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Protective
Coatings for
Ballast Tanks
and to test and classify corrosion Wave tanks, simulating service conditions
in ballast tanks, were one of two test meth-
By Helge Vold protection coating systems. ods used. (Photos courtesy of MARINTEK)
As part of the project, which was
MARINTEK
designed to reduce maintenance
Sandefjord, Norway and operating costs, a manual was Wave Tank
developed to give shipowners, The wave tank test consists of a
inspectors, and crews information tank with natural seawater at 35 C
continuous condensation, according Laboratory Test Method Description of Panels for Test
to ISO 6270.1 Deck wave tank panel with scribe
coating in this article). classified soft coating. at 90 volts. The number of pin-
These definitions contain some holes was recorded.
evaluation of the coating lifetime, Evaluation and Classification After the tests, adhesion was
which is reflected in the classifica- of Hard Coatings tested using the pull-off method
tion. Similar products are ranked At intervals during the exposure (ISO 4624).4 The effect of waves,
according to their performance. and after the test was completed, heat, and temperature gradients
When comparing products between the coatings were evaluated for were evaluated visually.
the groups, a low-classified hard degree of blistering and degree of Disbonding of the coating from the
coating may still give better protec- rusting according to ISO 4628/1-3.3 scribe was evaluated and recorded.
tion than a high-classified semi- Before exposure, one small Flexibility was tested according to
hard coating. Similarly, a low-clas- (15x15 cm) and one large (20x40 ASTM D4145.5 Three pieces from
sified semi-hard coating may still cm) panel were tested for pinholes the deck panel of the wave tank
give better protection than a high- with a low voltage pinhole detector and an unexposed control panel
18 PCE June 1997 Copyright 1997, Technology Publishing Company
Table 4: Test Results and Classification after Exposure for Hard Coatings (Paint)
Tested on Pre-rusted and Moist Substrate
(Degree of blisters and rust according to ISO 4628/1-33)
were cut out. The pieces were bent Coating Blisters on Panel Rust On
Undercutting Pull-off Class
180 degrees at 5, 20, and 40 mm No. from Scribe Adhesion
diameter, and the result was report- Wave tank Condensation Wave tank Wave tank Wave tank
ed as minimum diameter of no side panel chamber deck deck panel deck panel
paint fracture. If paint fracture was with cooling panel (mm) (Ref)1 (MPa)
seen even at 40 mm diameter, the 1 0 0 0 6 5.9 (5.9) B1
degree of bend at fracture was 2 0 0 0 9 6.1 (7.2) B1
reported. Pull-off and flexibility 3 0 0 0 3 8.0 (8.3) B1
tests were done a minimum of two 4 0 0 0 4 8.9 (7.4) B1
weeks after exposure. For the panel 5 1 (S4) 4 (S3) 0 9 6.1 (7.2) B4
with sacrificial anodes (Table 1), 0 0 11 6.6 (10.4)
6 3 (S2) B4
the current demand was calculated
1) In brackets: pull-off adhesion of reference panel not exposed.
and the effect of cathodic protec- First number is blister density; number in parentheses is blister size.
tion was evaluated visually.
The panels were evaluated main- ter formation. properties were probably the main
ly on the density of blisters and the Six hard coatings from five differ- reason for the formation of blisters.
area rusted. From the evaluation, ent producers were tested on pre-
coatings were classified from B1 to rusted/moist substrates. Table 4 Evaluation and Classification
B6, with B1 being the best rating shows that four products were clas- of Semi-hard Coatings
(Table 2). sified B1. These products included At intervals during exposure and
From 15 different producers, 30 a solvent-free epoxy, a high-solids at the end of the test, the semi-hard
hard coatings were tested on pre- epoxy, a surface-tolerant epoxy, and coatings were evaluated for degree
rusted substrates. The pre-treat- a urethane-based coating. of blistering and degree of rusting
ment of the pre-rusted panels was Deterioration of the coating systems according to ISO 4628/1-3. The
according to the producers recom- occurred in the form of blisters on degree of rusting in the pictures of
mendations. As shown in Table 3, the cold wall panel in the wave the standard is based on hard paint
only four products were classified tank and on the panels in the con- coatings, which flake during rust-
B1. All four were surface-tolerant densation test chamber (tempera- ing. Because of their softness and
epoxy coatings. Coal tar epoxy ture gradients). Again, salt contami- good adhesion, semi-hard coatings
coatings, which were believed to nation on the pre-rusted panels and do not flake off, and this should be
provide the best corrosion protec- poor wetting properties of the coat- remembered when comparing the
tion for ballast tanks, showed dif- ings were probably the main rea- exposed panels with the pictures in
ferent performances in this study sons for the formation of blisters. the standard. For all coating sys-
from producer to producer. Only From 12 different producers, 44 tems, evaluation of the degree of
two solvent-free products were test- hard coatings were tested on zinc rusting according to the standard is
ed on a pre-rusted substrate, and shop-primed or blast-cleaned sub- done without scraping off the coat-
they were classified B4 and B5. In strates. The highest classification, ing. However, the coating must be
the high-solids group (more than B1, was given to 29 products, as scraped off in order to see under-
80 percent volume solids), only one shown in Table 5. Surface-tolerant rusting on pre-rusted, blast-cleaned,
product was classified B2. Blisters epoxy coatings and coal tar epoxy or shop-primed panels.
on the cold wall panel in the wave coatings performed best in this test. Semi-hard coatings may develop
tank and on the panels in the con- Also, in the solvent-free epoxy and blisters that disappear later. Devel-
densation test chamber (tempera- the high-solids groups, 50 percent opment of blisters was recorded
ture gradients) resulted in the of the products were classified B1. during the test period and after the
largest deterioration of the coating Blisters on the cold wall panel in exposure. Because under-rusting
systems. Salt contamination on the the test tank and on the panels in often develops under blisters of
pre-rusted panels and poor wetting the condensation test chamber semi-hard coatings, this must be
properties of the coatings were caused the largest deterioration of regarded as a defect even if the blis-
probably the main reasons for blis- the coating systems. Poor wetting ters disappear when the exposure is
finished. The reported size and (20x40 cm) were tested for pin- panel with anodes (Table 1), the
density of the blisters is the highest holes with a low-voltage pinhole current demand was calculated and
level recorded during exposure. detector at 90 volts. The number of the effect of cathodic protection on
The effect of the blisters on the pinholes was recorded. the coating (disbonding/blistering)
substrate is studied by scraping off After the tests, the effect of the was evaluated visually.
the coating down to the steel sub- waves, heat, and temperature gra- As with hard coatings, classifica-
strate. dients again were evaluated visual- tion of semi-hard coatings was
Before exposure, one small panel ly. Undercutting from scribe was based mainly on the degree of rust-
(15x15 cm) and one large panel evaluated and recorded. For the ing and/or the density of blisters. If