what’s new with coatings in 2018? - nsrp · 2018-10-12 · updated mil-std-1687 to technical...

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NAVAL SEA SYSTEMS COMMAND

What’s New with Coatings in 2018?

NSRP

Charleston, SC

March 2018

Howard Castle

SEA 05P2

(202) 781-5082

[email protected] Distribution A: Approved for Public Release

OBJECTIVES

Summarize evolving Naval Sea Systems Command (NAVSEA)

organization and coating requirements.

Review some key changes regarding recent Standard Items and

MIL specs.

Present recent and planned updates to specifications affecting in-

service and new construction ships.

Distribution A: Approved for Public Release 2

Code Product Related Specs All All Technical Products, Managerial All

AF Antifouling Coating Systems MIL-PRF-24647

TNK Tank Coatings, Epoxy Primers MIL-PRF-23236

MIL-DTL-24441

PRM Primers, Single Component TT-P-645

TOP Topside, Alkyds & Polysiloxanes MIL-PRF-24635

INT Interior Coatings (SEA 08) MIL-DTL-24607

MIL-PRF-24596

MIL-DTL-15090

MIL-DTL-1115

HT High Temp Coatings, Metallic TT-P-28

PWD Powder, Interior, Cosmetic MIL-PRF-24712

NSK Nonskid MIL-PRF-24667

DCK Deck Coverings MIL-D-3134

MIL-PRF-3135

MIL-PRF-24613

MIL-PRF-32171

SUR Abrasive blasting, surface prep MIL-A-22262

SEL Sealants & Preservatives MIL-PRF-16173

NAVSEAINST 9630.1

DOC Policy Documents NSTM 631, NSTM 634

S636-MAN, CCAMM

Standard Item 009-32


COR Corrosion/PCOE Policy/Design DODI 5000.67

RSH Research & Development To be determined

UNDS Regulations, Underwater hull TBD

NAVAIR

Aircraft Engines

SEA 08R

SEA 08T

TWH: Underwater

Hull Husbandry

SDMs: Surface,

Submarine,

Carrier

Technical Authority Pyramid - Coatings & Corrosion Control Draft: Dec 2017

Navy Employee Navy Developmental Employee Contractor

Ingle all

Castle (EM)

All, COR

Lemieux (EA)

All, RSH

Vacant (EM)

NSK, All

Wegand (EM)

RSH, NSK

Lattner (EM) COR

Haslbeck (EM)

All, AF

J. Martin (EM)

TOP, TNK

Melhuish (EM)

All, NSK

Brinckerhoff (EM) All

Tagert (EM)

TNK, NSK

Vacant (EM)

VA-Class

Jones (EM)

NSK, DCK

Iezzi (EM)

RSH TOP

Smith (EM)

UNDS

Wigle (EM)

CCAT

Slebodnick (EM)

RSH, TNK, NSK

Truman (LE) COR

Carroll (LE) NSK

Kuljian NSK, RSH

Cassidy (LE)

DOCs

Stanke TNK, All

White INT

Adams (LE)

NSK, RSH

Miller TNK, NSK

Zuwiala COR

Park DOCs

Foster All

Hadziliac Cor, Doc

F. Martin HT, COR

Spicer TNK, NSK

Holm (LE) AF

Webb RSH

Intern All

Ellor COR

Ault (LE)

TNK, RSH

Langaster (LE) TNK

Ranero (EM)

All, NSK

EAs

EMs

LEs

Kogler SUR

TWH

Delegated signature authority

Ong (EA) All

Hicks (EM)

NSK, TNK

Duckworth (EA) All

Distribution A: Approved for Public Release

HQ

Messier COR, DOC

NAVAIR 4.4

Aircraft Engines

Ingle all

Castle (EM)

All, COR

Vacant (EM)

NSK, All

CNSP N42

Aviation

USFF N43

Maintenance

USMC AVN

Aviation

Preston- Baker (LE)

All RSH

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NAVSEA Strategic Business Plan NAVSEA Strategic Business Plan 2018-2022, has three key mission priorities:

1. On-Time Delivery of Ships and Submarines

2. Culture of Affordability

3. Cybersecurity

NAVSEA addresses these items through continual, ongoing interactions with shipbuilding

and ship repair community:

Brief at antifouling

program review

Attend FNC review

CWP

Funded NAVSEA

program.

