Marine Painting Manual

Size: px

Start display at page:

Download "Marine Painting Manual"

Cordelia Lawson
6 years ago
Views:

1 Marine Painting Manual A. M. Berendsen TNO Paint Research Institute Delft, The Netherlands Ш^м Netherlands Organization for Applied Scientific Research, Delft CMIO National Foundation for the l M 5 Co-ordination of Maritime Research, = ===Г Rotterdam Graham & Trotman A member of the Kluwer Academic Publishers Group LONDON/DORDRECHT/BOSTON

CONTENTS page CHAPTER I: THE PROTECTION OF DIFFERENT PARTS OF SHIPS UNDER CONSTRUCTION 1.1. Introduction 1 1.2. Protective methods 1 1.2.1. PAINTING IN SECTION BUILDING (BLOCK PAINTING) 5 1.2.1.1 Operations in the coating hall 5 1.

2 CONTENTS page CHAPTER I: THE PROTECTION OF DIFFERENT PARTS OF SHIPS UNDER CONSTRUCTION 1.1. Introduction Protective methods PAINTING IN SECTION BUILDING (BLOCK PAINTING) Operations in the coating hall Operations on the slipway and during final construction (fitting-out) Summary of painting in section building BUILDING IN THE SHOP-COAT Operations in the section hall Operations on the slipway and during final construction Summary of building in the shop-coat Paint systems for the separate parts of a ship in new construction UNDERWATER PARTS Requirements Suitable paint systems Procedures THE BOOTTOP ZONE Requirements Suitable paint systems TOPSIDES AND EXTERIOR PARTS ON DECK (SUPERSTRUCTURES) Requirements Suitable paint systems MAIN DECKS AND GANGWAYS Requirements Suitable paint systems Procedures 14

1.3.5. DRY-CARGO HOLDS 1.3.5.1 Requirements 1.3.5.2 Suitable paint systems 1.3.6. TANKS 1.3.6.1 Introduction 1.3.6.2 Procedures 1.3.6.3 Requirements 1.3.6.4 Suitable paint systems a.

3 DRY-CARGO HOLDS Requirements Suitable paint systems TANKS Introduction Procedures Requirements Suitable paint systems a. Water ballast tanks b. Fuel tanks с Lubricating oil tanks d. Drinking (potable) water tanks e. Water tanks other than ballast water or drinking water tanks f. Cargo tanks ENGINE ROOMS Requirements Suitable paint systems 'WET' ACCOMMODATION AND SERVICE SPACES Requirements Suitable paint systems DRY ACCOMMODATION SPACES Introduction Requirements Suitable paint systems APPENDIX I.A.: SUMMARY OF THE PROTECTION OF THE SEPARATE PARTS OF A SHIP UNDER CONSTRUCTION 30 APPENDIX l.b. : HULL ROUGHNESS APPENDIX l.c. : PART OF A RESISTANCE (COMMODITY) LIST CHAPTER II: THE PROTECTION OF DIFFERENT PARTS OF OFFSHORE STRUCTURES UNDER CONSTRUC TION 2.1. Introduction 50

2.2. Building/Painting of fixed offshore platforms 50 2.2.1. INTRODUCTION 50 2.2.2. PROTECTIVE METHODS 51 2.3. Protective systems for the separate parts of offshore platforms 54 in new construction 2.

4 2.2. Building/Painting of fixed offshore platforms INTRODUCTION PROTECTIVE METHODS Protective systems for the separate parts of offshore platforms 54 in new construction GENERAL UNDERWATER (SUBMERGED) ZONE Requirements Suitable protective systems TIDAL AND SPLASH ZONE Requirements Suitable protective systems a. Silica-filled (flint-reinforced) compounds b. Monel 400 (nickel-copper alloy) sheeting с Glass-flake reinforced epoxy coatings d. Thick rubber or neoprene (synthetic rubber) coatings e. Bituminous wrappings UNDERDECK AREA Requirements Suitable protective systems ATMOSPHERIC ZONE (TOPSIDE FACILITIES) Requirements Suitable protective systems DECKS (WORKING DECKS AND HELIDECKS) Requirements Suitable protective systems HIGH TEMPERATURE AREAS Requirements Suitable protective systems TANKS Requirements Procedures

