what’s new in nonskid? - · pdf filewhat’s new in nonskid? nsrp spc panel meeting...

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NAVAL SEA SYSTEMS COMMAND

What’s New in Nonskid?

NSRP SPC Panel Meeting

Charleston, SC

March 2017

Mr. Mark Ingle, P.E.

SEA 05P2

(202) 781-3665

[email protected]

Distribution A: Approved for Public Release

mailto:[email protected]

2

OBJECTIVES

• Summarize evolving Naval Sea Systems Command (NAVSEA) organization and coating requirements:

•• Headquarters NAVSEA organization & objectives.

• Summarize what’s new in NAVSEA nonskid and maintenance coating costreduction strategies:

•• Published FY-18 updates to Standard Item 009-32.•• Published new, thermal spray nonskid (TSN) Standard Item

and working on supporting documents.•• Developing new documents to streamline coating production

and reduce costs.

• Discuss opportunities for new ideas and NSRP SPC input into NAVSEA efforts to streamline coating installation requirements and field new materials.

Naval Systems Engineering Directorate (SEA 05)

Technical Domain Manager (TDM)Chief Systems Engineer (CSE)

Office of the CHENG

SEA 05B Deputy / COS

(SEA 05B1)

Aircraft Carrier Design &

Systems Engineering

(SEA 05V)

Chief Finance Office

(SEA 05B3)

Surface Ship Design &

Systems Engineering

(SEA 05D)

Integrated Warfare Systems

Engineering (SEA 05H)

Cost Engineering &

Industrial Analysis

(SEA 05C)

Ship Integrity &

Performance Engineering

(SEA 05P)

Chief Workforce Office

(SEA 05B2)

Special Projects

(SEA 00U/05X)

Executive Director / CHENG

Deputy / Chief Technology Officer

(SEA 05B)

Littoral and Mine Warfare

Design & Systems Engineering

(SEA 05L)

Technology Office

(SEA 05T)

Submarine/Submersible

Design & Systems

Engineering

(SEA 05U)

Technical Policy &

Standards (SEA 05S)

Undersea Warfare Systems

Engineering

(SEA 05N) (NUWCNPT TD)

Surface Warfare Systems

Engineering

(SEA 05W) (NSWCDD TD)

Marine Engineering

(SEA 05Z)

L&MW Warfare Systems

Engineering

(SEA 05M) (NSWCPC TD)

Explosive Ordnance

Engineering

(SEA 05E) (NSWC IH TD)

T&E Technical

Advisor

Deputy Commander /

CHENG(SEA 05)

Chief HR & Admin

Office

(SEA 05B6)

Draft: As of 2/22/17

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Code Product Related SpecsAll 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

Standard Item 009-26

COR Corrosion/PCOE Policy/Design DODI 5000.67

RSH Research & Development To be determined

UNDS Regulations, Underwater hull TBD

NAVAIR

Aircraft Engines

TWH:

Habitability

SEA 08R

TWH: Underwater

Hull Husbandry

SDMs: Surface,

Submarine,

Carrier

Technical Authority Pyramid - Coatings & Corrosion ControlDraft: March 2017

Navy Employee Navy Developmental Employee Contractor

Ingleall

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

Kenney(EM)

VA-Class

Jones(EM)

NSK, DCK

Iezzi(EM)

RSH TOP

Smith(EM)

UNDS

Wigle(EM)CCAT

Slebodnick(EM)

RSH, TNK, NSK

Merlino(LE)

DOCs

Carroll(LE)NSK

ThomasCOR

Clayton(LE)

DOCs

Lawrence(LE)AF

StankeTNK, All

HolmAF

Adams(LE)

NSK, RSH

MillerTNK, NSK

ZuwialaCOR

CisconAll

ParkDOCs

FosterAll

SheridanRSH, All

F. MartinHT, COR

SpicerTNK, NSK

Needham(LE)

COR, All

WebbRSH

InternAll

EllorCOR

Ault(LE)

TNK, RSH

Langaster(LE)TNK

Ranero(EM)

All, NSK

EAs

EMs

LEs

KoglerSUR

TWH

4

Delegated signature authority

Ong(EA)All

Eppard(EM)

NSK, TNK

Duckworth(EA)All


HQ

5

FY-18, Change 2, Standard Item 009-32

Published

• FY-18 Standard Item 009-32 provided to CNRMC on 3 Mar 2017 for publication on theStandard Specifications for Ship Repair and Alteration Committee (SSRAC) website.

“Top Five” Most significant new/modified requirements.

1. REQUIRE FLIGHT DECK NONSKID APPLICATOR TO ABRASIVE BLAST 20% OF THE DECK AREA.3.11.6.2 flight deck areas receiving a nonskid system and prepared to

NACE/SSPC-SP WJ-2, a minimum of 20 percent of the total area receiving a nonskid

system shall be abrasively blasted to an NACE 2/SSPC-SP 10 level of cleanliness.

The areas to be prepared to NACE 2/SSPC-SP 10 shall be as directed by the SUPERVISOR.

