[PPT] - Effect of Edge Preparation Methods on Effect of Edge Preparation PowerPoint Presentation

SLIDE 1

ISST ISST-

2007

2007

Effect of Edge Preparation Methods on Effect of Edge Preparation Methods on Edge Retention Rate of Epoxy Coatings Edge Retention Rate of Epoxy Coatings

S.S. S.S. Seo Seo, M.K. Chung, C.S. Park, C.H. Lee and K.K. Baek , M.K. Chung, C.S. Park, C.H. Lee and K.K. Baek Hyundai Heavy Industries Co., Ltd. Hyundai Heavy Industries Co., Ltd.

SLIDE 2

2 2 Water Ballast TK Water Ballast TK

Steel Steel

I.O.Z. (15 I.O.Z. (15 µ

µm)

m)

Epoxy HB (160 Epoxy HB (160 µ µm) m) Epoxy HB (160 Epoxy HB (160 µ µm) m)

IMO IMO’ ’s PSPC s PSPC

P Performance erformance S Standard tandard For For P Protective rotective C Coating

ating

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3 3

Corrosion Control Corrosion Control

f Water Ballast TK:
f Water Ballast TK:
Steel Thickness

Steel Thickness

Protective Coating

Protective Coating

Sacrificial Anode

Sacrificial Anode

Maintenance

Maintenance

IMO IMO’ ’s PSPC s PSPC

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4 4

<50 mg/m <50 mg/m2

2 NaCl,

NaCl, Bresle Bresle, Min. , Min. 1 Point/Block 1 Point/Block Soluble Salt Soluble Salt Size [5],[4],[3]: remove to Rating [1] Size [5],[4],[3]: remove to Rating [1] Size [2],[1],[0]: Size [2],[1],[0]: remove if visible on steel remove if visible on steel Dust Dust

Min. 2 S/C; proven weld seams 1 S/C
Min. 2 S/C; proven weld seams 1 S/C

Brush, Roller (Specified area only) Brush, Roller (Specified area only) Edge Stripe Coating Edge Stripe Coating (S/C) (S/C) 2R, or 3 2R, or 3-

Pass or at least equiv.

Pass or at least equiv. Edge Preparation Edge Preparation Welds, Damaged Area <2%: St 3(Grinding) Welds, Damaged Area <2%: St 3(Grinding) Erection Joint Erection Joint Sa 2.5 Blasting, Profile: 30~75 Sa 2.5 Blasting, Profile: 30~75 µ µm m 1 1st

st, 2

, 2nd

nd Surface

Surface Treatment Treatment Annex 3, Avg. 3~4 points/10 m Annex 3, Avg. 3~4 points/10 m2

2

D.F.T. Measurement D.F.T. Measurement 2 2-

Coats, 320

Coats, 320 µ µm NDFT(90/10) m NDFT(90/10) D.F.T. D.F.T. P S P C P S P C ITEM ITEM

IMO IMO’ ’s PSPC s PSPC

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5 5

4.4 Basic coating requirements 4.4 Basic coating requirements Table 1 Table 1 -

3.1 Secondary surface preparation

3.1 Secondary surface preparation The steel surface shall be prepared so that the coating The steel surface shall be prepared so that the coating selected can achieve an even distribution at the required selected can achieve an even distribution at the required NDFT and have an adequate adhesion by NDFT and have an adequate adhesion by removing removing sharp edges sharp edges, grinding weld beads and removing , grinding weld beads and removing weld spatter and any other surface contaminant. weld spatter and any other surface contaminant. Edges to be treated to a rounded radius of min. 2 mm, Edges to be treated to a rounded radius of min. 2 mm,

r
r subjected to 3 pass grinding or at least equivalent

subjected to 3 pass grinding or at least equivalent process before painting. process before painting.

IMO IMO’ ’s PSPC s PSPC

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6 6

■ ■ IMO IMO’ ’s PSPC s PSPC : : “ “3 3-

Pass or 2

Pass or 2-

R

R” ” edge grinding treatment edge grinding treatment ■ ■ Negative, side Negative, side-

effect :

effect :

DFT tend to be thicker than flat areas

DFT tend to be thicker than flat areas

More vulnerable to coating cracks

More vulnerable to coating cracks ■ ■ Practical edge preparation methods ? Practical edge preparation methods ?

