Universal Primer and Surface Preparation Process

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Britney Walsh
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1 Universal Primer and Surface Preparation Process Surface Preparation & Coatings Panel Sept 1, 2015

2 Outline Update on Zinc Rich Epoxy Primer Efforts Activities This Quarter Plans for Next Quarter Summary & Closing 2

UPDATE: Zinc Rich Epoxy Primer Cost Reduction Initiative Current Language Authorizing Zinc Rich Epoxy Primer: Zinc rich epoxy primer with extended overcoat

language as above to authorize zinc rich epoxy primer on other ship classes. Adjust list of prohibited spaces to fit class.

3 UPDATE: Zinc Rich Epoxy Primer Cost Reduction Initiative Current Language Authorizing Zinc Rich Epoxy Primer: Zinc rich epoxy primer with extended overcoat window may be applied, unless otherwise specifically prohibited, as the first coat of epoxy primer in lieu of other epoxy primers Short Term Proposal: Use same language as above to authorize zinc rich epoxy primer on other ship classes. Adjust list of prohibited spaces to fit class. Update: Zinc rich epoxy primer has been tentatively approved for use on another ship class. Specific inspection requirements are imposed and, if necessary, secondary preparation prior to over coating. 3

4 Universal Primer and Surface Preparation Method This project will reduce paint costs by qualifying a primer with an extended overcoat window (EOW) that eliminates the need for mechanical abrasion when over-coating the primer during construction. Assemble a multifunctional project team to define requirements and identify potential coating candidates. Conduct testing, analyze results, and deliver a report showing whether the candidate coatings meet the requirements for general use in new build construction of Navy ships 4

5 Applications, Requirements, and Constraints Target Applications Interior, Non-Critical Spaces Requirements Longer overcoat windows than MIL-DTL epoxies Less intensive surface prep when overcoat window is exceeded Constraints VOC compliant Compatible with pre-construction primer and topcoats Meets NAVSEA health, safety, and toxicity standards 5

6 Project Work Breakdown Structure (WBS) Task 1: Identify Target Applications, Requirements, Constraints Task 2: Select Candidate Materials Task 3: Finalize Applications and Test Requirements Task 4: Develop Validation Test Plans Task 5: Fabricate Test Articles Task 6: Perform Validation Testing Task 7: Issue Test Reports Task 8: Issue Final Report 6

7 Project Schedule Updated August 14,

8 Candidate Primers 8

9 Test Plan 9

10 Test Plan 12 x12 x 3/16 Panel SP MILS 10

11 Test Matrix Primer Condition Exposure Secondary Prep Topcoat A-G 1 Outdoor None 24607/24596 (1) A-G 2 Outdoor Solvent 24607/24596 (1) A-G 3 Outdoor Water 24607/24596 (1) A-G 4 Outdoor Light 24607/24596 (1) A-G 5 Outdoor Heavy 24607/24596 (1) A-G 6 Outdoor Sweep 24607/24596 (1) A-G 7 Indoor None 24607/24596 (1) A-G 8 Indoor Solvent 24607/24596 (1) A-G 9 Indoor Water 24607/24596 (1) A-G 10 Indoor Light 24607/24596 (1) A-G 11 Indoor Heavy 24607/24596 (1) A-G 12 Indoor Sweep 24607/24596 (1) A-G 13 None Immediate Recoat 24607/24596 (1) A-G 14 Indoor/Outdoor (2) Test Primer None Note 1: 1/2 of panel will be coated with each type of topcoat. Note 2: 1/2 of panel will be masked to prevent UV exposure. 11

12 Secondary Surface Prep Conditions (after aging) 1. None: Panels will be left as is after exposure with only a dry cloth used to wipe off any debris / dirt /or dust. This represents a worst-case scenario when topcoated. 2. Solvent Wipe: Panels will be solvent wiped using HII standard solvent* 3. Water Wash: Panels will be washed using the standard pressure washing system** 4. Light Scuff (Grit # TBD) with Solvent Wipe: Panels will be lightly hand sanded** followed by a solvent wipe 5. Heavy Scuff (Grit # TBD) with Solvent Wipe: Panels will be power abraded** followed by a solvent wipe 6. Sweep Blast: Panels will be swept using standard HII abrasive and pressure** *Stock solvent is a mineral spirits blend ** Materials and conditions will be documented and same for all panels 12

13 Topcoat Adhesion Tests Test Plates Four (4) adhesion tests will be performed on each test panel including duplicate (2) tests IAW ASTM D6677 and duplicate (2) tests IAW ASTM D4541. Figure 2 below shows what these tests will look like on each test panel. A total of 364 of each type of adhesion test will be performed on the test panels.

Each test area will have two (2) tests IAW ASTM D6677 and two (2) tests IAW ASTM D4541.