- Abrasive blasting on LHA, LHD, LPD, and LSD flight decks MAY NOT use steel shot, steel grit, ferrous

media or stainless steel shot.

- Abrasive blasting may be accomplished with mineral media, crushed glass, SSPC-AB 4 media, or other

media as required in the Tables/Lines.


Corrosion destroys profile. Contractor required to re-establishprofile in areas with known corrosion.

Corrosion pits DO NOTconstitute surface profileand will not support effective coating adhesion.

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Published

2. PROHIBIT USE OF MIL-PRF-24667, TYPE VIII, LOW TEMPERATURE CURE NONSKID ON

AMPHIBIOUS SHIPS.Note (83) - MIL-PRF-24667, Type VIII nonskid shall not be used on LHA, LHD, LPD,

and LSD Class ship flight decks.

- NRL conducted both small-scale and full-scale nonskid heat resistance testing.

- Small-scale and full-scale test results indicate MIL-PRF-24667 nonskid vulnerable to delamination.


Jig showing deflection in small-scale

nonskid test panel

Cracking / corrosion after five heat cycles

Full-scale nonskid

test panel

7


Published

3. ALLOW USE OF STEEL SHOT AND FERROUS MEDIA IN LHA, LHD, LPD, AND LSD TANKS WHILE

PRECLUDING RISK OF AIRCRAFT ENGINE FOD.

3.1.3.5 Steel media, defined as steel shot, steel grit, stainless steel media, and

SSPC-AB 4 media containing steel abrasive SHALL NOT be used for surface preparation on LHA,

LHD, LPD, and LSD Class ship flight deck, hangar, vertical replenishment deck, elevators,

catwalk, and superstructure above the flight deck. Steel media may be used on tanks and

voids below the flight, hangar, and vehicle storage decks and associated ramps with

containment that prevents release of the steel media onto the flight deck, hangar, vertical

replenishment deck, elevators, catwalk, and superstructure above the flight deck. SSPC-AB 4

media that does not contain steel abrasive or MIL-A-22262 abrasive may be used on flight

decks and other areas of LHA, LHD, LPD, and LSD Class ships. The following checkpoints apply

ONLY when steel media is being used on an LHA, LHD, LPD, or LSD Class ship on tanks and

voids below the flight, hangar, and vehicle storage decks and associated ramps.

- Four new (G) points to validate that the media is contained and that:

“ . . . media blasting equipment, steel media, wastes from steel media blasting, materials used to contain steel media, and workers conducting steel media blasting shall not be

allowed to transit or otherwise come into contact with the flight, hangar, and vehicle

storage decks and associated ramps. Accomplish a start of blasting media containment

inspection to ensure blast media is contained within the confines of the work area.

Any media detected outside of the containment shall be reported to the SUPERVISOR.”


NO STEEL SHOT, GRIT, OR MEDIA ABOVE,

ON, OR OVER FLIGHT DECK

STEEL SHOT, GRIT, OR MEDIA

https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjA4bee0abSAhVFJiYKHaC-DVsQjRwIBw&url=https://www.pinterest.com/pin/372672937890086107/&psig=AFQjCNFFdalRwnHVt2EyglCZea0KG4wRWQ&ust=1487953264697843

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Published

4. CLARIFY THAT THE PROFILE READINGS ON DECKS ARE NOT TO BE COLLECTED FROM

CORRODED / PITTED AREAS.

- Updated paragraphs 3.10.5.1 and 3.11.4 to add simple statement: “Surface profile shall be validated on areas without visible pitting.”


Full-scale nonskid

test panel

NAVSEA Guidance – Step 1 – Overview

ISSUE: Initial condition of flight deck before replacement includes multiple different conditions of the steel deck that

will directly influence the ability of the final nonskid applied to the deck to achieve specified service life.

Initial Condition

After Nonskid Removal Using Ultra

High Pressure Waterjet (UHPWJ)

Corrosion

under

nonskid

VVV

Nonskid

Removal

NAVSEA Guidance – Step 2 – Post UHPWJ Condition

ISSUE: Decks after UHPWJ cleaning include multiple surface conditions that require abrasive blasting.

GUIDANCE:

1. After nonskid removal validate SSPC-WJ2 cleanliness. Areas without extensive corrosion staining may have ACCEPTABLE

surface profile.

1. Define areas with LOW profile that does not satisfy requirements.

Define areas where profile is reading HIGH because of residual corrosion pitting/staining.

Define areas WITHOUT profile that simply represent rusted steel that has been waterjet cleaned.

3. Collect representative surface profile data from areas without visible pitting or corrosion metal loss using

ASTM D4417, Method B or Method C, in accordance with SSPC-PA 17.

Do not collect surface profile data from areas WITHOUT surface profile or with LOW surface profile.

Collect surface profile data from areas with HIGH profile or staining.

