Guidelines for the application of
the IMO Performance Standard for
Protective Coatings
June 2007
Guidance Note
NI 531 DT R00 E
17 bis, Place des Reflets - La Défense 2 - 92400 Courbevoie
Postal Address : 92077 Paris La Défense Cedex
Tel. 33 (0) 1 42 91 52 91 - Fax. 33 (0) 1 42 91 53 20
Email : [email protected]
Web : http://www.veristar.com
MARINE DIVISION
GENERAL CONDITIONS
ARTICLE 1
ARTICLE 6
1.1. - BUREAU VERITAS is a Society the purpose of whose Marine Division (the “Society”) is the classification (“Classification”) of any ship or vessel or structure of any type or part of it or system therein collectively
hereinafter referred to as a “Unit” whether linked to shore, river bed or sea bed or not, whether operated or
located at sea or in inland waters or partly on land, including submarines, hovercrafts, drilling rigs, offshore
installations of any type and of any purpose, their related and ancillary equipment, subsea or not, such as
well head and pipelines, mooring legs and mooring points or otherwise as decided by the Society.
6.1. - The Society accepts no responsibility for the use of information related to its Services which was not
provided for the purpose by the Society or with its assistance.
The Society:
• prepares and publishes Rules for classification, Guidance Notes and other documents (“Rules”);
• issues Certificates, Attestations and Reports following its interventions (“Certificates”);
• publishes Registers.
1.2. - The Society also participates in the application of National and International Regulations or Standards,
in particular by delegation from different Governments. Those activities are hereafter collectively referred to
as “Certification”.
1.3. - The Society can also provide services related to Classification and Certification such as ship and company safety management certification; ship and port security certification, training activities; all activities and
duties incidental thereto such as documentation on any supporting means, software, instrumentation, measurements, tests and trials on board.
1.4. - The interventions mentioned in 1.1., 1.2. and 1.3. are referred to as “Services”. The party and/or its representative requesting the services is hereinafter referred to as the “Client”. The Services are prepared and
carried out on the assumption that the Clients are aware of the International Maritime and/or Offshore
Industry (the “Industry”) practices.
1.5. - The Society is neither and may not be considered as an Underwriter, Broker in ship’s sale or chartering,
Expert in Unit’s valuation, Consulting Engineer, Controller, Naval Architect, Manufacturer, Shipbuilder, Repair
yard, Charterer or Shipowner who are not relieved of any of their expressed or implied obligations by the
interventions of the Society.
ARTICLE 2
2.1. - Classification is the appraisement given by the Society for its Client, at a certain date, following surveys
by its Surveyors along the lines specified in Articles 3 and 4 hereafter on the level of compliance of a Unit to
its Rules or part of them. This appraisement is represented by a class entered on the Certificates and periodically transcribed in the Society’s Register.
2.2. - Certification is carried out by the Society along the same lines as set out in Articles 3 and 4 hereafter
and with reference to the applicable National and International Regulations or Standards.
2.3. - It is incumbent upon the Client to maintain the condition of the Unit after surveys, to present the
Unit for surveys and to inform the Society without delay of circumstances which may affect the given
appraisement or cause to modify its scope.
2.4. - The Client is to give to the Society all access and information necessary for the performance of the requested Services.
ARTICLE 3
3.1. - The Rules, procedures and instructions of the Society take into account at the date of their preparation
the state of currently available and proven technical knowledge of the Industry. They are not a code of construction neither a guide for maintenance or a safety handbook.
Committees consisting of personalities from the Industry contribute to the development of those documents.
3.2. - The Society only is qualified to apply its Rules and to interpret them. Any reference to them has
no effect unless it involves the Society’s intervention.
3.3. - The Services of the Society are carried out by professional Surveyors according to the Code of Ethics
of the Members of the International Association of Classification Societies (IACS).
6.2. - If the Services of the Society cause to the Client a damage which is proved to be the direct and
reasonably foreseeable consequence of an error or omission of the Society, its liability towards the
Client is limited to ten times the amount of fee paid for the Service having caused the damage, provided however that this limit shall be subject to a minimum of eight thousand (8,000) Euro, and to a
maximum which is the greater of eight hundred thousand (800,000) Euro and one and a half times the
above mentioned fee.
The Society bears no liability for indirect or consequential loss such as e.g. loss of revenue, loss of
profit, loss of production, loss relative to other contracts and indemnities for termination of other
agreements.
6.3. - All claims are to be presented to the Society in writing within three months of the date when the Services
were supplied or (if later) the date when the events which are relied on of were first known to the Client, and
any claim which is not so presented shall be deemed waived and absolutely barred.
ARTICLE 7
7.1. - Requests for Services are to be in writing.
7.2. - Either the Client or the Society can terminate as of right the requested Services after giving the
other party thirty days' written notice, for convenience, and without prejudice to the provisions in Article 8 hereunder.
7.3. - The class granted to the concerned Units and the previously issued certificates remain valid until the
date of effect of the notice issued according to 7.2. hereabove subject to compliance with 2.3. hereabove and
Article 8 hereunder.
ARTICLE 8
8.1. - The Services of the Society, whether completed or not, involve the payment of fee upon receipt of the
invoice and the reimbursement of the expenses incurred.
8.2. - Overdue amounts are increased as of right by interest in accordance with the applicable legislation.
8.3. - The class of a Unit may be suspended in the event of non-payment of fee after a first unfruitful
notification to pay.
ARTICLE 9
9.1. - The documents and data provided to or prepared by the Society for its Services, and the information
available to the Society, are treated as confidential. However:
• Clients have access to the data they have provided to the Society and, during the period of classification
of the Unit for them, to the classification file consisting of survey reports and certificates which have been
prepared at any time by the Society for the classification of the Unit ;
• copy of the documents made available for the classification of the Unit and of available survey reports can
be handed over to another Classification Society Member of the International Association of Classification Societies (IACS) in case of the Unit’s transfer of class;
• the data relative to the evolution of the Register, to the class suspension and to the survey status of the
Units are passed on to IACS according to the association working rules;
• the certificates, documents and information relative to the Units classed with the Society may be reviewed
during IACS audits and are disclosed upon order of the concerned governmental or inter-governmental
authorities or of a Court having jurisdiction.
The documents and data are subject to a file management plan.
ARTICLE 10
3.4. - The operations of the Society in providing its Services are exclusively conducted by way of random inspections and do not in any circumstances involve monitoring or exhaustive verification.
10.1. - Any delay or shortcoming in the performance of its Services by the Society arising from an event not
reasonably foreseeable by or beyond the control of the Society shall be deemed not to be a breach of contract.
ARTICLE 4
ARTICLE 11
4.1. - The Society, acting by reference to its Rules:
• reviews the construction arrangements of the Units as shown on the documents presented by the Client;
• conducts surveys at the place of their construction;
• classes Units and enters their class in its Register;
• surveys periodically the Units in service to note that the requirements for the maintenance of class are
met.
11.1. - In case of diverging opinions during surveys between the Client and the Society’s surveyor, the Society
may designate another of its surveyors at the request of the Client.
11.2. - Disagreements of a technical nature between the Client and the Society can be submitted by the Society to the advice of its Marine Advisory Committee.
ARTICLE 12
The Client is to inform the Society without delay of circumstances which may cause the date or the
extent of the surveys to be changed.
12.1. - Disputes over the Services carried out by delegation of Governments are assessed within the framework of the applicable agreements with the States, international Conventions and national rules.