14 Topcoat Adhesion Tests Shipyard Test Article On the shipyard test article, four (4) adhesion tests will be performed on each of the twenty eight (28) test areas. Each test area will have two (2) tests IAW ASTM D6677 and two (2) tests IAW ASTM D4541. A total of 112 adhesion tests will be performed on the test article. Primer A Primer B Primer C Primer D Wash Abrade & Wash

Candidate Primer Application: May 14 June 10, 2015 120% MIN 2.4 MA 4.8 120% MIN 2.4 MA 7.2 120% MIN 1.6 MA 4.

15 Candidate Primer Application: May 14 June 10, % MIN 2.4 MA % MIN 2.4 MA % MIN 1.6 MA 4.8 INTERZINC 75V (3-4 MILS) SIGMACOVER 435 (3-6 MILS) DIMETCOTE 302H (2-4 MILS) Plate # AVG Plate # AVG Plate # AVG ETRA ETRA ETRA AVG 3.5 AVG 7.4 AVG % MIN 0.8 MA % MIN 3.2 MA % MIN 1.6 MA % MIN 1.6 MA 4.8 INTERGARD 268 (1-2 MILS) MIL-DTL F-150 (4-6 MILS) FAST CLAD ZINC HS (2-4 MILS) ZINC CLAD DOT (2-4 MILS) SPRAY II Plate # AVG Plate # AVG Plate # AVG Plate # AVG ETRA ETRA Extra Extra AVG 2.7 AVG 7.8 AVG 4.3 AVG 3.5

16 Sherwin Williams Test Plates Applied May 13, 2015 FAST CLAD ZINC HS ZINC CLAD DOT

17 Sherwin Williams Test Plates Applied May 13, 2015 (DOT Re-applied June 10, 2015) 120% MIN 1.6 MA 4.8 FAST CLAD ZINC HS (2-4 MILS) Plate # AVG Extra AVG % MIN 1.6 MA 4.8 ZINC CLAD DOT (2-4 MILS) SPRAY II Plate # AVG Extra AVG 3.5

18 PPG Test Plates Applied May 20, 2015 DIMETCOTE 302H SIGMACOVER 435

19 PPG Test Plates Applied May 20, % MIN 2.4 MA 7.2 SIGMACOVER 435 (3-6 MILS) Plate # AVG ETRA AVG % MIN 1.6 MA 4.8 DIMETCOTE 302H (2-4 MILS) Plate # AVG ETRA AVG 4.5

20 International Test Plates Applied June 9, 2015 INTERGARD 268 INTERZINC 75V

21 Test Plates Applied June 9, 2015 INTERZINC 75V F-150 INTERGARD 268

22 International Test Plates Applied June 9, % MIN 2.4 MA 4.8 INTERZINC 75V (3-4 MILS) Plate # AVG ETRA AVG % MIN 0.8 MA 2.4 INTERGARD 268 (1-2 MILS) Plate # AVG ETRA AVG 2.7

23 MIL-DTL Type IV Applied June 9, % MIN 3.2 MA 7.2 MIL-DTL F-150 (4-6 MILS) Plate # AVG ETRA AVG 7.8

24 Outdoor Test Plates Placed on June 11, 2015 F-150 INTERZINC 75V INTERGARD 268 ZINC CLAD DOT SIGMACOVER 435 FAST CLAD ZINC HS DIMETCOTE 302 H

25 Finish Coatings

26 Test Plates Masked for Latex

27 Test Plates after Application of Latex

28 Test Plates Masked for Alkyd Enamel

29 Test Plates after Epoxy Mist Coat over Zinc Primers

30 Test Plates after Alkyd Enamel

31 Typical Appearance after Application of Topcoat Primer DFT: 4.0 mils Total DFT: 5.2 mils Primer + Enamel Total DFT: 8.4 mils Primer + Mist Coat + Enamel

32 Defects after Removing Masking Tape Primer DFT: 3.4 mils Total DFT: 5.1 mils Primer + Enamel Total DFT: 4.5 mils Primer + Enamel

33 Defects after Removing Masking Tape Primer DFT: 7.1 mils Total DFT: 8.2 mils Primer + Enamel Total DFT: 8.3 mils Primer + Enamel

34 Panel Screening Tests at Elzly Technology Corp.

35 Plans for Next Quarter Apply topcoats to remaining test plates Conduct adhesion tests Prepare test reports and Project Final Report Propose a process and inspection standard for abrading epoxy that has exceeded its overcoat window. Develop an outline specification for qualifying zinc rich epoxy coatings with extended overcoat windows. 35

36 Universal Primer and Surface Preparation Process Questions? 36

NAVSEA REVIEWED ASTM F-718. If this product is to be applied as part of a coating system, all components of the system must be as listed on the QPL.

NAVSEA REVIEWED ASTM F-718. If this product is to be applied as part of a coating system, all components of the system must be as listed on the QPL. ASTM F-718 International Paint LLC Intertuf 6, Two Pack Anticorrosive Epoxy Primer PRODUCT DESIGNATIONS Part A: KH Series Part B: KHA6 MIL-PRF-336 MIL-PRF-67 If this product is to be applied as part of