4. Abrasive blast area WITHOUT surface profile and with LOW surface profile to satisfy SSPC-SP 10 near white metal level of

cleanliness. Abrasive blasting materials and operating parameters shall be selected in accordance with Standard Item 009-32

requirement to establish the required surface profile.

Areas with HIGH surface profile may be abrasive blasted as directed by the SUPERVISOR.

Standard Item 009-32 - Deck Surface Preparation Concept


LOW HIGH 5 mils

to

8 milsWITHOUT

ACCEPTABLE

NAVSEA Guidance – Step 3 – Final UHPWJ and Abrasive Blasted Deck Surfaces

ISSUE: Abrasive blasted decks require representative surface profile data collection.

GUIDANCE:

1. For abrasive blast cleaned areas and area where UHPWJ cleaning revealed ACCEPTABLE surface profile,

follow the requirements of SSPC PA-17, Appendix B to document and verify abrasive blasting process control

using a test coupon of blasting on a known area of smooth, un-corroded steel.

2. Validate SSPC-SP 10 near-white metal cleanliness using SSPC-VIS 1 for Rust Grade C or D in areas with visible

pitting or corrosion metal loss (as shown in red, center). Do not collect profile data in such areas because

the profile measurement will indicate a HIGH numerical value due to the localized corrosion metal loss.

3. Validate SSPC-SP 10 near-white metal cleanliness and collect required surface profile data using ASTM D4417,

Method B or Method C from ACCEPTABLE areas without visible pitting or appreciable staining.

4. Validate SSPC-WJ 2 cleanliness and collect required surface profile data using ASTM D4417, Method B or

Method C from areas with HIGH levels of retained staining and surface profile. Additional abrasive blasting in

such areas shall be as directed by the SUPERVISOR

5. Report required data on Standard Item 009-32 Appendices.

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Standard Item 009-32 – Abrasive Blasted Profile Assessment


Condition of deck after

abrasive blasting and

UHPWJ cleaning

HIGH

SSPC-VIS 1

ACCEPTABLE -

ASTM D4417HIGH

ASTM D4417

5 mils

to

8 mils

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Published

5. CLARIFY THAT THE INTENT OF TIE-DOWN COATING IS TO APPLY COATINGS WITHOUT

EXPENDING EXCESSIVE RESOURCES ON SURFACE PREPARATION IN AREAS SUBJECT

TO MECHANICAL DAMAGE BY HOOKS.- Updated paragraph 3.11.4 .1 to remove the term “bars.”


Full-scale nonskid test

panel

SSPC-SP 2 or SP 3

in these areas

NAVSEA Guidance

Surface Cleanliness & Coating Integrity Validation on Tie Downs

ISSUE: Interpretation of surface cleanliness and coating integrity validation requirements on aircraft and vehicle tie-downs highly

variable across RMCs & shipbuilders.

GUIDANCE:

1. Surface preparation to SSPC-SP 2 or SP 3 is authorized in

areas that are shielded or shadowed from abrasive blast or waterjet cleaning or power tool cleaning.

2. Required surface profile measurements to be taken in areas that can be abrasive blasted to SSPC-SP 10 or

waterjet cleaned to NACE/SSPC- WJ-2/L or power tool cleaned to SSPC-SP 15.

3. Tie-down coating coverage shall be validated without use of a mirror or flashlight on all fittings.

10% of all tie-downs in each work zone shall be inspected using a mirror and flashlight.

4. For tie-down installation, NAVSEA Drawing 803-1916300, Note T-1D requires that 100% of crossbars to be tested

to ensure proper fit of the TD-1 hook. Excessive coating runs, drips, sags, puddles, or inadequate removal

of old coating during surface preparation can interfere with fit of the TD-1 hook.

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Action Item to Develop Standard Item 009-32 Supporting Documentation

Reuse of Nonskid Mixing Blades


NAVSEA Guidance

Nonskid Mixing Blade Cleanliness

ISSUE: Nonskid mixing blades that are free of previously applied paint/nonskid may be reused to

mix nonskid.

Reused blade that Blade contaminated with

is free of nonskid - with nonskid –

ACCEPTABLE for use NOT ACCEPTABLE for use

New blade that is

free of nonskid -

ACCEPTABLE for use

GUIDANCE:

1. Blades shall be 95% free of residual coating or corrosion staining when viewed without magnification.

2. Up to 5% cured coating or corrosion staining may be retained in corners, welds, corrosion pits,

and other irregular surface areas.

3. All retained coating and corrosion staining, when wiped with solvent applied to a clean

light-colored rag, shall not leave any colored residue on the rag.

TSN To Improve Flight Deck Performance

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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.


14

TSN Technical Requirements Being Developed

TSN Fielding

Vital to Amphibious Ships

& Fleet Operations

FY-18 New

NAVSEA

Standard Item

New military

specification

MIL-PRF-XX704

for TSN wire

material.

