Shipbuilding Technology ISST 2007, Osaka, 2007

Effect of Edge Preparation Methods on

Edge Retention Rate of Epoxy Coatings for Ships Ballast Tanks

S. S. Seo*, K. K. Baek**, C. S. Park**, C. H. Lee** and M. K. Chung**

*) Hull Design Dept., Hyundai Heavy Industries Co. Ltd. 1 Jeonha-Dong, Ulsan, Korea
**) Protective Coatings & Corrosion Res. Dept., R&D Center, Hyundai Heavy Industries
Co. Ltd. 1 Jeonha-Dong, Ulsan, Korea
e-mail: mat@hhi.co.kr

ABSTRACT

To avoid insufficient coating film thickness at certain areas, such as corners, edges and weld seams in the
ballast tanks, mechanical grinding of the edge area is required since stripe coatings applied on a smoother
edge profile will retain liquid paints longer than the sharper shaped edge does. For this purpose, 3-Pass or
2-R edge grinding treatment prior to secondary surface preparation is specified by IMOs PSPC rule.
However, the coating application experience revealed that the actual coating thickness at these areas tend to
be thicker than flat areas, which makes those areas vulnerable to coating cracking during service. Therefore,
it is important to come up with proper edge preparation method to ensure achieving reasonable coating
thickness at the edge areas. Examination of disk grinding-induced burrs at the edges showed that most of
excessive burrs were removed during the ISO Sa 2 blasting stage before coating. This result combined with
measurements of the coating thickness at the edges showed that the widely practiced RC grinding(one pass
grinding + disk papering for burr removal) with stripe coating for 2 coats (avg. 300m total D.F.T.) epoxy
system would provide enough coating thickness at the edges with Edge Retention Ratio(ERR) reaching over
1.0 value.

1. INTRODUCTION

The protective coating for certain areas of the ballast tanks such as corners, edges and weld seams
need to be re-coated or stripe coated to avoid coating defects such as insufficient film thickness, resultant
corrosion of steel, etc. A common approach for solving these problems is mechanical grinding of the edge
area to provide a smoother edge profile, which will lead to better retention of liquid paint than the sharper
shaped edge does. For this purpose, the IMOs PSPC rule (adopted by Res. MSC.215(82) in SOLAS Reg.
II-1/3-2 and XII/6.3) calls for 3-Pass or 2-R edge grinding treatment prior to secondary surface preparation
based on the understanding that the rounder edge would better retain the coating. However, according to the
actual coating application experience, the negative effect of this requirement is that the final coatings at these
areas tend to be thicker than flat areas, making such areas more vulnerable to coating cracks during service.
Therefore, it is considered important to select a proper edge preparation method to ensure reasonable coating
thickness at the edges. Thus, in this paper, practical edge preparation methods are discussed based on the
several recent studies employing the cross sectional measurement of the coating thickness at the edges
[1]~[4].

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2. COMPARATIVE STUDY ON EDGE PREPARATION

2.1 Experimental Preparation

Steel panels (300mm100mm12mm thickness) or angle bars (25mm25mm(90o)3mm thk. 4mm

L) with various edge curvature were prepared [3], [4]. Edge curvature conditions were categorized as
follows:
sharp (as flame cut) 1C (1-Pass grinding)
2C or RC (equivalent to 3-Pass grinding) 2R (2mm radius edge)

For each steel panel (or angle bar) with specific curvature, coating (2 coats, avg. 300m total D.F.T.)
was applied by airless spray with 60% S.V.R. epoxy coating materials after ISO Sa 2 blasting. To measure
the coating thickness at the edges, cross-sections of coatings were observed using an optical microscope and
Scanning Electron Microscope(SEM). Edge Retention Ratio (E.R.R.) of coating for each edge curvature was
calculated with the following equation:

E.R.R.(%) = (D.F.T. at the edge) / (D.F.T. at the flat surface)

2.2 Results

Examination of disk-grinding-induced burrs at the edges showed that most of excessive burrs are
removed during the ISO Sa 2 blasting stage before the coating is applied, and that the areas of residual
burrs accounts for 0.59~0.72% of total edges of blocks to be painted, as shown in Fig.1 [1]. This result
strongly indicates that ISO Sa 2 blasting, as a secondary surface preparation method for blocks to be
painted, will either remove or minimize disk-grinding-induced burrs at the edges, thus eliminating the needs
for extra edge grinding for burr-removal purpose as shown in Fig. 1.
Additionally, E.R.R. measurements result showed that all edge-ground panels/angles displayed
improved edge retention tendency after ISO Sa 2 blasting [2]~[4]. The measurement of the coating
thickness at the edges, as shown in Fig.2~Fig.4, clearly showed that E.R.R. of epoxy coating in the area
which had undergone 1C edge grinding without the stripe coating (2 coats, avg. 300m total D.F.T.) were
0.8~1.0 [3], [4]. These results were believed to be due to the combined effect of ISO Sa 2 blasting and
2-layer coating practice. In other words, the sharp edges are rounded during ISO Sa 2 blasting stage and
become buried in the first coat, leading to the secondary and final coating being applied on much rounder
edges.