ARTICLE 5
12.2. - Disputes arising out of the payment of the Society’s invoices by the Client are submitted to the Court
of Nanterre, France.
5.1. - The Society acts as a provider of services. This cannot be construed as an obligation bearing
on the Society to obtain a result or as a warranty.
5.2. - The certificates issued by the Society pursuant to 5.1. here above are a statement on the level
of compliance of the Unit to its Rules or to the documents of reference for the Services provided for.
In particular, the Society does not engage in any work relating to the design, building, production or
repair checks, neither in the operation of the Units or in their trade, neither in any advisory services,
and cannot be held liable on those accounts. Its certificates cannot be construed as an implied or express warranty of safety, fitness for the purpose, seaworthiness of the Unit or of its value for sale,
insurance or chartering.
5.3. - The Society does not declare the acceptance or commissioning of a Unit, nor of its construction
in conformity with its design, that being the exclusive responsibility of its owner or builder, respectively.
5.4. - The Services of the Society cannot create any obligation bearing on the Society or constitute any warranty of proper operation, beyond any representation set forth in the Rules, of any Unit, equipment or machinery, computer software of any sort or other comparable concepts that has been subject to any survey by the
Society.
12.3. - Other disputes over the present General Conditions or over the Services of the Society are exclusively submitted to arbitration, by three arbitrators, in London according to the Arbitration Act
1996 or any statutory modification or re-enactment thereof. The contract between the Society and the
Client shall be governed by English law.
ARTICLE 13
13.1. - These General Conditions constitute the sole contractual obligations binding together the Society and the Client, to the exclusion of all other representation, statements, terms, conditions whether express or implied. They may be varied in writing by mutual agreement.
13.2. - The invalidity of one or more stipulations of the present General Conditions does not affect the validity
of the remaining provisions.
13.3. - The definitions herein take precedence over any definitions serving the same purpose which may appear in other documents issued by the Society.
BV Mod. Ad. ME 545 j - 16 February 2004
GUIDANCE NOTE NI 531
Guidelines for the application of the IMO
Performance Standard for Protective Coatings
Section 1
Introduction
Section 2
Main Contents and Requirements of the Performance
Standard for Protective Coatings - An Overview
Section 3
The Performance Standard for Protective Coatings Step
by Step
June 2007
Section 1
Introduction
1
General
1.1
1.2
1.3
2
5
General
Coating components
Main Contents and Requirements of the Performance Standard for
Protective Coatings - An Overview
1
General
1.1
1.2
2
3
6
9
General
Basic documents
Documents applicable during construction process
10
General
The Coating Technical File (CTF) - The evidence
of the PSPC implementation
6.1
9
General
The coating inspector
The coating manufacturer
The shipyard
The Classification Society and/or Recognised Organisation
The implementation of the coating standard into the shipyard
environment
5.1
7
General
Definition of the coating system
Approval of the coating system
Documents used for inspection agreement
4.1
4.2
4.3
5
PSPC overview
Flow chart of the PSPC
Parties involved in the coating process and their main duties
3.1
3.2
3.3
3.4
3.5
4
7
Design of the coating system
2.1
2.2
2.3
2
5
IMO PSPC
IACS PR 34
Terms and definitions
3.1
3.2
Section 2
Purpose
Scope of application of IMO PSPC
Scope of application of IACS PR 34
Reference documents
2.1
2.2
3
5
10
General
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June 2007
Section 3
The Performance Standard for Protective Coatings Step by Step
1
Achieving the coating quality level
1.1
2
3
5
6
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16
Coating application requirement
Inspection procedure requirement
Submission of document (CTF)
After finishing the coating application
Verification procedure requirement
Procedure requirement for in-service maintenance
6.1
15
Shop primer
Block assembly
Erection
Procedure requirement during application
5.1
5.2
5.3
5.4
5.5
15
The pre-job conference
Coating works inside the shipyard
4.1
4.2
4.3
11
Design requirement of the coating system
Approval requirement of the coating system
Preparation of the application procedure
Preparation of the inspection procedure
Submission of documentation (CTF)
Approval and verification requirement by the Society
Agreement between parties
3.1
4
General
Designing the coating system
2.1
2.2
2.3
2.4
2.5
2.6
11
19
General
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4
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NI 531, Sec 1
SECTION 1
1
1.1
INTRODUCTION
General
Tankers which are contracted for construction on or after 8
December 2006 and until the date of application referred to
in para.1 of SOLAS Regulation II-1/3-2 as adopted by IMO
Resolution MSC.216 (82).
Purpose
1.1.1 This Guidance Note provides information about coating inspection to be carried out in accordance with the
“Performance Standard for Protective Coatings in dedicated
seawater ballast tanks of all types of ships and double-side
skin spaces arranged in bulk carriers” referred to in SOLAS
Regulation II-1/3-2 as adopted by IMO Resolution MSC.216
(82).
1.2
1.3.2 Prior to 1 July 2008 IACS Common Structural Rules
invoke the PSPC for verification and inspection in accordance with IACS PR34.
2
Reference documents
2.1
Scope of application of IMO PSPC
1.2.1 The Performance Standard for Protective Coatings,
hereinafter referred to as “PSPC”, applies to ships of not less
than 500 gross tonnage:
• for which the building contract is placed on or after 1
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 1 January 2009
• or the delivery of which is on or after 1 July 2012.
All dedicated seawater ballast tanks arranged in ships and
double-side skin spaces arranged in bulk carriers of 150 m
in length and upwards shall be coated during construction
in accordance with the PSPC (excluding ballast hold in bulk
carriers, see [3.1.1])
1.2.2 The PSPC covers protective coating requirements for
the ship steel structure. It is noted that other independent
items are fitted within the tanks to which coatings are
applied to provide protection against corrosion.
IMO PSPC
2.1.1 IMO PSPC is the Performance Standard for Protective
Coatings for dedicated seawater ballast tanks in all types of
ships and double-side skin spaces of bulk carriers adopted
on 8 December 2006 by IMO Maritime Safety Committee
under Resolution MSC.215(82).
2.2
IACS PR 34
2.2.1 IACS PR 34 is the Procedural Requirement on application of the IMO PSPC, under IACS Common Structural
Rules for Bulk Carriers on Oil Tankers.
3
Terms and definitions
3.1
3.1.1
General
Seawater ballast tank
Seawater ballast tank is a tank which is used solely for salt
water ballast.
It includes:
1.2.3 It is recommended that the PSPC is applied, to the
extent possible, to those portions of permanent means of
access provided for inspection not integral to the ship structure, such as rails, independent platforms and ladders.
Other equivalent methods of providing corrosion protection
for the non-integral items may also be used, provided they
do not impair the performance of the coatings of the surrounding structure. Access arrangements that are integral to
the ship structure, such as increased stiffener depths for
walkways and stringers, are to comply with the PSPC.
1.2.4 It is also recommended that supports for piping and
measuring devices, be coated in accordance with the nonintegral items indicated in [1.2.3].
1.3
• side ballast tanks
• ballast double bottom spaces
• topside tanks
• hopper side tanks
• peak tanks.
Holds of bulk carriers used for both cargo and salt water
ballast are not considered as seawater ballast tanks in the
scope of this Guidance Note.
3.1.2
Edge grinding
Edge grinding is the treatment of edge before secondary surface preparation.