Update Naval Ships

Technical Manual

Chapter 634

Material Installation Process / Qualifications In-service

Update current

MIL-STS-1687A

to Technical

Publication


Update MRC

for TSN Inspection

and Repair

by Ship’s Force

Under review by

SEA 05P

Process: SEA 05S SSRAC SEA 05S SEA 05S NSWC-PD

Status: SEA 05P2 review SEA 05P2 SEA 05P2 review NSWC-PD 1st Draft of Maintenance

complete to comments complete to Action Card for TSN Inspection

SEA 05S on 1st Draft, SEA 05S to CNSP on 17 May 2016

19 May 2016 complete 19 May 2016

19 Aug 2016 1-5 Aug 2016 12 Aug 2016 29 Jul 2016 SEA 05P2

SEA 05S concurs Presented to SEA 05S suggests Delivers FINAL draft cards

with need for QPL SSRAC. Revision as Tech. Pub. to USFF N43 Flight Deck

Readiness Working Group

13 Jan 2017 3 Mar 2017 27 Dec 2016

SEA 05S releases Final draft SEA 05S releases for NSWC-PD to include in new

for 30 day Industry to CNRMC Industry Review with MRC deck with 17 Mar 2017

Review with comments comments adjudicated date for release to CNSP

adjudicated on 6 Mar 2017 on 6 Mar 2017

Plan: Standard Item 009-XX , “Thermal Spray Nonskid Application; accomplish”

defines the twin-wire arc spray process & equipment as demonstrated on LHA/LHD.

TSN Standard Item 009-XX defines detailed process and G-points to ensure successful coating application.

New TSN Standard Item 009-XX

Process Summary

15Distribution A: Approved for Public Release

Action Item - New TSN Standard Item

Re-establish Profile Using Aluminum-oxide Abrasive Blasting

Steel deck after UHPWJ cleaning,

extensive corrosion staining. SSPC-SP5 white metal level of cleanliness

with surface profile of 4.5- to 5.0-mils.

Background: Epoxy nonskid installed over steel shot SSPC-SP 10 with OQE indicating profile satisfied requirements.

NOT ADEQUATE for TSN installation.

Plan: New Standard Item 009-XX requires SSPC-SP 5, “White Metal” abrasive blast cleanliness.

TSN applications on LHA/ LHD have shown SSPC-SP 5 cleanliness obtained on old decks using Al2O3 media.16


Critical New

Requirement

Plan: New Standard Item 009-XX uses similar approach with columns to Standard Item 009-32 to show how layers

of thermal spray are to be applied to create corrosion-resistant, rough, nonskid system.

Standard Item 009-XX defines detailed process, with G-points, to ensure successful application of TSN nonskid coatings.



Process Summary to Define Coats

Plan: Standard Item 009-01 may need updates to address provisions for HEPA filters and air

emission controls to satisfy San Diego, CA Air Quality Management District requirements.

Status: Presented slides at SSRAC in Aug. 2016.

Key question is whether Standard Item 009-01 will ensure environmentally compliant application of TSN nonskid coatings.



New Process Creates New Environmental Challenges

Background:

Develop MIL-PRF-XX704 to define the wire material used with

twin-wire arc spray process & equipment as demonstrated on LHA/LHD.

Key Material Specification Provisions:

Coating to be formed over SSPC-SP 5 white metal level of cleanliness

by automated twin-wire arc system.

Multiple coats of TSN acceptable to build final coating system.

Wire material Type/Class to specify allowable 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 (another specification).

Qualification testing on coating with application parameters demonstrated on LHD

and LHA.

Status:

6 Mar 2017 - SEA 05P2, NRL, NSWC-CD, and NSWC-PD adjudicate comments for final document

publication.

New military specification is to have qualified products list for wire feed materials that can form TSN coatings.

New TSN Material Specification MIL-PRF-XX704

Final Comment Adjudication


● 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%

New MIL-PRF-XX704 to address Types or Class for both solid and cored TSN wire.


New TSN Material Specification MIL-PRF-XX704

Wire Type

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 wire material with the twin-wire arc

spray process & equipment demonstrated 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.

Status:

6 Mar 2017 - SEA 05P2, NRL, NSWC-CD, and NSWC-PD adjudicate comments for final document

publication.

Update to Technical Publication will leverage existing thermal spray training and certification requirements for TSN.

Update to MIL-STD 1687A on Process Qualifications

Final Comment Adjudication



New Commercial Item Description A-A-XX695 for Nonskid Mixer

Publication Pending

ISSUE: New Commercial Item Description for a nonskid mixer to improve consistency of nonskid mixing process.

Nonskid mixing is a manual process and that inadequately mixed nonskid exhibits irregular cure.

SOLUTION: NRL completed project to develop effective, automated nonskid mixing equipment.

Inadequate nonskid mixing adversely affected nonskid deck installation.

Effective performance demonstrated on nonskid deck at Puget Sound Naval Shipyard.

NRL adjudicated final comments on A-A-XX695 on 22 Feb 2017.

SEA 05P2 concurs with release to Specification Review Board on 1 Mar 2017.

