What’s New in Nonskid? - NSRP - National Shipbuilding ... OBJECTIVES • Summarize evolving Naval Sea Systems Command (NAVSEA) organization and coating requirements: •• Headquarters

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NAVAL SEA SYSTEMS COMMAND

What’s New in Nonskid?

NSRP SPC Panel Meeting

Portland, OR

September 2016

Mr. Mark Ingle, P.E.

SEA 05P2

(202) 781-3665

[email protected]

Distribution A: Approved for Public Release

mailto:[email protected]

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OBJECTIVES

• Summarize evolving Naval Sea Systems Command (NAVSEA) organization and coating requirements:

•• Headquarters NAVSEA organization & objectives.

• Summarize what’s new in NAVSEA nonskid and maintenance coating costreduction strategies:

•• FY-18 Standard Item 009-32 updates discussed at Aug 2016SSRAC.

•• Presented status of new, thermal spray nonskid (TSN) documentation at SSRAC.

•• Analyzing life-cycle performance of (TSN) materials to reduce total life cycle costs.

• Discuss opportunities for new ideas and NSRP SPC input into NAVSEA efforts to develop new requirements and streamline coating installation

practices.

Naval Systems Engineering Directorate (SEA 05)

Technical Domain Manager (TDM)Chief Systems Engineer (CSE)

Office of the CHENG

SEA 05B Deputy / COS

(SEA 05B1)

Aircraft Carrier Design &

Systems Engineering

(SEA 05V)

Chief Finance Office

(SEA 05B3)

Surface Ship Design &

Systems Engineering

(SEA 05D)

Integrated Warfare Systems

Engineering (SEA 05H)

Cost Engineering &

Industrial Analysis

(SEA 05C)

Ship Integrity &

Performance Engineering

(SEA 05P)

Chief Workforce Office

(SEA 05B2)

Special Projects

(SEA 00U/05X)

Executive Director / CHENG

Deputy / Chief Technology Officer

(SEA 05B)

Littoral and Mine Warfare

Design & Systems Engineering

(SEA 05L)

Technology Office

(SEA 05T)

Submarine/Submersible

Design & Systems

Engineering

(SEA 05U)

Technical Policy &

Standards (SEA 05S)

Undersea Warfare Systems

Engineering

(SEA 05N) (NUWCNPT TD)

Surface Warfare Systems

Engineering

(SEA 05W) (NSWCDD TD)

Marine Engineering

(SEA 05Z)

L&MW Warfare Systems

Engineering

(SEA 05M) (NSWCPC TD)

Explosive Ordnance

Engineering

(SEA 05E) (NSWC IH TD)

T&E Technical

Advisor

Deputy Commander /

CHENG(SEA 05)

Chief HR & Admin

Office

(SEA 05B6)

Draft: As of 8/22/16

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Code Product Related SpecsAll All Technical Products, Managerial All

AF Antifouling Coating Systems MIL-PRF-24647

TNK Tank Coatings, Epoxy Primers MIL-PRF-23236

MIL-DTL-24441

PRM Primers, Single Component TT-P-645

TOP Topside, Alkyds & Polysiloxanes MIL-PRF-24635

INT Interior Coatings (SEA 08) MIL-DTL-24607

MIL-PRF-24596

MIL-DTL-15090

MIL-DTL-1115

HT High Temp Coatings, Metallic TT-P-28

PWD Powder, Interior, Cosmetic MIL-PRF-24712

NSK Nonskid MIL-PRF-24667

DCK Deck Coverings MIL-D-3134

MIL-PRF-3135

MIL-PRF-24613

MIL-PRF-32171

SUR Abrasive blasting, surface prep MIL-A-22262

SEL Sealants & Preservatives MIL-PRF-16173

NAVSEAINST 9630.1

DOC Policy Documents NSTM 631, NSTM 634

S636-MAN, CCAMM

Standard Item 009-32

Standard Item 009-26

COR Corrosion/PCOE Policy/Design DODI 5000.67

RSH Research & Development To be determined

UNDS Regulations, Underwater hull TBD

NAVAIR

Aircraft Engines

TWH:

Habitability

SEA 08R

TWH: Underwater

Hull Husbandry

SDMs: Surface,

Submarine,

Carrier

Technical Authority Pyramid - Coatings & Corrosion ControlDraft: Sept. 2016

Navy Employee Navy Developmental Employee Contractor

Ingleall

Castle(EM)

All, COR

Lemieux(EA)

All, RSH

Vacant(EM)

NSK, All

Wegand(EM)

RSH, NSK

Lattner(EM)COR

Haslbeck(EM)

All, AF

J. Martin(EM)

TOP, TNK

Melhuish(EM)

All, NSK

Brinckerhoff(EM)All

Tagert(EM)

TNK, NSK

Kenney(EM)

VA-Class

Jones(EM)

NSK, DCK

Iezzi(EM)

RSH TOP

Smith(EM)

UNDS

Wigle(EM)CCAT

Slebodnick(EM)

RSH, TNK, NSK

Merlino(LE)

DOCs

Carroll(LE)NSK

ThomasCOR

Clayton(LE)

DOCs

Lawrence(LE)AF

StankeTNK, All

HolmAF

Adams(LE)

NSK, RSH

MillerTNK, NSK

ZuwialaCOR

CisconAll

ParkDOCs

FosterAll

SheridanRSH, All

F. MartinHT, COR

SpicerTNK, NSK

Needham(LE)

COR, All

WebbRSH

InternAll

EllorCOR

Ault(LE)

TNK, RSH

Langaster(LE)TNK

Ranero(EM)

All, NSK

EAs

EMs

LEs

KoglerSUR

TWH

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Delegated signature authority

Ong(EA)All

Eppard(EM)

NSK, TNK

Duckworth(EA)All


HQ

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FY-18, Standard Item 009-32

Updates Discussed at August 2016 SSRAC

• Standard Specifications for Ship Repair and Alteration Committee (SSRAC) met in Newport News, VA in August 2016 to address:

- 98 proposals addressed by Preservation Subcommittee:

“Top Ten” Action Items will create new requirements or help clarify existing requirements:

1. ESTABLISH working group to refine and develop new Standard Item on Thermal Spray Nonskid

(TSN). Working group to include:

- NAVSEA - Technical Warrants for coatings and materials, SEA 05D field representative.

- NRL - Engineers that developed and applied TSN to LHA/LHD.

- NSWC-PD - Nonskid ISEA.

- NSWC-CD - Thermal spray engineers.

- MARMC - Deck-plate nonskid QA.

- PSNS & IMF - Deck-plate nonskid QA.


Adopted = 14

Adopt as modified = 35

Not adopted = 36

Action Items = 13

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2. CONTINUE process of publishing TSN technical documentation to support TSN application

Standard Item to include:

MIL-PRF-XX704 TSN material specification MIL-PRF-24647 nonskid specification

Standard Item 009-XX on TSN installation Standard Item 009-32

Technical Publication (e.g., MIL-STD-1687) SSPC-QP 1, NACE/SSPC credentials

3. DEVELOP supporting documentation to clarify deck-plate assessment of surface profiles.

Supporting documentation to be in the form of slides or images to articulate concepts.

4. DEVELOP supporting documentation to clarify requirements for re-using nonskid

mixing blades and defining blade cleanliness.

5. DEVELOP supporting documentation to clarify requirements for preparing tie-downs, inspecting

tie-downs, and implementing the FY-18, Standard Item 009-32 update items on:

- Removing the term “bars” to allow coating of aircraft and vehicle tie-down types.

- Address reported tie-down inspection practices.

- Address dust tape call-out.


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6. COMPLETE PDS to reactivate TT-C-492 “Coating Compound, Paint Antisweat” or draft new specification for

anticondensation and/or insulation coatings.

● 19 Aug 2016 - SEA 05S concurs with transfer of “ownership” of TT-C-492 to SEA 05P2.