Scope of application of IACS PR 34
1.3.1 IACS has developed the Procedural Requirement (PR)
34 to be applied by IACS Societies to ships subject to the
IACS Common Structural Rules for Bulk Carriers and for Oil
June 2007
• segregated ballast tanks
3.1.3
“GOOD” condition
“GOOD” condition is the condition with minor spot rusting
as defined in Resolution A.744(18).
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NI 531, Sec 1
3.1.4 Hard coating
Hard coating is a coating that chemically converts during its
curing process or a non-convertible air drying coating
which may be used for maintenance purposes. It can be
either inorganic or organic.
3.1.5 DFT
DFT is the Dry Film Thickness.
3.2
Coating components
3.2.1 Pigments
Pigments are discrete particulate solids used to provide specific protective or decorative properties to the coating. They
are organic/inorganic chemical products.
3.2.2 Vehicle
Vehicle is the liquid part of the coating. It consists of the
binder, solvent and any liquid additives.
3.1.6 NDFT and 90/10 practice
NDFT is the Nominal Dry Film Thickness.
90/10 practice means that 90% of all thickness measurements shall be greater than or equal to NDFT and none of
the remaining 10% measurements shall be below 0.9
NDFT.
3.1.7 Primer coat
Primer coat is the first coat of the coating system applied in
the shipyard/manufacturer after shop primer application.
3.2.3 Binders
Binders (resins) are part of nonvolatile film-forming components. Their function is to bond coating material to object
surface during drying and after drying.
3.2.4 Solvents
Solvents are volatile components. They may be classified as:
a) Primary solvent (active): dissolves the resin to form a liquid solution
3.1.8 Shop-primer
Shop-primer is the prefabrication primer coating applied
before the first coat of a coating system to steel plates.
b) Latent solvent: often used together with the primary solvent (easiness of application, evaporation rate control,
enhancement of film properties)
3.1.9 Target useful life
Target useful life is the target value, in years, of the durability for which the coating system is designed.
c) Diluents are used with active solvents to dilute the coating. In some cases diluents may improve smoothness
and toughness of the film.
The two major characteristics of solvents, which influence
their use are:
3.1.10 Dust
Dust is loose particle matter present on a surface prepared
for painting, arising from blast-cleaning or other surface
preparation processes, or resulting from the action of the
environment.
3.1.11 Dew point
Dew point is the temperature at which air is saturated with
moisture.
3.1.12 Technical Data Sheet
The Technical Data Sheet (TDS) is coating manufacturer’s
product data sheet which contains detailed technical
instruction and information relevant to the coating and its
application. It is part of the coating system definition.
6
a) Solvency power: their ability to dissolve other chemical
compounds
b) Volatility: their ability to quit the coating (it governs the
evaporation rate)
Solvent safety is concerned with two types of hazards:
a) Fire hazards: Flash point
1) LEL (Lower Explosive Limit) is the lowest concentration of solvent vapor in air that can be ignited
2) UEL (Upper Explosive Limit) is the highest concentration of solvent vapor in air that can be ignited
b) Health hazards: all solvents to be handled with care
(ventilation, breathing apparatus and protective clothing)
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NI 531, Sec 2
SECTION 2
1
1.1
MAIN CONTENTS AND REQUIREMENTS OF THE
PERFORMANCE STANDARD FOR PROTECTIVE
COATINGS - AN OVERVIEW
General
c) Secondary surface preparation (including cleanliness
before and after surface preparation)
PSPC overview
d) Mixing and thinning operations regarding each type of
coat
1.1.1 The PSPC is addressing the following items/tasks:
e) Checking of environmental conditions during all coating operations
a) design of the coating system
b) parties involved in the coating process and their main
duties
c) agreement between parties with respect to contractual
documents
d) the implementation of the coating standard into the
shipyard environment
e) the Coating Technical File (CTF) - Demonstrating the
PSPC implementation
1.2
Flow chart of the PSPC
1.2.1 A general flow chart, pointing items listed in [1.1.1]
and tasks that are included inside of the PSPC, is presented
in Fig 1.
2
2.1
f)
Coating application manner, wet film thickness (uniformity of film thickness), nominal dry film thickness (per
layer, and for the total multi-coat).
Listed items a) to f) are specified inside of the PSPC, to referenced standards. Application of the referenced international
standards footnoted in the PSPC is mandatory under the
IACS PR 34.
The definition of the coating system, covering listed items a)
to f), is to be included into the manufacturing coating specification, which has to make reference to specific coating
Technical Data Sheets (TDS), and Material Safety Data
Sheets (MSDS).
The manufacturing coating specification must be in compliance with the PSPC's coating system definition.
At this stage, the manufacturing coating specification is to
be agreed upon between the shipowner, the shipyard and
the coating manufacturer (and coating applicator, as well),
with respect to the coating system definition.
Design of the coating system
General
The manufacturing coating specification is to address,
beyond of the coating system definition, other aspects, such
as safety and health, inspection, metrology.
2.1.1 The design of the coating system is consisting of:
a) Definition of the coating system
b) Approval of the coating system.
2.3
2.2
2.3.1 Within the scope of the CSR, the defined coating system must be qualified according to IACS PR 34, article 1,
“IACS procedure for coating system approval”.
Definition of the coating system
2.2.1 The definition of the coating system is consisting on
the following items:
a) Selection of the coating products: complete number and
types of coats applied to a substrate in a predetermined
order
b) Primary surface preparation (including cleanliness
before and after surface preparation)
June 2007
Approval of the coating system
A collection of relevant documents/reports regarding the
approval of the coating system is made by the coating manufacturer and provided to the shipyard.
Statement of Compliance (SOC) or Type Approval Certificate of the coating system is to be kept inside the Coating
Technical File (CTF).
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NI 531, Sec 2
Designing
coating
system
Coating
system
Definition and specification of the coating system
issue statement of
compliance or TAC
Approval of the coating system
request
Agreement on the inspection procedures & plan
review
Agreementbetween
between parties
Agreement
parties
check approval
Coating specifications
(Technical data sheets & statement of compliance or TAC)
review
Inspection
procedures & TDS
plan
Coating
specification,
check qualification
Selection ofofCoating
Inspector
(CI)
Qualification
the coating
inspector
agree
Coating Manufacturer
Third Party
Figure 1: PSPC Flow Chart
submit
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check ID
on containers
Steel preparation and Coating application
• Shop primer
• Block construction
• Erection
implement
Coating work records
check
Shipyard
New Construction
maintain
Inspection
• Inspection logs of CI checked for proper equipment,
Ship verified
techniques,
and inspection
methodologyreport
Technical
File (maintained
onboard)
CTF:Coating
COATING
TECHNICAL
FILE
compile
• Agreement between parties
• Statement of compliance or TAC of coating system
• Coating technical data sheets
• Shipyard work records
• Inspection procedures
• Coating inspection logs of CI
• Shipyard inspection report verified by CI
Shipowner
review
In-service procedures and records
In-service maintenance, repair and re-coating
8
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implement
June 2007
NI 531, Sec 2
3
Parties involved in the coating process
and their main duties
3.1
3.4
The shipyard
3.4.1 The shipyard:
a) ensures that all technical aspects of the PSPC are
addressed, with reference to relevant standards
General
3.1.1 The parties identified inside of the PSPC are:
a) The coating inspector (CI), with a specific qualification
level
b) The coating manufacturer
b) enforces the application of the manufacturing coating
specification and checks that relevant standards are met
c) ensures that the Quality Assurance system is addressing
all aspects regarding coating activities, including non
conformities and their relevant corrective actions.
c) The shipyard
3.5
d) The Administration, or the Recognised Organisation
The Classification Society and/or Recognised Organisation
e) The Classification Society
f)
The shipowner.
