MARINE COATINGS

Robert C. Spicer is a former cruise line executive and Chief Engineering Officer in the U.S. Merchant Marine. He is currently working toward a Doctor of Education degree in Organizational Learning and may be reached at [email protected].

Marine structures exist in one of the harshest environments on earth. Their exposure to sea salt, mechanical damage, biological fouling, and deterioration from the sun and wind requires the development of coating systems that will protect the investment of the owner, meet the needs of operators, and look good – all at an economical price. It’s a tall order, and that’s why you should read this article. A wise investment in the right coating can go a long way toward ensuring the integrity of your vessel and will actually save you money over the long haul. It can also reduce your environmental footprint by lowering fuel consumption and thus the volume of emissions.

Now for some background: Paints made their earliest appearance about 30,000 years ago with early cave-dweller drawings, and the first recorded paint mill in America was established in Boston around 1700 by Thomas Child. In 1867, D.R. Averill of Ohio patented the first prepared or "ready mixed" paints in the U.S., according to the American Coatings Association (ACA). ACA defines marine paints and coatings as those applied to commercial and military ships in both salt and freshwater. In this article, the terms “coating” and “paint” are used interchangeably; and the structures may be fixed or floating, such as offshore oil rigs, ships recreational vessels. Since marine coatings are designed with particular properties to best protect and preserve the surfaces to which they are applied, there are various types depending on the area of application – interior, open deck or underwater.

Choose Your Weapon
The various types of coatings available in the industry are typically defined as (1) industrial coatings, which are applied at the time of manufacture, (2) architectural coatings, which are used for decorative purposes, and (3) special purpose coatings, which are divided into the following major sub-segments: automotive refinish coatings, aerosol coatings (which are largely for consumers), and marine paints. In the marine industry, coatings of various types are routinely applied to interiors and exteriors with a significant focus of late on underwater hull bodies.

Ecospeed®, a product of Antwerp-based Hydrex Subsea Industries, is a protective coating made from a vinyl ester resin base with glass platelets. According to Hydrex’s founder, Boud van Rompay, it is the only homogenous coating that provides both hull protection and mechanical antifouling properties. In glassflake lining technology, glass flakes are incorporated into a matrix of a tough carrier resin applied in the form of a liquid coating and cured to create a tough, glass-like product, forming a powerful bond with a host of diverse substrates. This proven industrial technique has now been adapted for marine use. After the curing process is complete and the vessel put back in service, the coating is conditioned by use into an exceptionally smooth finish with hull roughness brought down to less than 20 microns. The result is a more efficient hull, and hence substantial fuel savings can be achieved. Ecospeed’s® properties prevent fouling penetration, making the cleaning process extremely easy underwater or with high-pressure tools in drydock. A significant advantage, according to the manufacturer, is that cleaning can be repeated during the vessel’s lifespan without causing damage or deterioration to the coating surface characteristics. Ecospeed® is promoted as a once-in-a-lifetime investment with an expected lifespan of 25 years if maintained properly. That can add up to big savings.

Corrosion Protection, FuelSavings and Long Life
One of the most challenging and significant developments in marine coatings recently has been the ban on tributyltin (TBT) compounds, which served as the standard antifouling coating for more than 40 years. With the IMO’s ban on the production and of coatings incorporating TBT, their presence was eventually eliminated, and copper-based coatings began taking their place. Concerns about the buildup of dissolved metals in bays and basins, however, soon drove the industry to explore other options. The result has been various innovative solutions that do not contain biocide elements.

In addition to the need to protect hull structures from corrosion and find alternatives to TBT, the recent increase in fuel prices has driven manufacturers to develop coatings that reduce hull drag and thus the amount of fuel consumed in propulsion. According to Jim Brown of International Paint, a world leader in marine coatings, the company was very active during 2010 in the introduction of new products. Shipbuilders and owners now have more choices to protect their assets and lower both fuel costs and volatile organic compound (VOC) emissions. Continued research and development, particularly in the area of adhesion mechanics, has resulted in the latest innovation to complement International’s line of Intersleek products. Intersleek 7180 Linkcoat, introduced last September, now allows access to fluoropolymer-based Intersleek 900 and silicone-based Intersleek 700 foul-release technology without the need and expense of full underwater hull blast cleaning.