2.3.8.3. Suitable protective systems 62 a. Drinking (potable) water tanks 62 b.

5 Suitable protective systems 62 a. Drinking (potable) water tanks 62 b. Tanks for crude oil/ballast water/drilling mud/drilling water/ 62 fresh water с Tanks for fuel oil/white petroleum products 62 d. Tanks for chemicals and solvents 62 e. Tanks for methanol (and other strong solvents) RISERS Requirements Suitable protective systems SEA WATER PIPING SYSTEMS Requirements Suitable protective systems SUPPLIERS EQUIPMENT 65 APPENDIX 2.A. : PART OF NACE-STANDARD RP , RECOMMENDED 66 PRACTICE, CORROSION CONTROL OF STEEL, FIXED OFFSHORE PLATFORMS ASSOCIATED WITH PETROLEUM PRODUCTION APPENDIX 2.B. : BUILDING/PAINTING OPERATIONS FOR MODULES 70 APPENDIX 2.C. : WEIGHT LOSSES OF STEEL 37 DUE TO CORROSION IN 75 VARIOUS ENVIRONMENTS APPENDIX 2.D. : EXAMPLES OF CURRENT SYSTEMS FOR THE ATMOSPHERIC 76 ZONE CHAPTER III: SURFACE PREPARATION 3.1. General Surface preparation of steel DEGREASING REMOVAL OF MILL SCALE BY WEATHERING 78

3.2.3. MECHANICAL SURFACE PREPARATION 79 3.2.3.1 Hand-cleaning 79 3.2.3.2 Mechanical-cleaning (power-tool cleaning) 79 3.2.3.3 Preparation grade 80 3.2.4. BLAST-CLEANING 82 3.2.4.1 Methods 83 3.2.4.2 Abrasives 87 3.

6 MECHANICAL SURFACE PREPARATION Hand-cleaning Mechanical-cleaning (power-tool cleaning) Preparation grade BLAST-CLEANING Methods Abrasives Surface roughness Preparation grade Surface contamination by water soluble salts Working conditions FLAME-CUTTING PICKLING Sulphuric acid/phosphoric acid method Hydrochloric acid/phosphoric acid method Phosphoric acid/phosphoric acid method THE USE OF RUST CONVERTORS COMPARISON OF PRETREATMENT METHODS FOR STEEL RECENT ISO STANDARDS Surface preparation of galvanized steel SWEEP-BLASTING (for hot-dip galvanized steel) CHEMICAL PRETREATMENT MECHANICAL CLEANING Surface preparation of aluminium 101 APPENDIX 3.A. : PROFILES (ROUGHNESS) PRODUCED BY SOME ABRASIVES 102 APPENDIX 3.B. : SURFACE PROFILE (ROUGHNESS) OF ABRASIVE BLAST- 103 CLEANED SURFACES APPENDIX 3.C. : GRADES OF SURFACE PREPARATION BY BLAST-CLEANING 105

CHAPTER IV: PAINTS AND PAINT SYSTEMS 4.1. Definitions; aims of painting 106 4.2. Paint systems 107 4.3. Composition of paints 109 4.3.1. BINDERS 109 4.3.2. PIGMENTS AND EXTENDERS 110 4.3.3. SOLVENTS AND THINNERS 110 4.

7 CHAPTER IV: PAINTS AND PAINT SYSTEMS 4.1. Definitions; aims of painting Paint systems Composition of paints BINDERS PIGMENTS AND EXTENDERS SOLVENTS AND THINNERS Classification of paints CLASSIFICATION OF PAINTS ACCORDING TO DRYING MECHANISM Physically drying paints Chemically drying paints Important types of paint used in the building of ships 115 and offshore structures PRIMERS Common primers for steel Special primers for steel a. Prefabrication primers b. Touch-up primers с Holding primers d. System primers e. Universal primers Primers for non-ferrous metals PAINT MATERIALS, CLASSIFIED ACCORDING TO THE BINDER TYPE Paints based on drying oils Bituminous paints Alkyd resin paints Chlorinated rubber paints Vinyl paints Epoxy paints Coal-tar epoxy paints Polyurethane paints

4.5.2.9 Polyurethane tar paints 129 4.5.2.10 Zinc silicate paints 129 4.5.2.11 Acrylic paints 131 4.5.2.12 Unsaturated polyester resin coatings 132 4.5.2.13 Silicon resin paints 132 4.5.2.14 Dispersion paints 132 4.