The duties of the coating inspector, the coating manufacturer, the shipyard, the Classification Society as the Recognised Organisation are addressed under [3.2] to [3.5].
3.2
The coating inspector
3.5.1 The Classification Society and/or Recognised Organisation will check, at random, that:
a) Basic documents listed in [4.2], including Technical
Data Sheet and Statement of Compliance or Type
Approval Certificate comply with the PSPC
b) Coating identification on representative containers is
consistent with respect to Technical Data Sheet and
Statement of Compliance or Type Approval Certificate
3.2.1 The main activities of the coating inspector are:
a) Before the job coating works starts:
• read, and comprehend the manufacturing coating
specification, referenced codes, and standards
• study coating material data sheets, checking for any
conflict with the specification
• visit the site.
c) Coating inspector’s qualification is in accordance with
the qualification level of the PSPC
d) Coating inspector's reports of surface preparation and
coating's application indicate compliance with Technical Data Sheet and Statement of Compliance or Type
Approval Certificate
e) Documents listed in [4.3] are duly filled in/written/signed, and form part of the CTF.
b) At the pre-job conference:
• resolve any questions about the specifications,
including specific reports, test instruments, and procedures
The Classification Society and/or Recognised Organisationwill also monitor implementation of the coating inspection
requirements.
• if required, be ready to state exactly what tests and
reports to adopt
3.5.2
• determine what are the responsibilities and authority
of the coating inspector.
The main duties of the Classification Society are stated in
the IACS PR 34.
c) During work:
• perform Quality Control tasks; report and record all
these Quality Control activities
• checks the compliance of the work with the specification requirements
• report all non conformities and relevant corrective
actions.
3.3
The coating manufacturer
4.1
Documents used for inspection
agreement
General
4.1.1 All the coating works shall be expressed in terms of
technical procedures and documents specific to the project,
which are to be agreed upon between involved parties.
These documents can be divided into two main classes:
basic documents and documents applicable during construction process, as listed in [4.2] and [4.3].
3.3.1 The coating manufacturer:
a) provides the coating material, selected to ensuring the
15 years of product target useful life, as required by
PSPC
b) provides TDS & MSDS related with relevant coating
material
c) advises and assists the shipyard & the coating applicator
if needed.
June 2007
4
Reference to IACS PR 34
4.2
Basic documents
4.2.1 These documents are:
• Manufacturing coating specification
• Technical Data Sheet
• Material Safety Data Sheet
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NI 531, Sec 2
• Procedure of coating application
It is the responsibility of the shipyard to provide clear
instructions regarding important steps of the coating
application
• TAC or SOC of coating system
• Inspection procedure of surface preparation and coating
process (specification review, pre-job meeting minutes,
scope of work, safety data, coating inspector's check list
and inspection details)
• Certificate of coating inspector
• Procedures for in-service maintenance and repair of
coating system.
4.3
Documents applicable during construction process
4.3.1 Synthesis document issued by the shipyard
A synthesis document, containing the list of all seawater
ballat tanks and double-side skin spaces of the ship under
construction, including their respective identification numbers, is to be issued by the shipyard. This document should
allow to trace the coating works and records. It should
clearly indicate, for each concerned tank, the identification
numbers of construction blocks, sub-items and tasks, that
are included in the CTF.
4.3.2 Documents during construction process
Documents applicable during construction process that are
to be added to the CTF are:
• shipyard work records of coating application
• coating log issued by coating inspector
• non conformity report if any, and relevant corrective
action
• shipyard's verified inspection report.
5
5.1
The implementation of the coating standard into the shipyard environment
General
5.1.1 The approved coating system must be integrated into
the whole ship construction process. This will be demon-
strated by making sure that the following aspects are
respected:
•
The approved coating system, which is defined in the
manufacturing coating specification, is the one being
implemented to the process
•
The manufacturing coating specification is complying
with the PSPC requirements
•
Raw materials are marked, stored and correspond to
those specified in the manufacturing coating specification and TDS
•
All coating operations are performed in accordance
with the manufacturing coating specification
•
Traceability of all coating operations is ensured along
the whole coating process, by keeping records on
reports and documents. These records are also to
include non conformities and corrective actions.
•
The PSPC is ensuring the implementation of the
designed coating system by clearly providing the list of
minimum inspection items to be covered by the coating
inspector.
•
Each process is ensuring the maintenance of the quality
level within the PSPC requirements and/or the workmanship preliminary defined by the shipyard as shown
in the attached example, given in Tab 1.
6
The Coating Technical File (CTF) - The
evidence of the PSPC implementation
6.1
General
6.1.1 All documents listed under [4.2] and [4.3] are to be
part of the Coating Technical File (CTF), providing the evidence that the designed coating system has been implemented into the whole ship construction process.
The CTF is to be submitted to the Administration or Recognized Organization, for review.
Table 1 : Implementation of PSPC
Construction process
Critical pass
Possible causes
Quality Control action
Shop primer
Water soluble salt ≤ 50
mg/m2
Improper cleaning process
To confirm cleaning process
before surface treatment
Surface treatment after erection
Damaged area < 2%
Overhaul of structure or
outfitting after coating
Proper Quality Control and
production planning/control
10
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SECTION 3
1
1.1
THE PERFORMANCE STANDARD FOR PROTECTIVE
COATINGS STEP BY STEP
at this area prepared to the relevant standard, for the coating application.
Achieving the coating quality level
General
1.1.1
The achievement of the coating quality level
requested by the PSPC is not only the challenge of the coating applicator, but a work to be conducted jointly by all
parties intervening in the various stages of the ship construction process.
Since the very beginning of the project, at the design stage,
the various aspects of the coating process are to be taken
into consideration. Complicated details of the structure, difficult access to certain areas, creation of regions of poor
ventilation, and poor drainage should be avoided. In other
cases, design deficiencies regarding the coating may add
difficulties to obtain the required level of standards referred
into the PSPC, for surface preparation activities, for the
nominal dry film thickness, or related with any other specific coating characteristic.
The PSPC is considering these aspects under paragraph
3.3.2, as follows:
The coating performance can be improved by adopting
measures at the ship design stage such as reducing scallops,
using rolled profiles, avoiding complex geometric configurations and ensuring that the structural configuration permits
easy access for tools and to facilitate cleaning, drainage and
drying of the space to be coated.
After the design, the specification of the coating works is to
be prepared in tightly contact with the coating manufacturer, to take into consideration some practical aspects of
the application process, such as:
• the easiness of the coating application
• the need of very high level of skilled labor, required for
the application of some modern coatings, and may be,
not available at the construction site
• the availability of necessary sophisticated equipment,
required for some types of coatings.
The subject of specifications and selection of coating systems is to be addressed taking into consideration all possible coating application problems that could exist for the
specific project under consideration.
Special attention is to be drawn to temporary construction
aids, to make sure they are removed after construction, and
not left in place, and coated along with the original coating
application. These aids are to be removed, and the surface
June 2007
The production of a quality coating is much dependent of
the ability of the coating applicator to perform its job, with
an appropriate application technique. Special attention is to
be paid to make sure that he has the required level of qualification. Typical problems caused by poor qualification
level and faulty application techniques could include:
improper thickness of the coat, pinholes, overspray, holidays and pinpoint rusting.