Mix all qualified nonskid Double vortex mixing blades

6,000 gal. mixed without repair Three blades per unit

One blade being used

1.7 hp pneumatic motor One blade free of nonskid

ready to be installed

1 to 175 rpm speed control

One blade being cleaned

with solvent, rags,

and wire brush

Blades for 5/6 gallon cans

NSRP SPC comments on adopting CID in future updates to Standard Item 009-32.

ISSUE: Standard Item 009-32 update “lessons learned” that nonskid ridges breaking off reported

to cause FOD, nonskid deck corrosion tracks low-points in ridges, and other issues.

SOLUTION: NRL completed project to develop effective, nonskid spray equipment.

Spray application of polysiloxane nonskid to appreciably increasing conventional

nonskid service life. 4X performance improvements validated to date.

Draft Commercial Item Description (CID) A-A-XX705 for nonskid spray equipment

16 Feb 2017 the public comment period on the specification closed.

NRL adjudicating final comments.

Progressive cavity pump Spray gun diffuser Able to spray all qualified nonskid

1,000 gallons without repair 30 minutes of spraying Electronic, pneumatic safety controls

Rotor speed control (1–200 rpm) <10 lbs for unit Able to spray >10 ft2/min.

NSRP SPC comments on adopting CID in future updates to Standard Item 009-32.

23

New Commercial Item Description A-A-XX705

Publication Pending


24

New Specification Update

Condensation Control Coatings

● PDS signed on 16 Feb 2017 to reactivate TT-C-492 “Coating Compound, Paint Antisweat” and update

specification for anticondensation and/or insulation coatings.

- Four phase task to support definition of current materials and evaluate candidate pool of “new”

materials that might require a Type/Class in the updated specification.

1. Literature review.

2. Update TT-C-492 to reflect current federal regulations for Volatile Organic Compounds,

lead (Pb), crystalline silica, asbestos, and other hazardous materials.

3. If needed, add the performance criteria for new Types/Classes for

higher performance insulation coatings.

4. Publish updated TT-C-492 following established SEA 05S process.

(a) Type/Class for products that absorb

moisture.

(b) Type/Class for single-pack products

that insulate with microspheres.

(c) Type/Class for two-pack products

that create high R-value coating.

SSPC SPC input needed on interest in spray applied anticondensation and insulation coatings.


25

Summary

• NAVSEA goal is to ensure all coating and nonskid applications satisfy performance requirements.

• NAVSEA transitioning new thermal spray nonskid to fleet service to support V-22 and F-35 operations and to reduce the risk of aircraft engine FOD.

• NAVSEA published FY-18, Standard Item 009-32 in Mar 2017.

• NAVSEA published DRAFT Standard Item 009-XX on TSN for industrycomment on 25 Jan 2017.

• NAVSEA goal to work with NSRP SPC to streamline coating productionprocesses while ensuring coating durability and attain anticipated service life.


26

Backup slides

27

Corrosion Control Assessment and Maintenance Manual (CCAMM)

Rev. 3 Published on 30 Jun 2015

● Rev. 3 update prepared in coordination with SEA 05P4 Structures technical warrant holders.

- Provides requirements for inspecting tanks and

conducting repairs.

- Defines qualification/experience for coating

and structural inspectors.

- Requires coating touch-up and repair to avoid

the cost increases (e.g., growth work) that occurs

when corrosion is allowed to continue to the

point of causing significant structural degradation.

- Improves tank and void assessment planning based

on historical lessons learned from

Corrosion Control Information Management System

(CCIMS) data.

- Outlines condition based repair planning.

● CCAMM Rev. 3 signed out by SEA 21 on 20 Jun 2014.

● CCAMM Rev. 3 signed out by SEA 05 on 30 Jun 2015.

CCAMM Rev. 3 supports the work planning process that invokes Standard Item 009-32 requirements.


Full-scale nonskid

test panel

28

Corrosion Control Assessment and Maintenance Manual (CCAMM)

Rev. 3 Published on 30 Jun 2015


29

New Construction Working Group - Paint

• WHERE WE ARE GOING - SEA 05P2 is seeking new ideas.

• SEA 05P2 Is Interested In Shipbuilder Input On The Following:

1. Apply new, rapid-cure, single-coat, MIL-PRF-23236, Type VII, Class 9/18 paint in potable-water tanks.

- New technology already demonstrated in Fleet service.

2. Apply powder (and liquid epoxy) coatings over chemical conversion coatings as per TT-C-490.Chemical Conversion Coatings and Pretreatments for Metallic Substrates.

- Common commercial practice that may be in-service with shipbuilder & parts suppliers.

- MIL-PRF-24712B published on 11 FEB 2014 - General purpose & topside powder.

- MIL-PRF-23236D published on 15 SEP 2009 – Includes high-performance, corrosion-control powders.

- TT-P-28H published on 28 JUN 2007 - High heat powder.

3. Expand use of powder coating to include watertight doors, hatches, scuttles.

- Powder coatings rapidly coat complex shapes and can be applied in single coat mode or in

two coats with a zinc-rich primer and TGIC polyester topcoat.