NAVSEA/Shipyard teams

Brief at meetings

Meet with industry

Serve on Executive

Committee

Attend quarterly review

Brief at NSRP Surface

Preparation and Coatings

Panel Meetings

SSRAC

MegaRust

PCOE

Chair, annual public

meeting to update


Vendors,

government, and

industry submit

changes, all changes

evaluated


Standard Item Updates

Development and publication of new Standard Item 009-124 “Thermal Spray Nonskid

Application; accomplish” as of 6 Mar 2018

- Defines process requirements for application of TSN products

- Requires thermal spray wire qualified to MIL-PRF-32577

Minor updates to 009-26 “Deck Covering; accomplish” captured in 1 Oct 2017 update

- References updated to new MIL-PRF-32584 specification

- Peel & stick terminology updated

Regular updates to Standard Item 009-32 “Cleaning and Painting Requirements;

accomplish” pending imminent release. Key changes:

- Added requirement to use low-density “Comp D” aggregate nonskid on amphibious

class ships to reduce risk of FOD

- Eliminate requirement for chloride/conductivity checks of potable, reserve feedwater,

and freshwater drain collecting tanks

- Added “flight deck nonskid” to areas not allowed to waive requirements when

performing touch-up of newly installed systems

- New attachments D & E for ICCP sprayable dielectric shield application


Does NAVSEA just keep adding requirements?

Based solely on length of 009-32, the answer could appear to be yes, but…

Of the changes incorporated into FY-19, Ch-2:

38% addressed clarification issues

28% reduced requirements or permitted lower-cost alternatives

34% reflected a new requirement or increased costs

Examples of relaxed requirements include:

- Eliminate SP 1 requirement for tie-downs when hand or power-tool cleaned

prior to waterjetting.

- Permit in-situ high-solids paint repair of louvers when more than 90% of

powder coating is intact and adherent.

- Permit use of low temperature coatings applied to “skin” tanks when

substrate temperatures cannot be maintained over 50°F


TSN Technical Requirement Status

TSN Fielding

Vital to Amphibious Ships

& Fleet Operations

FY-18, Change 1

Standard Item

009-32

7 Mar 2017

Military

specification

MIL-PRF-24667C

for epoxy nonskid

2 Sep 2009

Naval Ships

Technical Manual

Chapter 634

1 Jan 2009

Material Installation Process /Qualifications In-service


MRC (Multiple)

for Nonskid

Inspection

and Repair

by Ship’s Force

FY-19 New

NAVSEA

Standard Item

009-124

New military

specification

MIL-PRF-32577

for TSN wire

material.

Update Naval Ships

Technical Manual

Chapter 634 to

Include TSN

Update current

MIL-STD-1687A

to Technical

Publication 1687

Update MRC

for TSN Inspection

and Repair

by Ship’s Force

CURRENT

EPOXY

NONSKID:

NEW

TSN:

STATUS: Published on Published on Published on PDS for Developmental based

12 Jun 2017 6 March 2018 12 Jun 2017 FY-18 Task on current changes to

MRC to reduce risk of

nonskid undercutting

and forming chips

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TSN To Improve Flight Deck Performance

TSN is only material

that can withstand

direct F-35 exhaust

gas impingement.

TSN has low macro-

profile and smaller

“chips” that can

break off lowering

risk of aircraft engine

FOD.

TSN is aluminum and

small (e.g., 400 grit or

smaller) Al2O3 aggregate

as compared with 24-30

grit Al2O3 in conventional

epoxy nonskid. Conventional Nonskid Chips TSN, wear particles , 400 grit aggregate

TSN can resist V-22

exhaust gas heat.

