Corrosion and Marine Paints

CORROSION AND MARINE
PAINTS
BY
CAPTAIN THEIN WIN
CORROSION
Corrosion is the decaying or destruction
of a material caused by the environment
in which the material resides. For
example, steel rusts when immersed in
seawater. The process of corrosion
requires four elements: an anode, a
cathode, an electrolyte, and a metallic
path. Corrosion is a natural process that
cannot be prevented, but intervention
with the correct measures can control it.
Forms of Corrosion
Corrosion takes many different forms.
The type of material, the environment in
which the material resides, and the
length of exposure to the environment all
contribute to determine the form.
Uniform or General Corrosion
This is also called general corrosion.
The surface effect produced by most
direct chemical attacks (e.g., as by
an acid) is a uniform etching of the
metal.
Galvanic Corrosion
Galvanic corrosion is an
electrochemical action of two
dissimilar metals in the presence of
an electrolyte and an electron
conductive path. It occurs when
dissimilar metals are in contact.
Galvanic corrosion is an
electrochemical process in which one
metal corrodes preferentially to
another when both metals are in
electrical contact and immersed in
an electrolyte. The same galvanic
reaction is exploited in
primary batteries to generate a
voltage
Galvanic corrosion is caused by an
electric current generated by two
different metals in a conducting
medium such a seawater,
electrolytic corrosion is caused by a
current from an external source,
often the boat’s battery or a shore
supply.
Pitting Corrosion
Pitting corrosion is localized
corrosion that occurs at microscopic
defects on a metal surface. The pits
are often found underneath surface
deposits caused by corrosion
product accumulation.
Stress Corrosion Cracking
Stress corrosion cracking (SCC) is
caused by the simultaneous effects
of tensile stress and a specific
corrosive environment. Stresses may
be due to applied loads, residual
stresses from the manufacturing
process, or a combination of both.
Cathodic Protection
The anode and cathode in a
corrosion process may be on two
different metals connected
together forming a bimetallic
couple, or, as with rusting of steel,
they may be close together on the
same metal surface.
Corrosion occurs at the anode but
not at the cathode
Cathodic protection can be
achieved in two ways:
- by the use of galvanic
(sacrificial) anodes, or
- by “impressed” current.
The metals commonly

used, as sacrificial
anodes are aluminium,
zinc and magnesium.
Anode Weight (lbs)
= [(Wetted Surface Area) x (Current Density) x
(Immersion)]
[(Energy Content) x (1000
mA/Amp)]
Actual or Estimated Wetted
Wetted Surface Area (sq-ft):
Surface of Metal
1.5 – 5.0 for painted Steel hull /

structure
Current Density (mA per sq-ft):
0.2 – 3.0 for painted Aluminum
hull / structure
Number of hours in water per

Immersion (hours): replacement
interval (8766 hours per year)
368 for Mil-Spec zinc anodes

Energy Content (amp-hours per
1108 for Mil-Spec aluminum
pound):
anodes
Impressed-current systems employ
anodes and use an external source of
dc power to impress a current from
an external anode onto the cathode
surface.
Structures that are commonly
protected by cathodic protection are
the exterior surfaces of:
Pipelines
Ships’ hulls
Ship’s tanks (product and ballast)
Storage tanks (oil and water)
The main areas that get affected on
ship are the propeller region, piping
system, copper plates of heat
exchangers. Aluminum parts that
are used in the machineries. And the
steel plates in the different sections
of the hull.
Surface preparation prior applying paint -
corrosion prevention methods for cargo ship
The most common methods

employed to prepare steel surfaces
for painting are:
i) Blast cleaning
ii) Pickling
iii) Flame cleaning
iv) Preparation by hand
BLAST CLEANING
SA 2
thorough blast cleaning:Commercial
finish 65% clean
The surface shall be free from
visible oil, dirt and grease, from
poorly adhering mill scale, rust,
paint coatings and foreign matter.
Any residual contamination should
be firmly adhering.
SA 2.5
very thorough blast cleaning: Near
white metal 85% clean
The surface shall be free from visible
oil, dirt and grease, from poorly
adhering mill scale, rust, paint
coatings and foreign matter. The
metal has a greyish colour. Any
traces of contamination shall be
visible only as slight stains in the
form of spots or stripes.
SA 3
blast cleaning to pure metal: White
metal 100% clean
The surface shall be free from
visible oil, dirt and grease, from
poorly adhering mill scale, rust,
paint coatings and foreign matter.
The blasted surface must have a
uniform metallic colour.
The three main components of an
(organic) paint coating are:
Pigment:
provides opacity, color (also can
provide corrosion resistance, water
barrier properties, viscosity control,
etc.); primer coatings are
sometimes named after a pigment,
for example zinc-rich primer.
Binder (resin):
binds the ingredients (holds

everything together), forms the
film; also known as the non-
volatile vehicle; paint coatings
are often named after the resin,
for example epoxy, vinyl,
polyurethane, acrylic, etc.
Solvent
The main purposes of the solvent are to
adjust the curing properties and
viscosity of the paint. It also controls
flow and application properties, and
affects the stability of the paint while in
liquid state.
The drying may take place through
one of the following processes.
(i) When the vehicle consists of

