Evaluation of Spot and Sweep Blasting as a Cost Effective Method of Underwater and Outer Hull Surface Preparation

Stephen Cogswell, BAE Systems Southeast Shipyards PMT:Gordon Kuljian, Pete Ault, John Odwanzy

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Spot and Sweep, in progress

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Concept
Reduce Total Ownership Cost of cleaning and painting underwater hulls on US Navy ships by leaving intact anti-corrosive on the hull during repainting This paper is a result of the work being accomplished by the NSRP Surface Preparation and Coating Panel project team: Steve Cogswell, Pete Ault, Gordon Kuljian & John Odwazny
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Spot & Sweep to well adhered Epoxy

& , spot & sweep/full removal, edge check in progress Spot & Sweep, DFT in tact epoxy 7 to 15 mils

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Spot & Sweep to well adhered Epoxy

Spot & Sweep, robotic head Spot & sweep, robotic head

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Project Goals
Demonstrate commercial technology on US Navy ships
Document performance issues Identify process refinements Determine life cycle cost impact

Develop NSI 009-32 language

Process requirements Objective Quality Evidence (OQE)
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USS KLAKRING (FFG 42)

Demonstration in February, 2011
BAE Systems Southeast Shipyards, Jacksonville FL Existing coating applied in November, 2002 Performed on freeboard and underwater hull Data collected
Production rates Adhesion of coating before and after cleaning Extent of coating removed

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USS KLAKRING (FFG-42) Spot & Sweep

The surface
Spot and sweep to existing well adhered epoxy coating

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Chariot Robotics
Articulating robotic head making a turn.

Vertical, cutting path

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Flow Hydro Cat

& , Chariot(left), Flow (right)

Hydro Cat tracking vertically

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Adhesion Values, Spot & Sweep

1st and 2nd AC, cut through 2030 psi

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Hull Plating from the Side Shell Retained for Laboratory Testing

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APL-65 Berthing Barge Dry-docking Graving Dock, NAVSTA San Diego July 2011

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APL-65 Initial Condition

Heavy corrosion on Stern U/W Close-up of Stern Corrosion

Calcareous Biofouling on flat-bottom

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Port side looking aft

Spot and Sweep Demonstration (APL-65)

General result of high speed spot/sweep. Due to the wide-spread coating defects, much of the underwater hull coating was removed to bare steel. This platform would not meet our criteria of a good candidate for spot and sweep removal, however meaningful data was gathered. Criteria appears to be in the 5% range of general defects, vs. 40% found on this hull.

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APL-65 Initial Condition

After pressure washing, minor W/L grass remaining, heavy base plate calcareous shell remaining on flat underbelly, widespread corrosion along welds and at stern. Flat Bottom avg. DFT 21.4 mils Starboard Mid-ship avg. DFT 18.2 mils Centerline flat bottom fwd avg. DFT 38.4 mils Initial Coating applied approximately yr 2000 Standard MIL-PRF-24647 system applied Overall coating showed approximately 40% coating defects in the form of blistering and isolated corrosion. Defects were predominantly wide-spread. Job involved a complete WJ-2 water-jetting of the underwater hull and freeboard - 19,000 ft2 removed by Chariot Robotics Envirobot. Remainder of hull coatings removed by men-on-guns (open cycle UHPWJ). Spot and Sweep demonstration performed along bow underwater hull prior to complete re-blast to SSPC SP-12, WJ-2
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Spot and Sweep Demonstration Data (APL-65)

Trial runs were optimized at 30,000 psi with spray bar in highest position from substrate. (9 GPM Pump) Resulting surface - 25% bare steel, approx 75% red primer and grey midcoat (both MIL-PRF-24647 epoxy) Run 1 stripping rate 3260 ft2/hour Run 2 stripping rate - 1830 ft2/hour Adhesion of initial epoxy (after A/F carefully sanded away and solvent wiped: 1316 psi (3 dolly avg. ASTM D4541) Adhesion of epoxy remaining after spot and sweep: 1615 psi (3 dolly avg. ASTM D4541)

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USS RODNEY M DAVIS (FFG-60) SPOT-AND SWEEP DEMONSTRATION VIGOR SEATTLE FEBRUARY 2012
INITIAL CONDITIONS - (after 5000 psi pressure wash) Hull coating in great shape. Less than 0.5% overall coating defects. Defects were generally isolated to discharges, welds, rudder and stabilizers. U/W hull last painted in 2003 (according to Port Engineer) Coating average DFT - 30-35 mils (Consists of primarily 17-20 mils A/C, and remainder is A/F, as verified by destructive Tooke Gage readings) Initial A/C adhesion - 1414 psi Practice Section Under Stbd, fwd anchor , fwd of forward sonar Demo section - FWD of FR 100 STBD, aft of forward sonar Non-Export Controlled Information Releasable
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RODNEY DAVIS (FFG-60) DEMONSTRATION