NRL validating that

V-22 exhaust gas

impingement can

crack conventional

nonskid.


1.(V)(G) “CONTAINMENT AND VENTILATION INSTALLATION”

Process requires environmental controls on temperature, humidity, and dust.

Design approved by SUPERVISOR per Standard Item 009-01, 009-03, 009-05, etc.

Re-establishment of containment across deck is contractor verification point (V).

Environmental requirements are 55-90ºF ambient temperature, >50ºF deck temperature,

Relative humidity <70%, deck temperature >5ºF above the dew point as trades person verification point (V).

2.(I)(G) “CONDUCTIVITY MEASUREMENT”

Conductivity required (i.e., there are no separate chloride limits) using Bresle or

equivalent method. One reading from first 200 ft²/subsequent 400 ft² with limit of 30 micro-siemens/cm. Requires low pressure waterjet cleaning of any areas with high conductivity.

3.(I)(G) "CLEANLINESS PRIOR TO ABRASIVE BLASTING"

Clean and degrease surface by SSPC-SP 1 before surface preparation, requires verification

using water break test.

One water break test is required for every 200 ft².

4.(I)(G) “SECONDARY SURFACE PREPARATION”

Requires SSPC-SP 5 white metal blast on both general deck surface

and welds using requirements in SURFACE PROFILE section.

5.(I)(G) “SURFACE PROFILE”

Measures profile on the SSPC-SP 5 white metal level of cleanliness

created using 50/50 mixture of 16- to 24-grit virgin Al2O3 abrasive during surface preparation

within 10 hours of removing old nonskid using very thorough water jet cleaning

to SSPC-WJ 2.

Verifies compressed air cleanliness.

Requires ASTM D4417 Method B for profile peak height and ASME B46.1 for profile

texture. Profile shall be between 4.0 and 10.0 mils and texture by

root mean square (RΔq) >0.45 as measured on first 200 ft²/subsequent 400 ft².


Thermal Spray Nonskid Standard Item 009-124 Process

Includes Eleven Government QA Checkpoints

Failed Test

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6.(I)(G) “DUST TEST”

Requires ISO 8502-3 (Rating 2, Class 2) with “just visible” particles no larger

than 40 mils with three readings per 400 ft2.

7.(I)(G) “THERMAL SPRAY APPLICATION MACHINE SETTINGS”

Requires robot settings are same as those used in Technical Publication 1687 process. Check and validate settings at start of work shift.

8.(I)(G) “MANDREL BEND WITNESS PANELS”

Requires three witness panels attached to tie downs

to be removed from deck after first TSN coat and bent

180º over a 2 ¼ inch mandrel at start of each work day.

Only slight edge cracking allowed.

9.(I)(G) “FILM THICKNESS MEASUREMENTS”

Requires film thicknesses demonstrated in Technical Publication 1687 process

to be measured using modified SSPC-PA 2 method to take five spot

spot per every 200 ft2 and to locate and repair thin areas on a +- 3 inch basis.

10.(I)(G) “TSN CLEANLINESS”

Requires wire brush, dry vacuum, or low pressure, vacuum water cleaning,

at 2,500 to 3,000 psi, to clean dust off deck before color top.

11.(I)(G) “COLOR TOPPING HOLIDAY INSPECTION”

Requires wet film thickness of color top and visual inspection of deck.

Requires dark gray and VLA marking colors to be applied direct to TSN.

SUPERVISOR provides final approval of deck.

Standard Item 009-32 has eight (G) points to ensure nonskid quality while Standard Item 009-124 has eleven (G) points.

Thermal Spray Nonskid Standard Item 009-124 Process

Includes Eleven Government QA Checkpoints

Quantity of small particles


Plan: Update MIL-STD-1687A to Technical Publication 1687, “THERMAL SPRAY PROCESSES FOR

NAVAL SHIP MACHINERY APPLICATION,” to include requirements for personnel training

and process qualification to apply TSN wire material with the twin-wire arc spray process

and equipment , as-demonstrated by NRL on LHA/LHD.