- Size and heat capacity of oven drives powder coating production rate. An oven with insufficient

heat capacity can take an entire shift to heat a heavy part.

- NAVSEA authorizes over-coating of piece parts with powder coating in tanks & interior.

Zinc-rich Primer TGIC Topcoat Finished Part

Ideas that make sense can be submitted to NAVSEA or SEA 05P2 directly

30



• SEA 05P2 Is Interested In Shipbuilder Input On The Following:

4. Expand use of low-cost, easy to apply, deck paint as per MIL-PRF-32171 (update in progress).

- NAVSEA commonality initiative. NSWCCD Code 614 revising decking specifications to streamline

coating qualification and allow color chips.

- SEA 05P2 goal is 85% solution to allow deck paint in vast majority of interior applications, but

still provide ship with high-performance decking in:

Heads Food Preparation Spaces Laundry Spaces Sick Bay

Flag Quarters Senior Officer Quarters Wardrooms Barber Shop

Bridge Magazines Selected Passageways.

- Beyond deck paint, decking specification streamlining will allow more rapid qualification of

deck tiles and systems through:

ASTM-based requirements.

Taber Abraser wear test.

Elimination of in-service ship test for interior decking.


31



• SEA 05 Is Interested In Shipbuilder Input On the Following:

5. Reduce number of ship interior colors.

- Multiple colors required as per OPNAV Instruction 9640.1B “SHIPBOARD HABITABILITY

PROGRAM” and associated NAVSEA T9640-AB-DDT-010/HAB “SHIPBOARDHABITABILITY DESIGN CRITERIA MANUAL”

2.6.4 Color (Surface Ships and Submarines). Officer, CPO

and crew living and work spaces shall have an adequate number of

different color schemes to provide personnel with a visual

change in environment in their daily routines. The total number

of different colors of paint and deck coverings used, however,

should be kept small to minimize logistics support. When

practicable, selection of color schemes for senior officers

quarters, messrooms and lounges may be made by the prospective

commanding officers. Paints and other materials used on large

surface areas shall be of appropriate color and reflectance to

ensure proper lighting.

- NAVSEA Habitability & Paint Technical Warrant Holders could accept five different colors.

- SEA 05P2 goal is 85% solution to allow one color (e.g., off-white, soft-white) paint in vast majority

of interior applications, but still provide ship with high-performance decking in:

Flag Quarters Senior Officer Quarters WardroomsBarber Shop Selected Passageways BerthingSanitary Messing Lounge/Recreation Ship store Post office

- One color approach does not change requirements for light traps, bridge, and other functional spaces.


32

New Construction Working Group - Paint• WHERE WE ARE GOING - SEA 05P2 is seeking new ideas.

• SEA 05 Is Interested In Shipbuilder Input On the Following:

5 (Continued). Reduce number of ship interior colors.

- Multiple colors required as per OPNAV Instruction 9640.1B “SHIPBOARD HABITABILITY

PROGRAM” and associated T05U3-085, “NAVSEA Design Practices and Criteria

Manual for Submarine General Arrangements Design, 19 Aug 2012:

3.3.2.7.1.5 Color Schemes

Color schemes are put together with consideration of colors, patterns, and textures of

materials for bulkheads, overheads, decks, furniture, and accessories. . . .

Numbers - The number of different color schemes should be large enough to provide personnel

with a change of environment during their daily routine, but small enough to keep logistical

problems associated with repair and replacement of materials manageable. Provide officers,

CPO and crew with different color schemes for their respective berthing, sanitary,

recreation and messing spaces. Provide additional color schemes for community spaces that

are used by all personnel such as, passages, offices, and other work and utility spaces.

• Definition of change - A change in color scheme is a change in bulkhead or deck color and

an appropriate variation in accent colors. A small number of bulkhead and deck colors can be

combined with a greater variety of accent colors to provide a sufficient number of different

color schemes.

• Multiple color schemes - Multiple spaces of the same type that are not subject to general

submarine traffic, such as officer staterooms or crew living spaces, may use one color

scheme for all spaces. Multiple spaces with general submarine traffic, such as passages,

should have two or more different schemes to provide variety. This also enables personnel to

retain visual acuity and depth perception in the close confines of the submarine.

Objectives - In general, habitability space color schemes should be cheerful, clean, and

comfortable, lending a natural appearance to the skin, and minimize the institutional look.

Use socially stimulating color schemes in active spaces, such as messrooms, and quiet,

restful schemes in passive spaces, such as berthing spaces. Use neutralizing color schemes

in spaces that have more than one purpose as opposed to mixing too many colors. Since most

shipboard compartments are of minimal size, use colors that make the space appear larger and

cause projecting structure and furnishings to recede into the background.

33



• SEA 05 Is Interested In Shipbuilder Input On The Following:

6. Not coating inaccessible voids and using nitrogen purge to prevent corrosion.

NAVSEA has processed deviations/waivers on everything from in-service DDG-51 rudders to

DDG-1000 voids. NAVSEA could provide general guidance (e.g. purge with nitrogen, pressure check,

etc.) and shipbuilders could propose voids.