Norwegian-based Jotun Marine Coatings, another big global player, recently announced the launch of Hull Performance Solutions (HPS), a revolutionary new concept which guarantees significant reductions in fuel consumption. An innovative combination of its SeaQuantum X200 antifouling product, service and performance monitoring allows HPS to measure hull performance over time and offer a unique money-back guarantee. “HPS represents a genuine game-changer in the marine coatings segment,” says Geir Boe, Vice President, Marine Coatings. Jotun is the industry’s first marine coatings manufacturer to back fuel reduction claims with a guarantee, based on verifiable results. Jotun uses sensors to capture information from different data points, which calculate fuel savings over time. “Jotun, compared to other technologies, will provide substantial fuel savings. We claim a 10.5 percent fuel saving, and either we deliver on high performance or we return the additional investment in SeaQuantum X200. That's how confident we are,” stated Morten Eikenes, Ph.D., Concept Development Director for HPS.

Denmark-based Hempel A/S is another significant player in the marine coatings marketplace and has reported reductions in fuel consumption after application of HEMPASIL X3 aboard Holland America Line’s Zaandam and Prinsendam. The application of a full coat not only saved the company money but reduced CO2 emissions as well. Hempel states that HEMPASIL X3 is the only fouling-release system that is effective down to eight knots, which makes it an excellent choice fo r cruise liners.

Cost issues have made life more challenging of late for coatings manufacturers. The recent recession led to a decline in demand for maintenance and repair coatings, yet raw material costs have been rising. “We have attempted to minimize the impact on our customers for as long as possible by leveraging our buying power and driving internal cost-saving measures,” stated Paul Westcott, Commercial Director of Marine & Protective Coatings for International Paint. PPG’s Jacques de Coninck, Director, Global Marine Coatings, noted that demand in the last year was still in line with expectations in the newbuild segment, primarily driven by the existing order book. “Demand still depends on the region with the largest newbuilding demand in Asia Pacific. In North America there is a growing demand in the inland market as more financing becomes available,” he added.

In the U.S., the paints and coatings industry employs over 348,900 people and product shipments by U.S. producers total about $22.5 billion. The U.S. exports about $1.6 billion in paint and coating products annually with exports to China valued at $60 million. In the marine industry, leaders such as International Paint continue to provide value to owners. Norwegian Sun’s Intersleek hull coating recently marked its 10-year anniversary in service. Norwegian Sun was first coated at newbuilding with fuel-saving Intersleek silicone foul-release coating and has since traveled more than 800,000 nautical miles with only minor touch-ups.

Recent research findings from Professor James Corbett show that technology can considerably reduce emissions and bunker fuel costs and that International’s Fluoropolymer Foul Release Hull Coating saves an average of nine percent on CO2 emissions. More than 400 vessels in the commercial fleet currently use Fluoropolymer Foul Release technology for marine applications, making it one of the most widely used eco-efficiency technologies in the shipping industry. If similar fuel efficiency results were realized by all tanker and bulk cargo vessels in the commercial fleet, annual fuel oil expenditures could be reduced by $4.4 to $8.8 billion per year, according to the report.

Going Green

For years the paint and coatings industry has aggressively sought to make products in an environmentally conscious way without compromising performance. The pressures of market demands and regulatory requirements have contributed to reductions in both hazardous pollutants and VOC emissions. PPG Protective & Marine Coatings considers it an obligation and responsibility to wholeheartedly support new regulations, and their underwater hull coatings are designed to reduce hull roughness and contribute to fuel savings and CO2 reduction. Its packaging, such as in the recently launched SIGMADUR ONE product, a single-pack urethane polyester finish coat developed for onboard maintenance by the vessel’s crew, is unique. The one-pack properties make it user-friendly, reduce waste and improve efficiency. “PPG Protective and Marine Coatings continues to develop and bring coatings to market that meet the requirements of yards, owners and operators while complying with the latest regulations and standards,” stated Jacques de Coninck.

According to Hydrex Subsea’s van Rompay, the history of marine coatings continues to be newly written. He believes it’s important to build an industrial underwater hull maintenance network that will provide ultra-fast and efficient services to shipowners on a global basis. “Regulation is too slow to produce the necessary change while pollution continues to increase at a dramatically high level,” he noted. “At Hydrex Subsea, innovative technologies like Ecospeed® are one way to keep ahead of the curve.” We couldn’t agree more.