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Fig.1 Variation of bevel angle after sharp edge grinding and blast cleaning [2]

Fig.2 Edge retention on various E/G steel angles vs. coating thickness(D.F.T. flat) [3]

Fig.3 E.R.R. (%) with coating thickness (2 coats, avg. 300m D.F.T.) with 1 C and other E/G [3]

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Flame Cut

RC

SVR = 60%

Fig.4 Variation of coatings thickness (2 coats, avg. 300m D.F.T.) with 1 C and other E/G [4]

Table 1 shows the differences in edge coverage rate for the single coated (primer coating) and 2-layer
coated (primer and top coating) on the zero (flame cut) and 1mm roundness(1R) edge, yielding a higher ratio
for the 2-layer coated edge than a single coated edge. This difference was also attributed to the addition of
extra roundness, provided by a primer coating, in the 2-layer coating.

Table 1 Edge coverage rate for the 1-layer coated and 2-layer coated films [4]
Dry film thickness Dry film thickness
Coatings & Edge Edge coverage
(m, Flat) (m, Edge)
Roundness
1st coat 2nd coat 1st coat 2nd coat 1st coat 2nd coat
Flame
179.4 165.8 60.1 75.9 0.34 0.46
cutting
80% R=1mm 173.8 136.2 61.9 119.4 0.36 0.88
SVR R=2mm 174.7 153.7 141.9 152.0 0.81 0.99
R=3mm 158.0 142 141.4 159.0 0.90 1.20
Flame
cutting 153.5 122.4 64.0 133.8 0.42 1.13
60% R=1mm 133.7 155.1 137.8 152.7 1.03 0.99
SVR R=2mm 146.8 180.5 165.1 160.2 1.13 0.97
R=3mm 148.7 116.7 161.2 155.8 1.08 1.24

Another important aspect regarding on this subject is the possible coating breakdown at the edges
due to hull stress, vibration and water flow induced wear even under 100% edge retention condition, as
shown in Fig. 5. This rather new observation emphasizes the importance of measures against coating

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cracking, considering that less flexible, light colored epoxy coating system has already replaced tar epoxy
coating in order to comply with the Enhanced Survey Program(ESP) for W.B.T. section of ships. Considering
that additional stripe coating(s) is applied to edges, the chance of edges having overly (not under) thick
coating becomes greater, increasing the possibility of mud-type cracks at such areas also [5].

i on

Fig.5 EFM analysis of fluid status around T-bar in W.B.T., showing much higher wall shear
stress and impact load concentration around the edge [3]

The most favorable way to avoid overly thick coating, therefore, is to maintain proper balance
between edge preparation and stripe coating to ensure sufficient edge retention of coating and at
the same time, avoid overly thick edge coating.

3. CONCLUSIONS

Examination of disk grinding-induced burrs at the edges showed that most of excessive burrs were
removed during the ISO Sa 2 blasting stage before coating. This result combined with measurements of the
coating thickness at the edges showed that the widely practiced RC grinding(one pass grinding + disk
papering for burr removal) with stripe coating for 2 coats (avg. 300m total D.F.T.) epoxy system would
provide enough coating thickness at the edges with Edge Retention Ratio(ERR) reaching over 1.0 value.
Excessive edge preparation combined with multiple stripe coating would, on the other hand, cause
overly thick coating, which are more susceptible to premature cracking. Thus, it is critical to maintain
proper balance between edge preparation and stripe coating to ensure sufficient edge retention of coating
without risking overly thick coating on those areas.

REFERENCES

[1] S. K. Chi et al., Surface Preparation Effect on Edges Coating Performance, Presented at Annual
Workshop of Protective Coatings & Corrosion Engineers for Korean Shipbuilding Industries, Geoje,
July, 2004.

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[2] I. V. Kharlamov et al., Corrosion Protection of the Members (Elements) of Steel Structures with
Different Bevel Angles and Radii of Curvature of the Edges, Izvesiya VUZ, No. 8, 1976.
[3] J. T. Yun et al., A Critical Study on Edge Retention of Protective Coatings for a Ship Hull, Symposium
Paper No.5016 presented at NACE CORROSION/05, Houston, 2005.
[4] M. K. Chung et al., Approaches for Achieving Successful High Build Coatings on Sharp Edges in Ship's
Ballast Tanks, Symposium Paper No.3010 presented at NACE CORROSION/03, San Diego, 2003.
[5] E. H. Song, M. K. Chung, C. H. Lee, S. K. Lee, H. I. Lee, C. S. Park, C. S. Shin, and K. K. Baek, Why
We Do Have Cracks in Epoxy Coatings for Water Ballast Tanks?, Paper No.0615 presented at NACE
CORROSION/06, San Diego, 2006

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