Key Update Provisions:

- Defines required applicator training.

- Outlines safety requirements.

- Defines applicator qualification process and audit

For Quality Assurance.

- Explains to applicator the entire process.

Updated MIL-STD-1687 to Technical Publication 1687 and change was signed out on 9 Jun 2017.

Update to MIL-STD-1687A on Process Qualifications

Requirements for TSN Applicator Training, Certification & Qualification


Plan: New MIL-PRF-32577 “COATING SYSTEM, NONSKID,

METALLIC THERMAL SPRAY APPLICATION” defines the

wire material used with twin-wire arc spray process &

equipment to apply TSN to LHA/LHD flight decks.

Key Material Specification Provisions:

Wires based on aluminum alloys to withstand operational

requirements.

Multiple coats of TSN acceptable to build final coating system.

Wire material Type/Class to specify allowable levels of

hazardous heavy metals.

Wire material Type/Class to define whether wire is solid or cored.

Qualification Tests:

Conformance tests (e.g., metals levels, lubricants, packaging) to be

conducted on wire feed stock.

Coating conformance tests to exclude silicate color topping (need to prepare

a color top specification).

Qualification testing on coating with application parameters demonstrated on LHD

and LHA.

STATUS: New military specification published 12 June 2017.

New TSN Material Specification MIL-PRF-32577

Defines Thermal Spray Wire Requirements


● LHA 6 TSN installed using solid wire that is 97% Al / 3% Ti.

● LHD 1 and LHD 5 TSN installed using cored wire that is 5054 Al jacket / aluminum oxide (400 grit) core.

Cross Section: solid core aluminum wire

with elemental Ti.

Cross Section: hollow core aluminum alloy wire

with discrete aluminum oxide particles.

Transfer Efficiency: 68% Transfer Efficiency: 57%

Application Rate: 84 - 112 ft2/hour Application Rate: 84 - 112 ft2/hour

No reportable chromium on MSDS. Chromium reported as 0.15 – 0.35%

MIL-PRF-32577 addresses requirements for both solid and cored TSN wire.


New TSN Material Specification MIL-PRF-32577 Wire Type

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Recent and upcoming MIL spec updates

MIL-PRF-16173:

- Since 1993, spec paragraph 1.2.1 defined the product classes: Class I was defined as

VOC exceeding 340 g/L and Class II was defined as VOC not exceeding 340 g/L.

- Test requirement paragraph 3.4.2 stated: “…the VOC for Class I compounds may

exceed 340 g/L…” and “…Class II shall not exceed 340 g/L…”.

- Resulted in low VOC products on high VOC QPD. Interim update completed to MIL-

PRF-16173 to prevent high and low VOC products from being qualified to same

product classification.

MIL-PRF-24635:

- Interim update planned for MIL-PRF-24635 to define composition category for 1K vs.

2K polysiloxanes to address issues for in-service procurement.

- Ship’s Force preserved 105k ft² on

LHD 2 freeboard in April 2017 using

1K polysiloxane.

- Fleet requires method to procure

products capable of being applied

by Ship’s Force.

- NRL finalizing long-term spec update

to address universal pigment package and total solar reflectance changes. Distribution A: Approved for Public Release

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Recent and upcoming MIL spec updates

MIL-DTL-24441:

- NAVSEA demonstrating new “Type VI” UHS variant of formula product for use on key

submarine tanks

- Initial issues with surface wrinkle phenomenon appear to have been addressed

MIL-PRF-24667:

- Discussed next revision plan at Sept 2017 NSRP meeting.

- NSWCPD initiated rewrite kickoff Feb 2018 with aggressive 2018 plan due to USFF

funding.

- Interim update pending to define “Comp D” low density aggregate nonskid, based on

aggregate hardness and density, and cured nonskid weight/area.