INITIAL JEWEL CHECK

DEPLOYMENT OF ROBOT TO HULL

START OF PRACTICE SECTION:

SSPC-SP-10

EXISTING MIL-PRF-24647 SYSTEM RED EPOXY PRIMER GREY EPOXY MID-COAT (WHITE IS SUBSEQUENT TOUCH UP EPOXY OF ANCHOR CHAIN DAMAGE)
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RODNEY DAVIS (FFG-60) DEMONSTRATION

FORWARD PRACTICE SECTION RESULTING SURFACE IS INTACT A/C WITH COMPLETE A/F REMOVAL. POORLY ADHERED COATING HAS BEEN REMOVED TO BARE METAL.

AFTER OPTIMIZING REMOVAL TO GREY A/C, ROBOT PERFORMED SPOT-AND-SWEEP AT 2100 FT2/HOUR DFT OF REMAINING GREY - 16.5 MILS DFT OF REMAINING RED 8.5 MILS

LOWER PRESSURE SWEEP LEFT CONSIDERABLY MORE HIGH PRESSURE SWEEP LEFT LESS A/C A/C WITH MINIMAL REMOVAL DOWN TO RED PRIMER PREDOMINANTLY RED PRIMER Non-Export Controlled Information Releasable to Non-US Persons: S2DSEA2012-0051

RODNEY DAVIS (FFG-60 DEMONSTRATION)

DEMO SECTION DURING SPOT AND SWEEP

DEMONSTRATION SECTION BEFORE SPOT-AND-SWEEP

TENSILE ADHESION AFTER SWEEP GREY A/C 2170 PSI (AVG OF 3) RED A/C - 2189 PSI (AVG OF 3)
REMAINING GREY DFT - 18.8 MILS REMAINING RED A/C 8.9 MILS OBSERVED PRODUCTION - 695 FT2/HOUR

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RODNEY DAVIS (FFG-60) DEMONSTRATION

ASTM D4417 METHOD C

CLEANLINESS OF SURFACE CONDUCTIVITY = 9 S/cm (well below limit of 30 S/c, per Navy Standard Item 009-32)
4.5 mils (ASTM D4417 Method C) 8.1 mils (ASTM D4417 Method B)

PROFILE INDUCED ON SURFACE

PROFILE OF ORIGINAL BLAST

4.4 mils (ASTM D4417 Method C) 4.8 mils (ASTM D4417 Method B)

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ASTM D4541 TENSILE ADHESION

NSRP Spot and Sweep Blasting Project Remember - We are trying to reduce this:

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DRAFT- PROCESS FOR SPOT AND SWEEP BLAST DEMONSTRATION

1. The spot and sweep process preformed by the Chariot Robotics unit (or equivalent) may be used for all areas of the underwater-hull and freeboard on approved surface ships. For areas not prepared using the Chariot Robotics or equivalent; Ultra High Pressure (UHP) lances, abrasive blasting, may be used to create either an SSPC SP-12 WJ-2/M surface or an SSPC SP-10 surface. SSPC SP-3 Power tool cleaning may be authorized for fairing in the spot and sweep surface as required. 2. The contractor shall inspect the existing coating on the hull and shall determine the sequence of the epoxy coatings currently on the hull prior to blasting. The anticipated sequence is red primer followed by gray epoxy tie coat. The contractor shall note these colors for use in NAVSEA inspection of the hull prior to application of the first coat of epoxy primer. 3. The Chariot Robotics unit (or equivalent) shall be set up to accomplish the following: (a) Remove all rust and fouling from areas of bare metal to create a SSPC SP-12, WJ-2/M surface condition in accordance with specified NAVSEA Standard Item 009-32, FY 12 Change 1 processes. (b) Remove all antifouling coating and remove approximately 1/2 of the thickness of the current epoxy tie coat thickness from the underwater hull area. (c) Remove all silicone alkyd, regardless of coating thickness, and remove approximately 1/2 of the thickness of the current epoxy topcoat from the freeboard area. (d) Smoothly feather or transition from areas of bare metal to the retained epoxy primer/tie coat. Areas of sharp or "step" transition between bare metal and paint shall be noted by the NAVSEA representative for detailed inspection. *under review: Feather edges where the Chariot Robotics unit (or equivalent) leave behind markings in the existing paint (concentric circle areas which some describe as crop circles).

