Implementing The Paint Specification
in the Performance Standard for Protective
Coatings – The Challenge
The North East Coast Joint Branch of IMAREST and
RINA
Newcastle upon Tyne
12 March 2009
Dr M Raouf Kattan
FRINA C.Eng
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Objective
To provide a review of the requirements/challenges
posed by the IMO PSPC and highlight some key
issues.
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Rust is a Must – a poem
…….All the ships upon the sea
Slowly turn to Fe203…….
T.B Watson
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High Technology shipbuilding
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Surface preparation
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Painting
Improvement is needed
The Parties Involved at present
Shipyard
Ship-owner
Productivity/
Performance
Environment
Coating supplier
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The Parties Involved
A paint specification is in many ways a compromise:
– It has to meet with the yards building procedures,
environmental and productivity requirements
– The shipyard is the customer of the coating manufacturers
and they have to be competitive on standards as well as
price
– It has to match the paint suppliers product range.
The PSPC is in effect making the compromise
redundant
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Coating Performance Standard Review
The Performance Standard for Protective Coatings (PSPC)
provides the technical requirements for protective coatings in
dedicated sea water ballast tanks of all types of ships of 500 gt
and greater and double sided skin spaces on bulk carriers of
150m and greater in length.
It will be mandatory and is intended to be included as
amendments to SOLAS regs II-1/3-2 and XII/6
It is also recommended to be applied where possible to items,
not integral to the structure e.g. ladders, platforms – Permanent
means of access
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Tip of the iceberg
A family of regulations
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PSPC
Permanent means of access
Cargo tanks
Maintenance
These will change the current compromise solutions
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SOLAS Regulation
All vessels now cannot be delivered without a
compliant ballast tank coating systems
For Common Structural Rule vessels – this now
becomes a condition of class!
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Why?
Structural failures
Chase for minimum standards
Use of high tensile steels
Paint as part of the solution – but was it part of the
problem?
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Coating Performance Standard Review
Aims of the PSPC
– to provide a 15 year life for ballast tank coatings over which
it is defined as in being ‘good’ condition.
– ‘Good’ condition is defined in resolution A.744(18) and is
“ condition with only minor rust spotting”
– Better coating systems with reduced maintenance
– Improved safety at sea
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Coating Performance Standard Review
Aims of the PSPC
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Coating Performance Standard Review
Aims of the PSPC
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Coating Performance Standard Review
Entry into force
The proposals will apply to the aforementioned types of
vessels:
– For which the building contract is placed on or after 1st July 2008,
or
– In the absence of a building contract, the keels of which are laid or
which are at a similar stage of construction on or after 1st January
2009, or
– The delivery of which is on or after 1st July 2012
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Coating Performance Standard Review
Entry into force
However IACS applied the proposals on ratification to
tankers ( L > 150m) and bulkers (L > 90m) under the
Common Structural Rules (CSR) for contracts signed
from December 8th 2006
The first new building classed under the above rules
were delivered in the second half of 2008
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The Parties Involved
Shipyard
Productivity
Ship-owner
Classification Soc.
?
Performance
Coating supplier
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Coating Performance Standard Review
Main Elements of the PSPC:
– Design of a specification and coating system
– Coating System approval
– Definition of inspection procedures
– Production of a Coating Technical File (CTF) which records all
aspects of the process
– Verification of compliance
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The Paint Specification
The paint specification is at the heart of the PSPC
and covers:
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Primary and Secondary surface preparation standards
Steel profile range
Cleanliness of surfaces prior to coating
Soluble salt limits
Steel condition
Thickness and number of coats
Environmental conditions allowed
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The Paint Specification
The paint specification applies to the coating system
that has been selected
Selection of the coating system takes into account
the service conditions and planned maintenance
All coatings to be epoxy based or equivalent and
consist of multi-coat systems of contrasting colour
The top coat to be a light colour
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Type approval
All coatings to be pre-qualified by:
– A method corresponding to a specified test procedure or
equivalent ( now Annex 1), cross test with shop primer or…
– Documented field exposure with a final condition of “GOOD”
after 5 years
Non Annex 1 test must show equivalent testing
procedures and needs.
A Statement of Compliance or Type Approval
Certificate to be issued by a third party - independent
of the coating manufacturer
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Inspection process
The inspection process covers all the processes and
defines the standards from:
Shop Primer Application
Block Painting
Post Erection Repairs
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The inspection process
• The inspection processat each stage can be
separated into the following simple processes:
– Cleaning the surface
– Preparing the surface
– Coating the surface
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Coating technical file (CTF)
YARD
– A statement of agreement
between Owner/yard and paint
company for this contract
– Paint specification as issued by
yard including key criteria and
data sheets
– A summary or full log of work
carried out by yard/coating
inspector - one for each tank
and Non-conformity/repair
summary log for each tank including verified inspection
reports
– Statement of conformance
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– Copy of type approval
certificate or statement of
compliance
– Yard procedures (for inspection
and repair) audit certificate from
class (includes application ).
Paint Company
– Planned maintenance
procedures for in service
Ship owner
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Maintenance log
Inspection log
Condition log
Class inspection log
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DFT Measurement
Long spacing 0.7 – 0.95m
Typical Double Bottom Block
DFT Measurement
Flat area 22 points
Long and Trans 60 points
: Flat area (1 reading / 5 m2)
: Long & Trans (2 reading/2~3m)
DFT Measurement
26 Openings
12 Openings
8 Openings
42 openings – 92 measurements
Openings > 400mm – 4 measurements
DFT Measurement
Total area to paint 2,790m2
Total measurements 3,400
DFT measurements
Total area of WBT = 240,000m2
About 40 football fields
Data management - ELCOship
Remote
database
Electronic data gathering
Local PC
Coating Technical File
IMO PSPC Compliant
Reference drwgs
Standard documents
www.elcoship.com
Verification
Tri-party agreement
Type approval
Test results
Process audit
Inspection audit
CTF audit and sign off – currently cannot be complied
with
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The Paint Specification
The main elements of the specification in the PSPC are already
being carried out in many shipyards and have been for a
number of years
The main items that are new are :
– A Coating Technical File has to be produced by the shipyard
– All inspectors are to be qualified to a recognised standard
– Increased inspection and prescriptive inspection and data collection
– Audit by class
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Ambiguities
There are many ambiguities in the standard:
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Salt measurement
90:10 rule
Area judgement and other subjective elements
CTF detail and content
Products approved through testing – will they last 15 years target
life
– What happens if they do not
– Approved inspector
There are some guidelines
– PR34 from IACS
– IACS guidance notes
Maintenance requirements
Costs of implementation
IACS members not acting in harmony – adding costs
Conflict with other regulations
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Conclusions
Added time and cost to the process
Needs a bedding in period
Needs a cool and calm interpretation
In the wrong hands is adding to costs.
Places a clear increased burden on yards
It is going to get worse before it gets better.
Will it bring with it improvements?
Is it needed?
Can we do better?
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Do it soon
Thank you – but how does the poem end?
……Here’s to rust no doubt about it
Most of us would starve without it!…..
Acknowledgement to Hyun- Kug Lee for some images (Korean
Shipbuilders Assoc and Samsung Heavy Industry) for some images
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