Ballast tank inspection

after two years

Ballast tank inspection

after two years


ISSUE: LHD 6 Hazard Assessment Report (HAR) that defined “best practices” for reducing risk of aircraft engine Foreign Object

Damage (FOD) signed on 27 Mar 2017 by: SEA 00, SEA 05, SEA 21, AIR 00, AIR 4.0, CNSF 00, and USMC Deputy

Commandant for Aviation and included:

RISK MITIGATION 2 – Determine if alternative nonskid materials or processes inherently reduce aircraft engine FOD risk.

Publication of Interim Change to MIL-PRF-24667C to create “Composition D” low density nonskid requirements and update to

Standard Item 009-32 to require use of Composition D on amphibious ship flight decks closes LHD 6 HAR RISK MITIGATION.

APPROACH: NRL 6130 / SEA 05P2 tested qualified nonskids University of Dayton Research Institute (UDRI) / AIR 4.4

to determine if any products reduce risk of used laboratory air cannon test to simulate impact of nonskid

V-22 exhaust heat causing nonskid to crack/ chips on turbine blades to determine which nonskid chips

delaminate on flight deck. cause relatively less blade damage.

NRL 6130 tests simulates exhaust heat and deck UDRI tests fire nonskid chips in foam sabot at fixed aircraft

deflection due to thermal expansion and provide engine blades to rate relative impact damage.

relative cracking / delamination resistance.

What drove the MIL-PRF-24667 interim change?

Potential FOD Potential FOD

Vertical landing stirs up nonskid debris

Taxiing aircraft may ingest nonskid debris

Potential FOD

Potential FOD

Foam sabot with nonskid

Foam sabot

with nonskid

Blade on

bench


LABORATORY

TEST RESULTS: NRL 6130 simulated V-22 exhaust heat cracking tests UDRI nonskid chip and turbine blade impact tests show lightweight

show lightweight, low density nonskid cracks/ low density nonskid causes less blade damage than conventional

delaminates less than 11 other conventional, nonskids. Composition G nonskids.

NEW REQUIREMENTS: MIL-PRF-24667C Interim Change defines Composition D, low density nonskid as containing only polymeric/crushed glass

aggregate with:

- Cured coating density: <0.66 lbs/ft2

- Aggregate blend density: 0.6 - 0.9 gm/cm3

- Maximum aggregate hardness: 6 Mohs

Update to FY-19 Standard Item 009-32 to require use of Composition D nonskid on LHA, LHD, LSD, & LPD flight decks.

Publishing Interim Change to MIL-PRF-24667C to define new Composition D nonskid and updating Standard Item 009-32 to require Composition D on

amphibious ship flight decks closes out 2017 LHD 6 HAR “Risk Mitigation” task to identify new materials that reduce aircraft engine damage.


Conventional nonskid

Thermal spray nonskid

Conventional nonskid Low density nonskid

Low density nonskids resist V-22 heat cracking/delamination and cause less turbine blade damage and

as such will be the first, qualified, Composition D nonskids

Low Density Nonskid



TRANSITION TO FLEET SERVICE: Transition of Composition D products to Fleet service is in progress and requires:

1. Publication of Interim Change to MIL-PRF-24667C nonskid specification to define

Composition D nonskid requirements.

2. Update of ASSIST data base to include new Composition D qualified product database listing.

3. Update to the FY-19, Change 2, Standard Item 009-32 to require Comp D on amphibious ships.

STATUS: Interim Change to MIL-PRF-24667C to create new, Composition D complete, with SEA 05 concurrence, and submitted to

SEA 05S for publication on 7 Mar 2018 and includes:

Interim Change to MIL-PRF-24667C to define new Composition D nonskid is complete and listing on ASSIST database is pending.

3.2.6 Aggregate density (composition D only). When evaluated in accordance with 4.5.30, the aggregate blend density value shall be between 0.6 and 0.9 g/cm³.