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4. Upon completion of standard zones or work areas, in accordance with current, standard contractual requirements, the contractor shall inform the NAVSEA representative when they are ready to apply the first coat of primer to the zone or work area. NAVSEA representative shall conduct all standard data reviews and inspections on bare metal areas in accordance with specified Standard Item 009-32 requirements. Areas of retained paint shall be visually inspected and shall satisfy the following: (a) There shall be no more than two colors of paint visible in any area of retained coating. Inspectors shall observe the red primer adjacent to any bare metal areas and then continue observations into the bulk of the retained epoxy. Gray epoxy may be retained on top of the red primer, but any visual evidence of additional coats of red or black paint on top of the gray shall be cause for closer inspection. Closer inspection shall be conducted from a minimum distance of 3 feet. Upon closer inspection, a solvent-wipe test with a white rag shall be conducted using the antifouling coating clean-up solvent. If the solvent wipe test shows color transfer onto the rag, the area shall be rejected. Rejected areas shall be cleaned again until no color transfers to the rag. (b) There are no areas of sharp transition or steps between bare metal and paint. Any such areas shall be inspected and tested with a dull putty knife to determine adhesion. If the paint flakes or can be dislodged, the area shall be rejected and cleaned again to remove the loose paint. (c) *Under review Effort will be needed to smooth out the transition areas where partial blasted areas occur next to bare steel blasted areas. Sharp edges shall be removed in accordance with SSPC SP-3 and the areas feathered for a smooth transition. (d) Measurements of existing DFT shall be recorded for historical purposes in accordance with SSPC PA-2.

5. Upon approval of the surface preparation, the contractor shall apply one coat of AC primer, in accordance with established Standard Item 009-32 requirements to all areas in the zone or work area (i.e., bare metal and retained epoxy primer) to achieve the specified 5-7 mil dry film thickness. The contractor is not obligated to apply a thin or varied primer thickness when traversing areas between bare metal and retained epoxy. Again following standard practices, SUPSHIP shall inspect the zone or work area coating thickness. Because the coating thickness retained will vary notably, DFT readings shall be taken and recorded; however high DFT readings shall not be means for rejection, such readings shall only be taken for documentation purposes. In place of DFT readings for determining proper coating thickness, WFT readings shall be taken and recorded on each coat to confirm proper coating thickness (i.e. follow the 00932 requirement for taking WFT readings in place of DFT readings for accept/reject criteria). All other QA requirements of 009-32 shall be accomplished. 6. Once the primer has cured to overcoat the surface area shall be inspected for edge lifting of the remaining epoxy that was over coated. This inspection shall be conducted at a maximum distance of 15 feet. The curing epoxy primer will lift any loose edges of the existing coating as it cures that may not have been visible during the initial surface preparation inspection. These areas shall be prepared in accordance with SSPC-SP-3 and primed. 7. For underwater hull areas, apply second or tie coat of epoxy and first coat of antifouling in accordance with Standard Item 009-32 requirements (using WFT readings). 8. For underwater hull areas, apply complete antifouling system in accordance with Standard Item 009-32 requirements and note final coating thickness. Again, use WFT readings in place of DFT readings for determining proper coating application, with DFT readings being recorded for documentation purposes. 9. For freeboard areas, apply second coat of epoxy then the topcoat in accordance with Standard Item 009-32 requirements (using WFT readings). 10. The contractor and NAVSEA representative shall retain time, cost, or productivity metrics to report to NAVSEA and to be used to provide supporting data for any future Standard Item 00932 proposal to incorporate spot and sweep processes.

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Potential Cost Savings to the Fleet

Defining the cost savings is a deliverable of the project due March 31, 2012. Schedule and budget savings measured against the life cycle of the coating system to docking evolutions. Freeboard preservation may be the land of opportunity. Non Critical, often top coated for aesthetics only. Easily inspected. Greater than double the square footage over the UWH. Cost per square foot for surface preparation freeboard and UWH are close. Draft document was explained to inspectors who accomplished the G point on the following day. Their comments/feedback will be incorporated into final revision. PSNS, NWRMC, VIGOR. We have successfully demonstrated Spot and sweep on both coasts to the draft document.

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QUESTIONS
Special thanks to the Project Team: Chariot Robotics; John Odwazny, Gordon Kuljian Elzly technologies; Pete Ault NAVSEA: Mark Ingle, David Ciscon The commands of FFG-42 and FFG- 60, PSNS code 400, SERMC and the PMTs of BAE Systems SSYI and Vigor Shipbuilding

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