solid resinous material dissolved in
a volatile solvent, the latter
evaporates after
application of the paint, leaving a
dry film.
(ii) A liquid like linseed oil as a

constituent of the vehicle may
(iii) A chemical reaction may occur
between the constituents of the
vehicle after application, to produce
a dry paint film. The reactive
ingredients may be separated in two
containers (‘two-pack paints’) and
mixed before application.
Corrosion-inhibiting paints for
application to steel have the following
vehicle types:
(1)Bitumen or pitch
(2)Alkyd resin
(3)Epoxy resins
(4)Coal tar/epoxy resin
(5)Chlorinated rubber and
isomerized rubber
(6)Polyurethane resins
(7)Vinyl resins
(8)Zinc-rich paints
Three basic types of marine paints
are in use. The types are as per
paint composition.
1. General purpose marine paints:
Alkyd resin based, Bitumen based
and Gilsonite based
These paints have a protection life
of about five to six months and cost
relatively less. After the protection
period, the vessel needs repainting.
2. Chlorinated rubber based: Good
resistance to salt water and
atmospheric corrosion. The
protection life is about two years.
3. Epoxy resin based: This type is an

expensive type, but the protection
life is up to five years. There are
also zinc-rich paints, which are still
costlier, but the performance is very
high.
Volatile vehicle (solvent or
dispersant):
dissolves or disperses the binder,

allows the coating to spread out.
Topside
Vertical bottom
Topsid
e
Vertica
l Anti-Fouling Area
Bottom
Flat
Bottom
Anti-Fouling Paint
Bio-fouling, or biological fouling, is the
undesirable accumulation of
microorganisms (barnacles, algae) on
submerged structures – especially ships'
hulls.
Anti-fouling is the process of removing the

accumulation, or preventing its
accumulation. Ships' hulls are painted with
anti-fouling paint in order to increase speed
and reduce fuel consumption.
What is leaching action?
The anti-fouling paint is toxic.
Copper compounds are the
toxicants. There are two types of
anti-fouling paints. One type
releases the toxicants into the
seawater, which kill the fouling
organisms. The other type erodes
itself thus releasing the toxicants.
The release of toxicants into the
seawater is called leaching action.
The
International Convention on the Cont
rol of Harmful Anti-fouling Systems o
n Ships
, which was adopted on 5 October
2001, will prohibit the use of harmful
organotins in anti-fouling paints
used on ships and will establish a
mechanism to prevent the potential
future use of other harmful
substances in anti-fouling systems..
The convention entered into force
Marine paints have Product Name,
Quality number & Color Code (Color
Card)
HEMPADUR 15590 ,19990 (Black)
Description: is a two-component epoxy
primer coating especially for use on
surfaces exposed to severe abrasion.
HEMPALIN DECKPAINT 53240, 40900 (Green)
Description: is a quick-drying, styrenated
alkyd paint.
HEMPATEX HI-BUILD 46330, 10000 (white)

Description: is based on chlorinated rubber
HEMPATHANE ENAMEL 55100, 50630 (Red)
Description: is a two-component, high-gloss
acrylic polyurethane enamel with good
gloss and colour retention.
Painting Scheme
Shipping Lines have established
Painting scheme, provided for each
ship in their fleet, indicating what
product name, quality number, and
color code is to be used on different
locations to have uniformity in paint
quality and color on all of their ships.
Based on their application there are
three kind of paints namely;
1.Primer
2.Undercoat
3.Finish coat
Purpose of Painting;
• Preservation
• Protection
• Prevention
• Decoration
Failure of a Paint
Dilution
This usually occurs when the
dilution of the paint is not done as
per manufacturers
recommendation. There can be a
case of over dilution and under
dilution, as well as dilution with the
incorrect diluent.
Contamination
Foreign contaminants added
without the manufacturers consent
Peeling/Blistering
Most commonly due to improper
surface treatment before application
and inherent moisture/dampness
being present in the substrate.
Chalking
Chalking is the progressive
powdering of the paint film on the
painted surface. The primary reason
for the problem is polymer
degradation(a change in the
properties) of the paint matrix
Cracking
Cracking of paint film is due to the
unequal expansion or contraction of
paint coats. It usually happens when
the coats of the paint are not
allowed to cure/dry completely
before the next coat is applied.
Erosion
Erosion is very quick chalking. It
occurs due to external agents like
air,water etc.
Blistering
Blistering is due to improper surface
exposure of paint to strong sunshine.
Airless spray
forcing the paint through a
specially designed nozzle or 'tip'
at very high pressures (176-246
kg/cm
This very high pressure is
provided by a hydraulic pump
driven by an air motor, which
explains why the pump unit
requires a supply of compressed
The End
Thank You

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CORROSION AND MARINE

The metals commonly

1.5 – 5.0 for painted Steel hull /

Number of hours in water per

368 for Mil-Spec zinc anodes

The most common methods

binds the ingredients (holds

(i) When the vehicle consists of

(ii) A liquid like linseed oil as a

3. Epoxy resin based: This type is an

dissolves or disperses the binder,

Anti-fouling is the process of removing the

HEMPATEX HI-BUILD 46330, 10000 (white)

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