3.2.7 Aggregate hardness (composition D only). When evaluated in accordance with 4.5.31, the maximum hardness value of any aggregate type tested shall not

exceed a rating of 6 on the Mohs scale.

4.5.30 Aggregate density (composition D only) The blend density of the aggregate shall be evaluated in accordance with ASTM D1895, method B. The

aggregate blend density shall meet the requirement of 3.2.6.

4.5.31 Aggregate hardness (composition D only) A random sample of 5 grams of aggregate shall be selected, and if comprised of multiple aggregate types

(e.g., polycarbonate and glass), separated by aggregate type. For each aggregate type, place a minimum of 3 grains of aggregate between two microscope slides.

While wearing appropriate safety gloves and applying considerable finger pressure, slowly move one slide over the other with a reciprocating motion for 10

seconds. Examine the glass surface and if not scratched, the aggregate shall be considered to have a Mohs value of 6 or less. Repeat for each aggregate type

previously separated. The samples shall meet the requirement of 3.2.7.








STATUS: Interim Change to MIL-PRF-24667C to create new, Composition D requires update to ASSIST qualified products

database:

21 Mar 2018 – SEA 05P2 e-mail to International Paint and AST/ITW to contact SEA 05S via letter with

request to qualify products to Composition D “by extension”

31 Mar 2018 - NRL to submit short, letter report to SEA 05P2 on Intershield 5150LWT and

MS-4100G aggregate hardness and density.

20 Apr 2018 - SEA 05S to list new Composition D products on ASSIST qualified products database.

No new data required to update Composition D nonskid on ASSIST database, but product listing must follow required SEA 05S process.

Add TYPE I, COMP D line and list will show

Intershield 5150LWT and MS-4100G low

density nonskids.








STATUS: Update to the FY-19, Change 2, Standard Item 009-32 to require Comp D on amphibious ships is complete and

will be submitted to CNRMC for publication by 31 Mar 2018.

New FY-19, Change 2, Standard Item 009-32, Table 2, Lines 16B & 16C requires LHA, LHD, LPD, and LSD flight decks use Composition D nonskid.

Only TYPE I, COMP D listing on

ASSIST database in near term

for Intershield 5150LWT and

MS-4100G low density nonskids


ISSUE: Interior Deck Covering specifications are being revised and combined to reflect the recommendations for commonality

generated during the NAVSEA Deep Dive (CMN-003-2011-11).

APPROACH: Update the existing specification content to streamline outdated and inconsistent testing and qualification requirements,

remove unnecessarily expensive requirements to promote qualification of additional materials of high interest to the fleet, and

combine similar specs to reduce administrative and maintenance costs associated with each spec.

WORK COMPLETED:

1. MIL-PRF-32584, Deck Covering Materials, Monolithic

was published on 01 August 2017. The following

specifications for liquid deck covering materials

were incorporated into MIL-PRF-32584:

• MIL-PRF-32171

• MIL-PRF-24613

• MIL-D-3134

• MIL-D-21631

2. Qualification letters have been

sent to the manufacturers of

products qualified to the

legacy specifications for

qualification to MIL-PRF-32584.

Consolidation of Deck Covering Specifications

and Institution of Industry Standard Test Methods

Sweep deck clean

MCRRS


WAY AHEAD:

1. COMPLETE AND PUBLISH draft specification

MIL-PRF-XX642, Deck Covering Materials,

Resilient Flooring, for the consolidation of

all solid deck covering materials.

2. REVISE MIL-PRF-3135, Deck Covering

Underlay Materials, to update legacy

requirements and test methods and

consolidate all underlay material

specifications.

Consolidation of Deck Covering Specifications

and Institution of Industry Standard Test Methods

Sweep deck clean

MCRRS


Summary

- NAVSEA goal is to reduce coating life-cycle costs from application at

ship acquisition through to ship disposal.

- NAVSEA continually updates specifications and Standard Items to

address real issues encountered by the fleet.

- NAVSEA to continue efforts to streamline coating processes.