7. Relax requirements for painting non-compensated fuel tanks.

CCIMS data showed very low corrosion risk and not painting fuel tanks is authorized in FY-14,

Change 1, Standard Item 009-32. PCP retention is not authorized (e.g., risk of zinc contaminating fuel).

Key issue for shipbuilders is preservation of unpainted steel during long construction period.

8. Wet abrasive blasting to SSPC SP-10.

NAVSEA allows wet abrasive blasting as per SP-10, Section 5.3 and allows water-based processes

in FY-14, Change 1, Standard Item 009-32. Provided profile is validated, risk of allowing process

is low.


34

Allow Topcoat Direct to Metal (No Primer) In Dry Space

IDEA: Allow application of MIL-DTL-24607B chlorinated alkyd direct to metal in air-conditionedspaces like the interior of submarines, ward rooms, offices, etc. Process is not authorized for spaces that ventilate directly to the weather, nor in nuclear spaces, machinery spaces, fan rooms, sanitary spaces, wet spaces, laundries, or medical spaces.

RISK: Performance risk is minimal, all spaces are dry and not subject to aggressive cleaning.Shipbuilder data demonstrated a low corrosion risk.

REFERENCE: Not applicable, but like Table 3, Line 1 without the primer.

Technical Requirements to Allow Direct to Metal Application of Interior Topcoat

Material: MIL-PRF-24607BOQE: As per established contract.

Surface preparation: SSPC SP-10 with sharp, angular media. Surface profile 2- 4 mils with no single readingin excess of 5-mils or below 1-mil

- or –Hand tool cleaning to SSPC SP-2. For MIL-PRF-24607B PCP may not be retained due to adverse reaction between alkyd resins and zinc.

OQE: As per established contract.

Application: Product shall be applied in two coats at 1.5 - 4 mils per coat. Contrasting colors are not required.

OQE: Government visual checkpoint for complete surface coverage and final coating system thickness as per established contract with 3-8 mils DFT as thickness requirement.

35

Single Coat Paint in Bilges

IDEA: Allow tinted MIL-PRF-23236D, Type VII, Class 5/18 or 7/18 in bilges.

RISK: Performance risk is minimal, rapid-cure, single-coat paint is already used in tanks. At new construction, a tank and a bilge are similar. Moderate cosmetic risk of product yellowing over years.

REFERENCE: FY-12, Change 1, to Standard Item 009-32, Table 4, Line 13.

Technical Requirements to Allow Single Coat in Bilges

Material: MIL-PRF-23236D, Type VII, Class 5/18 or 7/18. Product tinted to approximate Federal Standard 595colors. Exact color match is not required.OQE: As per established contract. Contractor shall verify tinted coating satisfies MIL-PRF-23236D,

Table II & III hazardous materials (e.g., Pb, Cr, Cd, etc.) limits. Tinted products ARE NOT AUTHORIZED for use in potable water or other tank coatings.SUPSHIP shall concur with color.

Surface preparation: SSPC SP-10 with sharp, angular media. Surface profile 2-4 mils with no single readingin excess of 5-mils or below 1-mil. OQE: As per established contract.

Application: Product shall be applied in a single coat provided edge thickness readings are measured as per Attachment A or applied with a stripe coat. Final dry film thickness (DFT) is to be 20-30mils with an allowance for up to 50-mils DFT in runs, drips and sags.

OQE: Government checkpoint for final film thickness. Bilge areas shall be considered tanks for purpose of SSPC PA-2 or other DFT assessment protocol as per the existing contract.Runs, drips, and sags <50-mils do not require remediation unless visible from the deck grating/plate.

Powder Coating of Electrical BoxesIDEA: Allow application of MIL-PRF-24712 powder coating direct to metal on parts like

electrical boxes, brackets, cable ways, and other hardware to be installed in air-conditioned spaces like the interior of submarines, or air-conditioned spaced on surface ships.

RISK: Performance risk is minimal, all spaces are dry and small parts like electrical boxes arenot subject to aggressive cleaning. Electric Boat data demonstrated a low risk. Shipbuildermust demonstrate their specific combination of powder, process, and substrate results inacceptable adhesion.

REFERENCE: FY-12, Change 1, to Standard Item 009-32, Table 5, Line 22 and Uniform IndustrialProcess Instruction (UIPI) 631-901

Technical Requirements to Allow direct to Metal Application of Powder Coating

Material: MIL-PRF-24712 powder coating or as approved by NAVSEA in color of space (e.g., white, gray, etc.), Specific Federal Standard 595 color match is not required. Epoxy powder coatings to be considered for this

application include: 3M Skotchkote 135, International Paint, Interpon 100, Sherwin Williams EAS6- 3003,Herberts O’brien EFH-400-S9, Morton Corvel Envelon Haze Gray DG-7004, Protech Gray PC8816, PFS Epoxy D108, Jones Blair Metal Mate, 12P055E. OQE: As per established contract.