Several Practices

Several Practices

Cross sectional measurement of DFT at

Cross sectional measurement of DFT at Flat/Round area (Edge Retention Rate, %) Flat/Round area (Edge Retention Rate, %)

Background Background

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7 7

Experimantal Experimantal Methods Methods

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8 8

■ ■ Preparation of Specimen/Spray Coating Preparation of Specimen/Spray Coating

Edge roundness condition: Edge roundness condition: Flame cutting, R=1mm, R=2mm, R=3mm, RC Flame cutting, R=1mm, R=2mm, R=3mm, RC

■ ■ Measurement of Roundness at Edge Measurement of Roundness at Edge

(HHI Yard Practice) (HHI Yard Practice)

RC : One Pass Grinding + Burr Removal (Sand Paper)

RC : One Pass Grinding + Burr Removal (Sand Paper)

Automatic Edge Roundness M/C

Automatic Edge Roundness M/C

RC Cutter

RC Cutter

■ ■ Cross Cross-

sectional observation of D.F.T.

sectional observation of D.F.T.

Evaluation: Edge Retention Ratio, Edge Roundness Evaluation: Edge Retention Ratio, Edge Roundness

Experimentals Experimentals

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Edge Retention Ratio (ERR) Edge Retention Ratio (ERR)

Steel Plate Steel Plate Primer coat Primer coat Top coat Top coat

ERR(Primer ERR(Primer) = E1/F1 ) = E1/F1 ERR(Top ERR(Top coat) = E2/F2 coat) = E2/F2

E1 E1 F2 F2 T3 T3 E2 E2 F1 F1 ERR(%) = ERR(%) = DFT(Edge DFT(Edge) ) DFT(Flat DFT(Flat) )

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Edge Preparation (1) Edge Preparation (1)

Automatic Edge Automatic Edge Roundness M/C Roundness M/C

RC RC

(1 Pass grinding + Sand Papering) (1 Pass grinding + Sand Papering)

45° ± 10°

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Rolled Plate Rolled Plate

RC Cutter RC Cutter

Edge Preparation (2) Edge Preparation (2)

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Coating Materials Coating Materials

Product Product “ “B B” ” Product Product “ “A A” ” Modified epoxy Modified epoxy (Tar Free) (Tar Free) Pure epoxy Pure epoxy (Tar Free) (Tar Free) Type Type 5 % 5 % 5 % 5 % Thinning Thinning 60 % 60 % 80 % 80 % Solid Vol. Ratio (SVR) Solid Vol. Ratio (SVR) 1,103/88.6 1,103/88.6 1,237/91.8 1,237/91.8 Viscosity ( Viscosity (cP cP/KU) /KU) (0% Thinning) (0% Thinning) 1.25 kg/ 1.25 kg/ℓ ℓ 1.5 kg/ 1.5 kg/ℓ ℓ Specific Gravity Specific Gravity Bronze/Aluminum Bronze/Aluminum Grey/Light Grey Grey/Light Grey Color Color

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RC RC

Flame Flame cutting cutting

R = 1 R = 1 abt abt : 1mm : 1mm R = 2 R = 2 abt abt : 2mm : 2mm R = 3 R = 3 abt abt : 3mm : 3mm

Coating Sample Preparation Coating Sample Preparation

Stripe coating Stripe coating Spray coating Spray coating

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Results & Findings Results & Findings

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15 15

Sharp Edge

Sharp Edge

One

One “ “C C” ” Grinding Grinding

D.F.T. Increase D.F.T. Increase → → Outer Surface Radius Increase Outer Surface Radius Increase

Coating Thickness Effect Coating Thickness Effect

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16 16

Crack Tendency w/ D.F.T. Crack Tendency w/ D.F.T.

Edge Cracking after 4 Point Bending Test

Edge Cracking after 4 Point Bending Test

Crack width varies directly as coating D.F.T.

Crack width varies directly as coating D.F.T.

Initial crack site varies inversely as coating D.F.T.

Initial crack site varies inversely as coating D.F.T.

Number of crack:

Number of crack: Thin coating > Thick coating Thin coating > Thick coating

Crack Width:

Crack Width: Thin coating < Thick coating Thin coating < Thick coating

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17 17

Coating Material A 20 40 60 80 100 120 Sharp Edge C RC R=1 R=2 R=3 E dge R etention R atio(%

Before Blasting After Blasting Increasing Rate

Edge Roundness Effect Edge Roundness Effect

SLIDE 18

18 18 Coating Material B 20 40 60 80 100 120 Sharp Edge C RC R=1 R=2 R=3 Edge R etention ratio(%

Before Blasting After Blasting Increasing Rate

Edge Roundness Effect Edge Roundness Effect

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19 19

Before Blasting

Before Blasting

After Blasting

After Blasting

Edge Blasting Effect Edge Blasting Effect

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20 20

20 40 60 80 100 120 140 160 180 Sharp Edge C RC R=1 R=2 R=3 E d g e R e te n tio n R a tio (%