8 Polyurethane tar paints Zinc silicate paints Acrylic paints Unsaturated polyester resin coatings Silicon resin paints Dispersion paints SPECIAL PRODUCTS, CLASSIFIED ACCORDING TO THEIR FUNCTIONS Varnishes (clear coatings) Anti-fouling paints 134 a Soluble-matrix anti-fouling paints 136 b. Contact-matrix anti-fouling paints 136 с Self-erodable (polishing, ablative) anti-fouling paints 137 d. Future anti-foulings Non-slip/non-skid paints Paints with laminar (flake) pigments Heat-resistant paints Fire-retardant and fire-resistant paints DATASHEETS TABULAR COMPARISON OF THE DIFFERENT PAINT TYPES 143 APPENDIX 4.A. APPENDIX 4.B. APPENDIX 4.C. PIGMENTS AND EXTENDERS 145 SOLVENTS AND DILUENTS (THINNERS) 150 CLASSIFICATION OF PAINTS ACCORDING TO DRYING 151 MECHANISM APPENDIX 4.D. : SPECIAL PRIMERS FOR STEEL 152 APPENDIX 4.E. : EXAMPLE OF A DATA SHEET FOR A COAL-TAR EPOXY PAINT 153 APPENDIX 4.F. : COMPARISON OF PAINT TYPES ACCORDING TO THEIR BINDER 156 COMPOSITION APPENDIX 4.G. : FOULING AND ANTI-FOULING 160 CHAPTER V : PREFABRICATION (SHOP) PRIMERS 5.1. Introduction 167

5.2. Requirements for prefabrication (shop) primers 168 5.3. Blast-cleanliness and surface roughness 169 5.3.1. BLAST-CLEANLINESS 169 5.3.2. SURFACE ROUGHNESS 169 5.4.

9 5.2. Requirements for prefabrication (shop) primers Blast-cleanliness and surface roughness BLAST-CLEANLINESS SURFACE ROUGHNESS Dry film thickness of the prefabrication (shop) primer Behaviour during automatic welding and flame-cutting Common types of prefabrication (shop) primers ZINC DUST CONTAINING PREFABRICATION PRIMERS Composition Dry film thickness, anti-corrosive properties, recoatability Welding (flame-cutting) fumes Comparison of zinc-epoxy and zinc silicate prefabrication (shop) 173 primers ZINC-FREE PREFABRICATION PRIMERS Composition Dry film thickness, anti-corrosive properties, recoatability Welding (flame-cutting) fumes Comparison of zinc dust free epoxy prefabrication primers with 175 reinforced wash primers 5.7. Summary 175 APPENDIX 5.A. : PROPERTIES OF THE MAIN TYPES OF PREFABRICATION 177 (SHOP) PRIMERS CHAPTER VI: STORAGE AND APPLICATION OF PAINTS 6.1. Storage Preparation before application Application methods 180

6.3.1. BRUSHING 180 6.3.2. ROLLING 181 6.3.3. CONVENTIONAL SPRAYING (AIR SPRAYING) 182 6.3.4. AIRLESS SPRAYING 183 6.4. Application conditions 185 6.4.1. ATMOSPHERIC HUMIDITY 185 6.4.2. TEMPERATURE 187 6.

10 BRUSHING ROLLING CONVENTIONAL SPRAYING (AIR SPRAYING) AIRLESS SPRAYING Application conditions ATMOSPHERIC HUMIDITY TEMPERATURE OTHER CONDITIONS Supervision/Inspection 189 APPENDIX 6.A. : RELATION BETWEEN AIR TEMPERATURE AND MAXIMUM 190 WATER VAPOUR CONTENT APPENDIX 6.B. : RELATION BETWEEN DEW POINT, AIR TEMPERATURE AND 191 RELATIVE HUMIDITY APPENDIX 6.C. : GRAPH SHOWING THE RELATIONSHIP BETWEEN AIR 192 TEMPERATURE, RELATIVE HUMIDITY AND DEW POINT CHAPTER VII: MAINTENANCE OF PAINT SYSTEMS 7.1. General Maintenance operations on the various parts of ships GENERAL MAINTENANCE OF THE UNDERWATER HULL MAINTENANCE OF TANKS Offshore maintenance 201

APPENDIX 7.A. : RELATION BETWEEN THE DISTRIBUTION OF RUST SPOTS AND 203 THE AREAS TO BE REPAIRED APPENDIX 7.B. : AREA INVOLVED WHEN TOUCHING-UP A RUST SPOT 204 APPENDIX 7.C. : DAMAGED AREA CAUSED BY SPOT-BLASTING 205 8.