Surface preparation: Approved substrate materials include galvanized steel or mild steel as per current contractfor candidate parts. SSPC SP-1 cleaning or SSPC SP-2 on surfaces to be coated(i.e., interior of electrical boxes are unpainted for electrical ground & require no preparation). OQE: Contractor with ISO 9001 process verification once per shift. SUPSHIP may conductrandom inspection.

Application: Powder shall be applied by electrostatic application direct to metal. Powder dry film thickness shall be

3-6 mils DFT with no reading below 2 or above 8 mils. Powder shall provide complete visual coverage of

surfaces to be coated. A coated product shall satisfy an ASTM-D-3359, Method A cross-cut adhesion

test 3A criteria at time of process demonstration to SUPSHIP.

OQE: Contractor with ISO 9001 process shall verify DFT on one part once per shift. SUPSHIP may conduct random DFT and/or ASTM-D-3359 tests.

37

Do Not Bounce Docking Blocks

IDEA: Do not bounce blocks during new construction.

RISK: Low risk of paint damage or fouling in block spaces. Process not used on in-service ships for decades.

REFERENCE: None, non-standard practice

Technical Requirements to Not Bounce Blocks

Material: MIL-PRF-24647 antifouling.OQE: As per established contract.

Surface preparation: SSPC SP-10 with sharp, angular media. Surface profile 2-4 mils with no single readingin excess of 5 mils or below 1 mil. OQE: As per established contract.

Application: A minimum of two coats of epoxy primer and two coats of antifouling topcoat shall be installed and cured for a minimum of 48-hours in way of the blocks. Block surfaces shall be covered with polyethylene film or equivalent to impede adhesion of the block top to the antifouling paint.


Installation: Surrounding coating shall be faired into the coating at the block spots following established practices for erection butts and/hull cuts. Epoxy primer shall not be applied over antifouling topcoat.OQE: As per established contract.

Launch: If blocking areas do not match surrounding color (e.g., black vs. red) record condition to allowdivers to anticipate the inconsistent color during future inspections. If colors match, no action is required.OQE: As per established contract.

38

Reduce Surface Preparation on Tie Downs

IDEA: Do not require SSPC SP-10 on deck tie downs and allow SSPC SP-3 hand tool preparation.

RISK: Negligible, because coatings are damaged from normal use by ship’s force. Standard Item 009-32 already allows relaxed surface preparation.

REFERENCE: FY-12, Change 1, NAVSEA Standard Item 009-32, FY-12, paragraph 3.11.3.1

Technical Requirements to Not Require SSPC SP-10 on Tie Downs

Material: MIL-PRF-24667 non-skid or as approved by contract.OQE: As per established contract.

Surface preparation: SSPC SP-10 with sharp, angular media. Surface profile 2-4 mils with no single readingin excess of 5 mils or below 1 mil on accessible surfaces like the tops of the cross bars and deck area around the tie-down.

Inaccessible areas shall be prepared using either power-tool cleaning to SSPC SP-3 or hand-tool cleaning to SSPC SP-2.

OQE: As per established contract. As per SSPC SP-2, paragraph 2.2, SUPSHIP shall validate that all loose rust, mill scale, or paint has been removed using a dull putty knife.

Application: Paint shall be applied in accordance with established practices at established dry film thicknesses (DFTs).OQE: As per existing contract.

Repair: As per requirements listed above.OQE: As per established contractual requirements. SUPSHIP shall be authorized to require SP-3 to repair

damaged coating that is allowing tie-down corrosion.

39

Use Galvanized Fasteners Instead of Painted Steel

IDEA: Use galvanized steel instead of painted steel inside the ship.

RISK: Negligible risk of corrosion, practice superior to paint over carbon steel.

REFERENCE: None, standard practice.

Technical Requirements to Use Galvanized Fasteners

Material: Mild, carbon-steel fasteners (i.e., strength lower than or equal to SAE J429 Grade 5)that are sized and procured with a galvanized coating.

Galvanized coatings shall be ASTM-A-123 or ASTM-A-153 that call out use of an ASTM-B-6 zinc bath.ASTM-B-6, “Prime Western Grade Zinc” could have Pb content of between 0.5% to 1.4 % NAVSEA concurs with accepting the Pb levels in the Prime Western Grade Zinc,or any other galvanizing bath grade with lower levels of Pb, because the fasteners oninterior ducts on the ship are considered life-of-the-ship parts that will not be abrasiveblasted, welded, or otherwise disturbed throughout the life cycle in a manner thatwould create airborne dust/fume.

OQE: As per established contract. Shipbuilder and SUPSHIP shall concur on galvanized partprocurement specifications.

Surface preparation: Galvanized surfaces covered by lagging require no surface preparation orcoating. Surfaces to be painted shall be cleaned to SSPC SP-2.


Application: Galvanized surfaces covered by lagging require no surface preparation or coating. Surfaces to be painted shall be painted using the same system as the surrounding duct.