Spray Spary & One Stripe Increasing Rate

Stripe Stripe Coating Coating Effect Effect

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3 Pass Grinding 3 Pass Grinding

R = 2.0 mm R = 2.0 mm

45° ± 10°

3 3-

pass Grinding

pass Grinding

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Automatic Edge Automatic Edge Roundness M/C Roundness M/C

RC RC

(1 Pass G/R + Sand Papering) (1 Pass G/R + Sand Papering)

R = 2.0 mm R = 2.0 mm R = 3.5 mm R = 3.5 mm RC or Edge Rounder RC or Edge Rounder

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23 23

Rolled Plate Rolled Plate

RC Cutter RC Cutter

R = 2.0 mm R = 2.0 mm R = 2.75 mm R = 2.75 mm RC Cutter or Edge Roller RC Cutter or Edge Roller

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24 24

0.5 1 1.5 2 2.5 3 3.5 4 E d g e R

u

n d n e s s ( m m

Roundness Summary Roundness Summary

3 Pass 3 Pass Grinding Grinding RC RC Edge Edge Roundness M/C Roundness M/C RC Cutter RC Cutter Rolled Plate Rolled Plate R = 2mm R = 2mm

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1. Variation of coating D.F.T. at the edges with
1. Variation of coating D.F.T. at the edges with

different roundness were measured. different roundness were measured.

2. Equivalency for R = 2mm or 3 Pass grinding
2. Equivalency for R = 2mm or 3 Pass grinding
RC(One

RC(One Pass grinding + Sand Papering) Pass grinding + Sand Papering)

Automatic Edge Roundness M/C

Automatic Edge Roundness M/C

RC Cutter

RC Cutter

Rolled Plate

Rolled Plate

Conclusions Conclusions

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Effect of Edge Preparation Methods on Effect of Edge Preparation Methods on Edge Retention Rate of Epoxy Coatings Edge Retention Rate of Epoxy Coatings

IMO IMO’ ’s PSPC s PSPC

P Performance erformance S Standard tandard For For P Protective rotective C Coating

Corrosion Control Corrosion Control

Steel Thickness

Protective Coating

Sacrificial Anode

Maintenance

IMO IMO’ ’s PSPC s PSPC

IMO IMO’ ’s PSPC s PSPC

IMO IMO’ ’s PSPC s PSPC

Background Background

Experimantal Experimantal Methods Methods

■ ■ Preparation of Specimen/Spray Coating Preparation of Specimen/Spray Coating

■ ■ Measurement of Roundness at Edge Measurement of Roundness at Edge

■ ■ Cross Cross-

sectional observation of D.F.T.

Experimentals Experimentals

Edge Retention Ratio (ERR) Edge Retention Ratio (ERR)

E1 E1 F2 F2 T3 T3 E2 E2 F1 F1 ERR(%) = ERR(%) = DFT(Edge DFT(Edge) ) DFT(Flat DFT(Flat) )

Edge Preparation (1) Edge Preparation (1)

RC RC

RC Cutter RC Cutter

Edge Preparation (2) Edge Preparation (2)

Coating Materials Coating Materials

RC RC

Coating Sample Preparation Coating Sample Preparation

Results & Findings Results & Findings

D.F.T. Increase D.F.T. Increase → → Outer Surface Radius Increase Outer Surface Radius Increase

Coating Thickness Effect Coating Thickness Effect

Crack Tendency w/ D.F.T. Crack Tendency w/ D.F.T.

Edge Roundness Effect Edge Roundness Effect

Edge Roundness Effect Edge Roundness Effect

Edge Blasting Effect Edge Blasting Effect

Stripe Stripe Coating Coating Effect Effect

3 Pass Grinding 3 Pass Grinding

R = 2.0 mm R = 2.0 mm

3 3-

pass Grinding

RC RC

R = 2.0 mm R = 2.0 mm R = 3.5 mm R = 3.5 mm RC or Edge Rounder RC or Edge Rounder

RC Cutter RC Cutter

R = 2.0 mm R = 2.0 mm R = 2.75 mm R = 2.75 mm RC Cutter or Edge Roller RC Cutter or Edge Roller

0.5 1 1.5 2 2.5 3 3.5 4 E d g e R

n d n e s s ( m m

Roundness Summary Roundness Summary

different roundness were measured. different roundness were measured.

Conclusions Conclusions

Thank you ! Thank you !