2
2.1
Designing the coating system
Design requirement of the coating system
2.1.1 The definition of the coating system must meet all relevant requirements of Table 1 of the PSPC.
Coating manufacturers shall provide a specification of the
protective coating system to satisfy the requirements ofTab
1, which is an extract of Table 1 of the PSPC, regarding the
design of the coating system.
2.2
Approval requirement of the coating
system
2.2.1 Coating type is epoxy based systems.
Coating pre-qualification test should comply with Tab 1,
item 3.
Epoxy based systems tested prior to the date of entry into
force of the PSPC, except for CSR, for which IACS PR 34
applies (December 8, 2006 is the entry into force date), in a
laboratory by a method corresponding to the test procedure
in annex 1 of the PSPC or equivalent, which as a minimum
meets the requirements for rusting and blistering; or which
have documented field exposure for 5 years with a final
coating condition of not less than "GOOD" may be
accepted.
For all other systems, testing according to the procedure in
annex 1 of the PSPC, or equivalent, is required.
Results from prequalification tests (Tab 1, item 3) of the
coating system shall be documented, and a Statement of
Compliance or Type Approval Certificate shall be issued if
found satisfactory by a third party, independent of the coating manufacturer.
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Table 1 : Basic coating system requirements for dedicated seawater ballast tanks of all type of ships
and double-side skin spaces of bulk carriers of 150 m and upward
Item
Characteristic
Requirement
1
Selection of the coating
system
The selection of the coating system should be considered by the parties involved with respect to
the service conditions and planned maintenance. The following aspects, among other things
should be considered:
• location of space relative to heated surfaces
• frequency of ballasting and deballasting operations
• required surface conditions
• required surface cleanliness and dryness
• supplementary cathodic protections, if any (where coating is supplemented by cahodic
protection, the coating should be compatible with the cathodic protection system).
Coating manufactures shall have products with documented satisfactory performance records and
Technical Data Sheets. The manufactures should also be capable of rendering adequate technical
assistance. Performance records, Technical Data Sheet and technical assistance (if given) shall be
recorded in the Coating Technical File.
Coating for application underneath sun-heated decks or on bulkheads forming boundaries of
heated spaces shall be able to withstand repeated heating and/or cooling without becoming
brittle.
2
Coating type
Epoxy based systems.
Other coating systems with performance according to the test procedure in annex 1 of PSPC.
A multi-coat system with each coat of contrasting colour is recommended.
The top coat shall be of a light colour in order to facilitate in-service inspection.
3
Coating pre-qualification
test
Epoxy based systems tested prior to the date of entry into force of the PSPC in a laboratory by a
method corresponding to the test procedure in annex 1 of PSPC or equivalent, which as a minimum meets the requirements for rusting and blistering; or which have documented field exposure
for 5 years with a final coating condition of not less than "GOOD" may be accepted.
For all other system, testing according to the procedure in annex 1 of PSPC, or equivalent, is
required.
4
Job specification
There shall be a minimum of two stripe coats and two spray coats, except that the second stripe
coat, by way of welded seams only, may be reduced in scope where it is proven that the NDFT
can be met by the coats applied in order to avoid unnecessary over thickness. Any reduction in
scope of the second stripe coat shall be fully detailed in the CTF.
Stripe coats shall be applied by brush or roller. Roller to be used for scallops, ratholes, etc., only.
Each main coating layer shall be appropriately cured before application of the next coat, in accordance with coating manufacturer's recommendations.
Surface contaminants such as rust, grease, dust, salt, oil, etc. shall be removed prior to painting
with proper method according to the paint manufacturer's recommendation. Abrasive inclusions
embedded in the coating shall be removed. Job specifications shall include the dry-to-recoat
times and walk-on time given by the manufacturer.
5
NDFT (Nominal Dry
Film Thickness)
NDFT 320 µm with 90/10 rule for epoxy based coatings, other systems to coating manufacturer's
specifications.
Maximum total dry film thickness according to manufacturer's detailed specifications.
Care shall be taken to avoid increasing the thickness in an exaggerated way.
Wet film thickness shall be regularly checked during application.
Thinner shall be limited to those types and quantities recommended by themanufacturer.
IACS interpretation of PSPC: as for the IACS CSR for Bulk
Carriers and for Oil Tankers, which are contracted for construction on or after 8 December 2006 and until the date of
application referred to in para.1 of SOLAS Regulation II-1/32, as adopted by IMO Resolution MSC.216(82), the procedure for coating system approval refer to PR34, article 1.
Method A: Laboratory Test
Type Approval Certificate showing compliance with the
PSPC section 5 shall be issued if the results of either method
A+D, or B+D, or C+D are found satisfactory by the Society.
b) Results from satisfactory pre-qualification tests (PSPC
table 1, paragraph 1.3 of the PSPC) of the coating system shall be documented and submitted to the Society.
12
a) Coating pre-qualification test shall be carried out by the
test laboratory which is recognized by the Society and
meets the requirements set out in IACS UR Z17 paragraphs 4, 5, 6 and 7 (except for 4.6 & 5.3) as below.
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June 2007
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Method B: 5 years field exposure
This verification should be performed with respect to:
a) Coating manufacturer's records are to be examined to
confirm coating system has 5 years field exposure.
a) Surface preparation and allied discipline:
b) A joint (coating manufacturer/Society) survey of all ballast tanks of a selected ship is to be carried out for the
purpose of verification of compliance with the requirements of item a) and item e). The coating manufacturer's representative is to be qualified as defined in 2.2
of PR34.
• steel surface
• staging, lighting, ventilation, dehumidifying, and
heating
• contamination, abrasive blasting and water jetting
b) Application:
• stripe coating
• application method
c) The selected ship is to have ballast tanks in regular use,
of which:
•
at least one tank approx 2000 m3
•
at least one tank shall be adjacent to heated tank
and
•
at least one tank underdeck exposed to sun.
c) Repairs during new building:
e) All ballast tanks are to be in "GOOD" condition, without touch up or repair in the prior 5 years.
•
• materials for repair
• repair process
d) Supplementary cathodic protection.
d) In the case that the selected ship does not meet the
requirements in 1.5 then the limitations shall be clearly
stated on the type approval certificate. For example, the
coating cannot be used in tanks adjacent to heated
tanks or underdeck or tanks with volume greater than
the size surveyed.
•
• conditions for painting application work
“GOOD" is defined as: condition with spot rusting
on less than 3% of the area under consideration
without visible failure of the coating. Rusting at
edges or welds, must be on less than 20% of edges
or welds in the area under consideration.
Examples of how to report coating conditions with
respect to areas under consideration should be as
those given in IACS Recommendation 87, Appendix 1.
Method C: Existing Marintek B1 approvals.
a) Epoxy coatings systems with existing satisfactory
Marintek test reports minimum level B1 issued before
Dec 8th 2006 can be accepted.
b) Such coatings are to be applied in accordance with
Table 1 of the PSPC rather than the application conditions used during the approval test which may differ
from the PSPC, unless these are more stringent than
table 1 of the PSPC.