11 APPENDIX 7.A. : RELATION BETWEEN THE DISTRIBUTION OF RUST SPOTS AND 203 THE AREAS TO BE REPAIRED APPENDIX 7.B. : AREA INVOLVED WHEN TOUCHING-UP A RUST SPOT 204 APPENDIX 7.C. : DAMAGED AREA CAUSED BY SPOT-BLASTING Introduction The contract painting speciflcation (painting schedule) BASIC CLAUSES SUPPLEMENTARY CLAUSES The paint list The checklist The maintenance painting schedule 210 APPENDIX 8.A. : EXAMPLE OF CONTRACT PAINTING SPECIFICATION 212 (PAINTING SCHEDULE) FOR A SHIP'S NEW BUILD APPENDIX 8.B. : EXAMPLE OF A PART OF A PAINT LIST FOR SHIP'S 215 NEW BUILD APPENDIX 8.C. : CHECKLIST OF A SHIP 217 CHAPTER IX : QUALITY ASSURANCE, QUALITY CONTROL, TESTING AND INSPECTION 9.1. Introduction Quality plans Quality control Testing (inspection) methods 222

9.4.1. GENERAL 222 9.4.2. INSPECTION OF EQUIPMENT 222 9.4.3. SUBSTRATE INSPECTION PRIOR TO SURFACE PREPARATION 223 9.4.4. MEASUREMENT OF AMBIENT CONDITIONS AND SUBSTRATE 223 TEMPERATURES 9.4.5.

12 GENERAL INSPECTION OF EQUIPMENT SUBSTRATE INSPECTION PRIOR TO SURFACE PREPARATION MEASUREMENT OF AMBIENT CONDITIONS AND SUBSTRATE 223 TEMPERATURES ABRASIVES STEEL SURFACE CONDITIONS Surface cleanliness (finish) Surface roughness Water soluble salts Grease Dust PAINTS Film thickness 228 a. Agreements 228 b. Calculation of the quantity of paint 228 с Measurement of wet film thickness 229 d. Measurement of dry film thickness on smooth substrates 230 e. Measurement of dry film thickness on blast-cleaned steed Cure Adhesion Holiday (pinhole) detection ASSESSMENT OF COATING DEFECTS 234 APPENDIX 9.A. : CURRENT STANDARDS USED FOR THE ASSESSMENT OF 235 COATING DEGRADATION (DEFECTS) APPENDIX 9.B. : SOME EXAMPLES OF (PARTS) OF STANDARDS USED FOR 236 THE ASSESSMENT OF COATING DEFECTS CHAPTER X : CATHODIC PROTECTION Corrosion 240

10.2. Galvanic corrosion 241 10.3. Other forms of corrosion 241 10.4. Principles of cathodic protection 242 10.5. Potential and current density 242 10.6. Cathodic protection systems 243 10.6.1. SACRIFICIAL (GALVANIC) ANODE SYSTEMS 244 10.

13 10.2. Galvanic corrosion Other forms of corrosion Principles of cathodic protection Potential and current density Cathodic protection systems SACRIFICIAL (GALVANIC) ANODE SYSTEMS IMPRESSED CURRENT SYSTEMS Cathodic protection of ship's hulls Cathodic protection of fixed offshore structures Cathodic protection of tanks Damage by stray currents Control and adjustment of cathodic protection systems Cathodic protection and paint EFFECT OF CATHODIC PROTECTION ON PAINTS PAINTS SUITABLE FOR USE WITH CATHODIC PROTECTION 254 APPENDIX 10.A. : CORROSION CELL (STEEL WITH BROKEN MILL SCALE IN 256 SEA WATER) APPENDIX 10.B. : POTENTIAL OF METALS IN SEA WATER 257 APPENDIX 10.C. : PRINCIPLES OF CATHODIC PROTECTION 258 APPENDIX 10.D. : COMPARISON OF CATHODIC PROTECTION SYSTEMS 259 APPENDIX 10.E. : CHARACTERISTICS OF SOME ANODE MATERIALS 260

APPENDIX 10.F. : QUANTITY OF ANODE MATERIAL TO BE USED (GALVANIC CATHODIC PROTECTION SYSTEM) APPENDIX 1 O.G. : AVOIDANCE OF DAMAGE BY STRAY CURRENTS 262 APPENDIX 10.H. : RELATIONSHIP BETWEENTOTENTIAL,DEGREE OF 264 CORROSION AND SECONDARY PHENOMENA CHAPTER XI: HEALTH SAFETY AND THE ENVIRONMENT 11.

