 – Immersion in liquids other than water

• ISO 4628-2/3: 2003 – Assessment of degree of blistering / rusting

• ISO 8217:2005 – Specification of marine fuels

• ISO 6618:1997– Determination of acid or base number

• ASTM D1141-98:2008 – Standard Practice for preparation of substitute ocean water



► IMO MSC.288 (87) – Appendix 1 Gas-Tight Cabinet Test

► Duration: 3 months

► Test gas composition as per PSPC (COT) Annex 1 – Sec.5

► Test temp 60°C, RH 95%, Monitoring for test gas refreshed

150 mm

100 mm

Two panels to be tested for each test

► IMO MSC.288 (87) – Appendix 2 Immersion Test

► Duration: 6 months

► Test liquid composition as per PSPC (COT) Annex 1 – Sec.6

► Test temp 60°C

►Coating identification: IR, SG, Batch No.

►Test panel preparation and Tests conditions

►Test results: No blisters and No rusting

► Test reports shall include information as per PSPC COT Annex 1 Sec.4:



► Cross over test - IMO MSC.215(82) Table 1 § 3.2

Type approved Coating System + Shop primer as per PSPC Annex 1 (Method A)

Tested Shop Primer compatibility as per PSPC Appendix 1 § 1.7 (Panel no.2)

Demand for type

test SP2

PassCross over test

Issued Type Approval for Coating System

EBS1 + SP2; SP3 etc.

Epoxy Based System (EBS2)+

Shop Primer (SP2)


Shop Primer (SP1)

Demand for type

test EBS1


Shop Primer (SP3)

Demand for type

test SP3



N°2 (Bottom)

Cross over test

Cross over Test (6 months)

40 mm

25 mm

200 mm

400 mm

Zinc anode

Ø 8 mm

100 mm

40 mm

25 mm 40 mm

25 mm

200 mm

400 mm

200 mm

400 mm

Zinc anode

Ø 8 mm

100 mm

Zinc anode

Ø 8 mm

Zinc anode

Ø 8 mm

100 mm

2

Static immersion

► Cross over test - IMO MSC.215(82) Table 1 § 3.2



4 – Typical Tasks for Survey


►Check documentation requested in NR 530, Sec 5 [2.2]


► Recognition of testing laboratory – BV NR 530 / IACS UR Z 17

Instructions TTE 3005 Recognition of testing laboratory as per NR 320

Instructions TTE 3040 Type approval of coating system as per IMO PSPC


► Assessment to check Audit requirements as per NR 530, Sec 5 [2.3]:



Instructions TTE 3005 Recognition of testing laboratory as per NR 320


• Training of personnel & Personnel records

• Supervision

• Equipment and facilities (look for test standard methods)

• Procedures covering testing activities (look for IMO PSPC testing procedures)

• Subcontractors

• Verification

• Reporting


►Check documentation requested in NR 530, Sec 5 [3.5.2]


► Coating Manufacturer Assessment – BV NR 530 - IACS UI SC 223/259

Instructions TTE 3002 BV Mode II Recognition



►Assessment to check Audit requirements as per NR 530, Sec 5 [3.5.3]:



Instructions TTE 3002 BV Mode II Recognition


• Management of type approval with the Society

• Training & qualification of personnel

• Traceability of products

• Management of equipment including maintenance and calibration

• Testing standards and procedures (look for IMO PSPC testing requirements)

• Management of complaints and non-conform products

• Verify items of Checklist recognition coating manufacturer (App.01 – TTE 3040)


►Main items of Checklist recognition coating manufacturer (App.01 – TTE 3040)



• Formulation adjustment clearly state in the Quality control procedures

• Manufacturer ‘s quality control system ensures that all current production is the

same formulation as that supplied for type approval certificate

• Traceability and Quality control records of raw material and coating batch production

• Records of Coating Quality control tests (i.e. viscosity, specific gravity, airless spray

characteristics)

• Technical Data Sheets up to date and Quality control procedure of technical centre

© - copyright bureau veritas coating systems - bvn tm coat 01 head office – v0 – june 2014

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