2.4
Preparation of the inspection procedure
2.4.1 The procedure of inspection of surface preparation
and coating processes shall be agreed upon between the
shipowner, the shipyard and the coating manufacturer and
presented to the Society for review. The Society may, if it so
requires, participate in the agreement process. Clear evidence of these inspections shall be reported and be
included in the Coating Technical File (CTF) (PSPC, section
3.2 and PR34, article 3).
2.4.2 Procedures for inspection and repair procedures at
new construction stage are to give sufficient details for:
-
Equipment and condition (staging, accessibility lighting,
ventilation, dehumidifying, and heating)
-
The inspection items as a minimum, identified in section
6.2 of PSPC (surface preparation, coating application)
-
Acceptance criteria:
• Visual appearance
• Measurements of DFT
• Control for adhesive/cohesive properties, for holidays and for mechanical damage.
2.4.3 Qualification - The coating inspector is to have at
least one of the following qualifications:
Method D: Coating manufacturer
• NACE coating inspector Level 2
a) The coating manufacturer shall meet the requirements
set out in IACS UR Z17 paragraphs 4, 5, 6 and 7,
(except for 4.6), which is to be verified by the Society.
• FROSIO inspector Level III
b) In the case that a manufacturer wishes to have products
which are manufactured in different locations under the
same name, then infrared (IR) identification and specific
gravity shall be used to demonstrate that they are the
same coating, or individual approval tests will be
required for the paint manufactured in each location.
Moreover, only coating inspectors with at least 2 years relevant coating inspector experience, can write and\or authorize procedures, or decide upon corrective actions to
overcome non-compliances.
2.3
Preparation of the application procedure
2.3.1 Shipyard application procedure is to be verified by
coating inspectors and coating manufacturer to check its
conformance with the PSCPC.
June 2007
• Equivalent qualifications accepted by the Society.
2.4.4 Equivalent qualification:
Equivalent qualification is the successful completion, as
determined by course tutor, of an approved course.
The course tutors shall be qualified with at least 2 years relevant experience and qualified to NACE coating inspector
Level 2 or FROSIO inspector Level III, or with an equivalent
qualification.
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Approved course: a course that has a syllabus based on the
issues associated with the PSPC including the following:
• Health environment and safety
• Corrosion
• Materials and design
• International standards referenced in PSPC
• Curing mechanisms
• Role of inspector
• Test instruments
• Inspection procedures
• Coating specification
• Application procedures
• Coating failures
• Pre-job conference
• MSDS and product data sheet review
• Coating technical file
• Surface preparation
• Dehumidification
• Water jetting
• Coating types and inspection criteria
• Specialized application equipment
• Use of inspection procedures for destructive testing and
non destructive testing instruments.
• Inspection instruments and test methods
• Coating inspection techniques
• Cathodic protection
• Practical exercises, case studies.
Examples of approved courses may be internal courses run
by the coating manufacturers or shipyards.
Such a course shall have an acceptable measurement of
performance, such as an examination with both theoretical
and practical elements. The course and examination shall
be approved by the Society.
Equivalent qualification arising from practical experience is
considering an individual who:
• has a minimum of 5-years practical work experience as a
coating inspector of ballast tanks during new construction within the last 10 years, and
• has successfully completed the examination given hereabove.
2.5
• application methods, tools and/or machines
• condition of surface to be coated (de-rusting grade,
cleanness, profile), and
• environmental limitations (temperature and humidity).
d) Safety data sheet:
• identification of the preparation and of the company
• composition/information on ingredients
• hazards identification
• first aid measures
• fire-fighting measures
• accidental release measures
• handling and storage
• exposure control/personal protection
• physical and chemical properties
• transport information
• regulatory information
• additional information.
e) Specification of the coating system to satisfy the requirements of PSPC, including:
• project name and application area
• steel preparation and surface preparation and surface cleanliness
• product information: paint system, physical constant, application method, recoating interval, etc.
• environmental conditions
• how to do:
Documents issued by the coating
manufacturer
The following documents are to be provided by the coating
manufacturer to the shipyard:
a) Copy of Statement of Compliance or Type Approval Certificate
b) Documents on products with satisfactory performance
records
c) Technical Data Sheet of the coating system complying
with the IMO PSPC and containing at least:
• product name and identification mark and/or number
• materials, components and composition of the coating system, colours
-
application procedure
-
acceptance criteria and
-
inspection
In case of a technical assistance, if any: refer to service
agreement.
2.5.2 Documents issued by the shipyard
The following document, issued by the shipyard, with the
assistance of the coating manufacturer, is to be provided:
•
Verified coating application procedure of shipyard.
2.6
Submission of documentation (CTF)
2.5.1
14
• minimum and maximum dry film thickness
Approval and verification requirement
by the Society
2.6.1 The procedure for inspection of surface preparation
and coating processes shall be agreed upon, between the
shipowner, the shipyard and the coating manufacturer. It
should be presented by the shipyard to the Society for
review.
2.6.2 Coating system approval: Type Approval Certificate
showing compliance with the PSPC section 5 shall be
issued if the results of either method A+D, or B+D, or C+D
are found satisfactory by either the Society or a third party
recognised by the Society (see IACS PR34).
2.6.3 Check that the Technical Data Sheet and Statement of
Compliance or Type Approval Certificate comply with the
PSPC.
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June 2007
NI 531, Sec 3
2.6.4 Check that the inspector is qualified in accordance
with the qualification standards in paragraph 2.4.2 to 2.4.4
of PR34.
3
scaffold, tarpaulins
m) communication means
n) safety issues.
The pre-job conference
3.1.1 General
The shipyard prior to starting works, notifies the coating
manufacturer, the shipowner and the coating inspector in
advance, about the pre-job conference. During this meeting, the parties can analyse and discuss the following contractual documents:
• manufacturing coating specification
• technical data sheet
• material safety document sheet
• procedure of coating application complied by shipyard
It is the responsibility of the Shipyard to provide clear
instructions regarding all important steps of the coating
application, including time schedule
• TAC or SOC of coating system
• inspection (procedure) of surface preparation and coating process (specification review, scope of work, safety
data, coating inspector's check list, inspection details)
• certificate of coating inspector
• procedures for in-service maintenance and repair of
coating system.
A collection of applicable standards and relevant technical
documents should be available during the meeting, permitting to clarify any specific technical issue, if necessary.
3.1.3 Minutes of meeting
All involved parties in the scope of the PSPC should be represented in this meeting. As an example, a list of persons
participating in this meeting could be: shipowner, shipyard
(management: construction operator, project manager; purchasing agent, design engineer, safety engineer, Quality
Assurance), subcontractors (suppliers, coating applicator,
coating manufacturer), coating inspector, etc. The coating
inspector is a key party, and may be in contact with all these
persons during the project. The pre-job conference is in
general a good opportunity to permit all parties to be in
contact.
Clear minutes of the meeting should be written, covering all
questions and answers. At the end of the meeting all potential sources of problems should be raised, and appropriate
solutions adopted. The minutes will become a contractual
document, which is a part of the agreement between parties, containing the issues covered during the meeting.