14 APPENDIX 10.F. : QUANTITY OF ANODE MATERIAL TO BE USED (GALVANIC CATHODIC PROTECTION SYSTEM) APPENDIX 1 O.G. : AVOIDANCE OF DAMAGE BY STRAY CURRENTS 262 APPENDIX 10.H. : RELATIONSHIP BETWEENTOTENTIAL,DEGREE OF 264 CORROSION AND SECONDARY PHENOMENA CHAPTER XI: HEALTH SAFETY AND THE ENVIRONMENT Introduction Some important characteristics FLASHPOINT LOWER EXPLOSIVE LIMIT UPPER EXPLOSIVE LIMIT EXPLOSIVE RANGE SELF-IGNITION TEMPERATURE TLV(MAC) Safety hazards ELECTRICAL HAZARDS MECHANICAL (PHYSICAL) HAZARDS FIRE HAZARDS Solvents, ready-to-use paints, etc Deposits in dry spray-booths Waste materials EXPLOSION HAZARDS Mixtures of solvent vapour and air Spray mist and air suspended combustible dust Occupational health hazards 271

11.4.1. ASPHYXIATION 271 11.4.2. WORKING AT HIGH TEMPERATURES 272 11.4.3. EXPOSURE TO NOISE 272 11.4.4. EXPOSURE OF THE RESPIRATORY TRACT TO HARMFUL SUBSTANCES 272 11.4.5.

15 ASPHYXIATION WORKING AT HIGH TEMPERATURES EXPOSURE TO NOISE EXPOSURE OF THE RESPIRATORY TRACT TO HARMFUL SUBSTANCES EXPOSURE OF THE SKIN TO HARMFUL SUBSTANCES EXPOSURE OF THE EYES TO HARMFUL SUBSTANCES EXPOSURE OF THE DIGESTIVE TRACK TO HARMFUL SUBSTANCES The prevention of risk ORGANIZATION OF THE WORK TO BE CARRIED OUT PROCEDURES INSTRUCTION AND TRAINING OF THE WORKFORCE SELECTION, MAINTENANCE AND USE OF EQUIPMENT SELECTION OF SURFACE PREPARATION TECHNIQUES SELECTION OF PAINTS AND THINNERS SELECTION OF PAINT APPLICATION TECHNIQUES ELIMINATION OF IGNITION SOURCES VENTILATION PROTECTIVE CLOTHING, GLOVES, RESPIRATORS ETC Clothing Aprons Gloves Footwear Respiratory protection Eye protection Noise protection Skin protection Protection of the head 283

11.5.11. CLOAK ROOMS AND SANITARY FACILITIES 284 11.5.12. PERSONAL HYGIENE 284 11.5.13. TOTAL ABSTINENCE AT WORK 284 11.6. Some activities characterized by enhanced risks 285 11.6.1. STORAGE OF FLAMMABLE PAINTS AND THINNERS 285 11.

16 CLOAK ROOMS AND SANITARY FACILITIES PERSONAL HYGIENE TOTAL ABSTINENCE AT WORK Some activities characterized by enhanced risks STORAGE OF FLAMMABLE PAINTS AND THINNERS APPLICATION OF ANTI-FOULINGS WORKING IN CONFINED SPACES The main hazards Organization Accessibility Procedures, measurements etc. before entering a confined space Temporary lighting Temporary heating Equipment Spot cleaning WELDING AND FLAME-CUTTING OF PAINTED STEEL Some environmental aspects Some relevant dutch compulsory rules and regulations SAFETY AND INDUSTRIAL HEALTH PREVENTION OF ENVIRONMENTAL POLLUTION International compulsory regulations and rules 293 APPENDIX H.A. : BOILING POINTS, FLASH POINTS, EXPLOSION LIMITS, 294 IGNITION TEMPERATURES AND TLV'S (MAC'S) OF VARIOUS SUBSTANCES APPENDIX ll.b. : DEFINITIONS THRESHOLD LIMIT VALUES (TLVS) 295 APPENDIX 11.C. : SAFE WORKING IN CONFINED SPACES 297

Epoxy Coal Tar. Protects Steel and Concrete in Marine and Industrial Environments.

Epoxy Coal Tar. Protects Steel and Concrete in Marine and Industrial Environments. Epoxy Coal Tar Protects Steel and Concrete in Marine and Industrial Environments. General Epoxy Coal Tar is a protective coating designed to resist chemical attack and rigorous weather conditions by combining