4
3.1.2 Topics to cover in the meeting
The items to be discussed should cover:
a) review of standards and work procedures, to resolve any
ambiguities or errors inside of these documents
b) scope of coating works:
• list of all items/sub items to be coated, indicating
areas not to be coated
c) surface preparation:
• cleaning process
-
pre-inspection - a procedure to inspect for, mark,
and correct fabrication defects
-
pre-cleaning - removal of contaminants (oil,
grease, dirt) by solvent cleaning to a known standard
-
accessibility to all items and sub-items to be coated
k) all capabilities at site (power supplies, water, shower,
toilets)
l)
Agreement between parties
3.1
j)
cleaning operations to referenced standards
(hand tool, or power tool, or abrasive blasting
cleaning operations)
• anchor profile
d) coating material standards (TDS/MSDS are provided,
and suitably written)
e) workmanship
4.1
Coating works inside the shipyard
Shop primer
4.1.1 Coating works according to Table 1 of PSPC
Before starting the surface preparation, all steel defects have
to be treated according to the standards referred into the
PSPC. These defects are including, amongst others, surface
laminations, shelling, and inclusions.
The soluble salt content should be checked to the acceptable limit of the PSPC (50 mg/m2).
Oil, grease, and any other contaminations should also be
checked according to the PSPC.
All these operations are to be performed taking into account
the environment conditions (air and surface temperatures,
relative humidity and dew point.)
4.1.2 Inspection requirement
Raw materials should be confirmed to meet the requirements of the approved coating manufacturer’s documents
(TDS, MSDS). Cleanliness should be monitored, and oil
grease be checked by relevant method such as 'chalk mark
test".
h) frequency of tests
Measurement of salt content and, if necessary, removal
before going into shot blasting is to be considered. Otherwise shipyard procedures are to check salt content after shot
blasting. The whole conductivity value is calculated to
NaCl equivalent.
i)
DFT shall be confirmed to conform to the specified values.
f)
work schedule
g) inspection methods and interpretation of results / reporting forms (formats)
non conformities and corrective actions
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4.2
4.2.1
Block assembly
Surface preparation
The performance of coating system is very dependent on
the quality and type of surface preparation (adhesion properties of the film).
During abrasive blasting and cleaning operations, checks of
ambient climate must be done at the following chronological points:
a) immediately before abrasive blasting
that openings for tank cleaning machines are adequately covered to prevent ingress of dirt or water
•
that rain shelters are built over tank accesses.
Stripe coating of welds and places difficult to reach by spray
should be done by brush, to ensure sufficient film thicknesses on such areas.
Improper film formation is not acceptable as this will
reduce the protective properties of the coating.
4.2.3
b) during the mid-shift break if possible
Acceptance
DFT measurements shall be taken according to annex 3 of
the PSPC, to prove that the coating has been applied to the
specified thickness.
c) at the inspection after the rough cleaning
d) at the completion of the final cleaning inspection.
Steel work should be treated before blasting for welding
defects.
Edges are to be treated to a rounded radius of minimum 2
mm, or subjected to three pass grinding or at least equivalent process before painting. Edges means all edges except
the natural rounded edges of sections (or profiled steel
bars).
Any oil, grease or other visible contamination are to be
removed.
Blasting abrasives to be used should comply with relevant
requirement or ISO standard, such as ISO 11124, ISO
11125, ISO 11126 and ISO 11127.
After blasting and cleaning and prior to the application of
the first coat of the system, the steel surface shall be tested
for levels of remaining soluble salts in at least one location
per block. The limit of salt content should comply to table 1
of PSPC. In case of non compliance, effective remedy methods could be referring to coating manufacturer's recommendation.
4.2.2
•
Another acceptance criterion should be based upon the
visual appearance inspection, used to make the decision on
whether detected defects should be repaired.
4.3
4.3.1
Checks of ambient conditions must be done before coating
and regularly during the coating process.
The identification and appraisal of damaged area are to be
duly performed. The calculated damaged area is to comply
with the requirement of table 1 of PSPC. For this purpose,
the scribing matrix method, based on photos and area calculations could be adopted.
Procedure requirement during application
For paint application work, the coating applicator (contractor or shipyard) must ensure that:
5.1
• safety regulations are obeyed
• storage of paint is duly considered.
Before application of any paint the coating applicator (contractor or shipyard) should also check the following:
• suitability of application equipment
Surface preparation
After erection of blocks, conformance to table 1 of PSPC,
and to the agreed coating specification is to be verified, by
considering, amongst others, the visual inspection for steel
surface condition, and surface preparation.
5
Coating application
Erection
Coating application requirement
5.1.1 The shipyard shall apply the protective coating in
accordance with the verified Technical Data Sheet and its
own verified application procedures.
5.1.2 The requirements for protective coating systems
meeting the PSPC are listed in Tab 2.
• wet film thickness during application
• air dehumidification level, ventilation and heating
equipment to maintain the steel in a dry condition at a
temperature above the specified minimum at all times
during the paint application and subsequent curing.
5.1.3 Shipyard work records of coating application are to
provide information on:
•
applied actual space and area (m2) of each compartment
•
applied coating system
• that the ventilation and/or air-conditioning equipment is
kept running
•
time of coating, thickness and number of layers
•
ambient condition during coating
• that coating applicator (contractor or shipyard) keeps
the deck free from blasting material and debris in the
vicinity of tanks being coated
•
method of surface preparation
During the coating application the following must be controlled:
16
An extract of table 1 of the PSPC is given in Tab 2.
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June 2007
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Table 2 : Requirements for coating application
Item
Characteristic
Requirement
PSP (Primary Surface Preparation)
1
Blasting and Profile
Sa 2½; with profiles between 30-75µm
Blasting shall not be carried out when:
• the relative humidity is above 85 %; or
• the surface temperature of steel is less than 3° C above the dew point
Checking of the steel surface cleanliness and roughness profile shall be carried out at the end of
the surface preparation and before the application of the primer, in accordance with the manufacturer’s recommendations.
2
Water soluble salts limit
equivalent to NaCl
≤ 50 mg/m² of sodium chloride.
3
Shop primer
Zinc containing inhibitor free zinc silicate based or equivalent.
Compatibility with main coating system shall be confirmed by the coating manufacturer.
Secondary surface preparation
1
Steel condition
The steel surface shall be prepared so that the coating selected can achieve an even distribution
at the required NDFT and have an adequate adhesion by removing sharp edges, grinding weld
beads and removing weld spatter and any other surface contaminant.
Edges to be treated to a rounded radius of minimum 2 mm, or subjected to three pass grinding or
at least equivalent process before painting.
2
Surface treatment
Sa 2½ on damaged shop primer and welds.
Sa 2 removing at least 70% of intact shop primer, which has not passed a pre-qualification certified by test procedures in 1.3 of Table 1 of PSPC.
If the complete coating system comprising epoxy based main coating and shop primer has
passed a pre-qualification certified by test procedures in 1.3 of Table 1 of PSPC, intact shop
primer may be retained, provided the same epoxy coating system is used. The retained shop
primer shall be cleaned by sweep blasting, high pressure water washing or equivalent method.
If a zinc silicate shop primer has passed the pre-qualification test of 1.3 of Table 1 of PSPC as
part of an epoxy coating system, it may be used in combination with other epoxy coatings certified under 1.3 of Table 1 of PSPC, provided that the compatibility has been confirmed by the
manufacturer by the test in accordance with paragraph 1.7 of appendix 1 to annex 1 of PSPC
without wave movement.
3
Surface treatment after
erection
Butts St 3 or better or Sa 2½ where practicable. Small damages up to 2% of total area: St3.
Contiguous damages over 25m² or over 2% the total area of the tank Sa 2½ should be applied.
Coating in overlap to be feathered.
4
Profile requirements
In case of full or partial blasting 30-75µm, otherwise as recommended by the coating manufacturer.
5
Dust
Dust quantity rating "1"for dust size class "3", "4" or "5". Lower dust size classes to be removed if
visible on the surface to be coated without magnification.
6
Water soluble salts limit
equivalent to NaCl after
blasting / griding
≤ 50 mg/m² of sodium chloride.
7
Oil contamination
No oil contamination.
Miscellaneous
1
Ventilation
Adequate ventilation is necessary for the proper drying and curing of coating. Ventilation should
be maintained throughout the application process and for a period after application is completed, as recommended by the coating manufacturer.
2
Environmental conditions
Coating shall be applied under controlled humidity and surface conditions, in accordance with
the manufacturer's specifications. In addition, coating shall not be applied when:
• the relative humidity is above 85%; or
• the surface temperature is less than 3ºC above the dew point.
3
Testing of coatings
Destructive testing should be avoided.
Dry film thickness shall be measured after each coat for quality control purpose and the total dry
film thickness shall be confirmed after completion of final coat, using appropriate thickness
gauges (see annex 3 of PSPC).
4
Repair
Any defective areas, e.g. pin-holes, bubbles, voids, etc. should be marked up and appropriate
repairs effected. All such repairs shall be re-checked and documented.
June 2007
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5.2
5.2.1
Inspection procedure requirement
Inspector’s qualification
The inspection shall be carried out by qualified coating
inspectors, as stated in [2.4.3].
5.2.2
Inspection
Inspection activities are to be carried out, as follows:
a) Coating inspectors shall inspect surface preparation and
coating application during the coating process by carrying out, as a minimum, those inspection items identified
in Tab 3 to ensure compliance with the PSPC.
b) Copy of Technical Data Sheet, including:
• product name and identification mark and/or number
• materials, components and composition of the coating system, colours
• minimum and maximum dry film thickness
• application methods, tools and/or machines
• condition of surface to be coated (de-rusting grade,
cleanliness and profile)
• environmental limitations (temperature and humidity).
c) Shipyard work records of coating application, including:
b) Emphasis shall be placed on initiation of each stage of
surface preparation and coatings application as
improper work is extremely difficult to correct later in
the coating progress:
• applied actual space and area (in m2) of each compartment
• applied coating system
• time of coating, thickness and number of layers
• ambient condition during coating
• method of surface preparation.
• representative structural members shall be nondestructively examined for coating thickness
• the coating inspector shall verify that appropriate
collective measures have been carried out
• results from the inspection shall be recorded by the
coating inspector.
5.3
Submission of document (CTF)
5.3.1 Coating log issued by the coating inspector (examples of daily log and non-conformity report are given in
annex 2 of the PSPC):
d) Procedures for inspection and repair of coating system
during ship construction.
e) Coating log issued by the coating inspector, stating that
the coating was applied in accordance with the specifications to the satisfaction of the coating supplier representative and specifying deviations from the
specifications.
f)
• inspection records by block and erection
• list of deviations for each compartment
• amendment/correction record.
g) Procedures for in-service maintenance and repair of
coating system.
5.3.2 Shipyard's verified inspection report, including:
5.5
• completion date of inspection
• result of inspection, for each compartment
• coating inspector’s signature.
After finishing the coating application
5.4.1 Shipyard should compile the complete CTF and
present it to the Classification Society and/or the Administration for review.
5.4.2 Specification of the coating system applied to the
dedicated seawater ballast tanks and double-side skin
spaces, record of the shipyard's and shipowner's coating
work, detailed criteria for coating selection, job specifications, inspection, maintenance and repair shall be documented in the Coating Technical File (CTF).
5.4.3 The Coating Technical File (CTF) contains at least the
following items related to the PSPC at new ship construction stage:
a) Copy of Statement of Compliance or Type Approval Certificate.
18
Verification procedure requirement
5.5.1 Check that the coating identification on representative containers is consistent with the coating identified in
the Technical Data Sheet and Statement of Compliance or
Type Approval Certificate.
• remarks
5.4
Shipyard's verified inspection report, including:
• completion date of inspection
• result of inspection
• remarks
• coating inspector's signature.
5.5.2 Check that the coating inspector's reports of surface
preparation and coating application indicate compliance
with the manufacturer's Technical Data Sheet and Statement of Compliance or Type Approval Certificate.
5.5.3 Monitoring:
a) Implementation of the coating inspection requirements,
as called for in PSPC, section 7.5, means checking, on a
sampling basis, that inspection documents show that the
coating inspectors are using the equipment, techniques
and reporting methods as described in the agreed procedure for inspection. The logs of the coating inspector
and relevant documentation describing the techniques
and equipment are to be submitted to the Classification
Society for this purpose, see [5.3.1].
b) Any deviations to item a) are to be raised initially with
the coating inspector, who is responsible for identifying
and implementing the corrective actions.
Bureau Veritas
June 2007
NI 531, Sec 3
c) In the event that corrective actions are not acceptable to
the Society or in the event that corrective actions are not
closed out then the shipyard shall be informed.
6
Procedure requirement for in-service
maintenance
6.1
6.1.2 In-service maintenance, repair and partial re-coating
activities shall be recorded in the Coating Technical File.
6.1.3 If full re-coating is carried out, the requirement is
same as the items specified in new ship construction stage,
and reports shall be recorded in the Coating Technical File.
6.1.4 The Coating Technical File prepared by the shipyard
is to be kept on board and maintained by the shipowner
throughout the life of the ship.
General
6.1.1 Procedures for in-service maintenance and repair of
coating system should be prepared at new ship construction
stage.
Table 3 : Inspection items
Construction
stage
Primary surface
preparation
Inspection items
1
The surface temperature of steel, the relative humidity and the dew point shall be measured and
recorded before the blasting process starts and at times of sudden changes in weather.
2
The surface of steel plates shall be tested for soluble salt and checked for oil, grease and other contamination
3
The cleanliness of the steel surface shall be monitored in the shop primer application process.
4
Thickness
Block assembly
Erection
June 2007
The shop primer material shall be confirmed to meet the requirements in Tab 2Tab 1, item 3.
If compatibility with the main coating system has been declared, then the thickness and curing of the
zinc silicate shop primer to be confirmed to the specified values.
1
After completing construction of the block and before secondary surface preparation starts, a visual
inspection for steel surface treatment including edge treatment shall be carried out.
Any oil, grease or other visible contamination to be removed.
2
After blasting/grinding/cleaning and prior to coating, a visual inspection of the prepared surface shall be
carried out.
On completion of blasting and cleaning and prior to the application of the first coat of the system, the
steel surface shall be tested for levels of remaining soluble salts in at least one location per block.
3
The surface temperature, the relative humidity and the dew point shall be monitored and recorded during the coating application and curing.
4
Inspection to be performed of the steps in the coating application process mentioned in Tab 1Tab 2.
5
DFT measurements shall be taken to prove that the coating has been applied to the thickness as specified
and outlined in annex 3 of the PSPC.
1
Visual inspection for steel surface condition, surface preparation and verification of conformance to
other requirements in Tab 2, and the agreed specification to be performed.
2
The surface temperature, the relative humidity and the dew point shall be measured and recorded before
coating starts and regularly during the coating process.
3
Inspection to be performed of the steps in the coating application process mentioned in Tab 1Tab 2.
Bureau Veritas
19
NI 531, Sec 3
20
Bureau Veritas
June 2007