● 22 Aug 2016 - SEA 05P2 proposes NRL/NSWC team to update requirements with:

- Type/Class for products that absorb

moisture.

- Type/Class for single-pack products

that insulate with microspheres.

- Type/Class for two-pack products

that create high R-value coating.

7. REVIEW Army specification MIL-PRF-14105, “Paint, Heat-Resisting (for Steel Surfaces)” for possible

replacement of FY-17, Change 1, Standard Item 009-32, Note (39) and Table 5, Line 7.

8. DEVELOP MRC for Fleet to clean flight deck using “Green Clean” technology in FY-17, Change 1,

Standard Item 009-32, Table 2, Line 26.

9. UPDATE ASTM F718 to include additional information or “rules of thumb” from paint manufacturers about

ventilation issues.

10. ASSESS new anticondensation coatings based on Action Item 6 schedule.


SSRAC meeting group accepted or will accept 63% of proposed changes.

Why Use TSN To Improve Flight Deck Performance?

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TSN is only material

that can withstand

direct F-35 exhaust

gas impingement.

TSN has low macro-

profile and smaller

“chips” that can

break off lowering

risk of aircraft engine

FOD.

TSN is aluminum and

small (e.g., 400 grit or

smaller) Al2O3 aggregate

as compared with 24-30

grit Al2O3 in conventional

epoxy nonskid. Conventional Nonskid Chips TSN, wear particles , 400 grit aggregate

TSN can resist V-22

exhaust gas heat.

NRL validating that

V-22 exhaust gas

impingement can

crack conventional

nonskid.


Action Item - New TSN Standard Item

Re-establish Profile Using Aluminum-oxide Abrasive Blasting

Steel deck after UHPWJ cleaning,

extensive corrosion staining. SSPC-SP5 white metal level of cleanliness

with surface profile of 4.5- to 5.0-mils.

Background: Epoxy nonskid installed over steel shot SSPC-SP 10 with OQE indicating profile satisfied requirements.

NOT ADEQUATE for TSN installation.

Plan: Develop new Standard Item 009-XX to define the twin-wire arc spray process & equipment demonstrated

on LHA/LHD.

TSN applications on LHA/ LHD have shown SSPC-SP 5 cleanliness obtained on old decks using Al2O3 media.9


Critical New

Requirement


Process Summary

10Distribution A: Approved for Public Release

Plan: Standard Item 009-XX to define the twin-wire arc spray process & equipment as

demonstrated on LHA/LHD.

TSN Standard Item 009-XX will define detailed process and G-points to ensure successful coating application.

Plan: New Standard Item 009-XX will include similar approach with columns to Standard Item 009-32 to show how layers

of thermal spray are to be applied to create corrosion-resistant, rough, nonskid system.

Standard Item 009-XX will define detailed process, with G-points, to ensure successful application of TSN nonskid coatings.



Process Summary to Define Coats

TSN COATING FORMED IN LAYERS

TSN COATING FORMED IN

TWO, UNIQUE LAYERS

6”

ASSESSMENT: Location forward and in tram-line deck marking.

- Blister area: 0.03 ft2

- Hammer and chisel needed break blister and pry up the

delaminated layer.

- No evidence of “red rust,” or inter-coat delamination between

aluminum layers.

- No evidence of cracking or spreading of blister.

ROOT CAUSE: TSN applied in this area to correct thin initial coating using small,

hand-controlled robotic spray unit.

Likely lack of cleanliness in overcoated area.

Why Must Standard Item Define Cleanliness Between Coats?

Delamination Risk

ISSUE: Ship’s force detects “blister” in TSN nonskid after 23 months of service.

Key Point: Blister was apparent and ship’s force could repair area before FOD created.12

Plan: Standard Item 009-01 may need updates to address provisions for HEPA filters and air

emission controls to satisfy San Diego, CA Air Quality Management District requirements.

Status: Presented slides at SSRAC in Aug. 2016.

Key question is whether Standard Item 009-01 will ensure environmentally compliant application of TSN nonskid coatings.



New Process Creates New Environmental Challenges

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TSN Technical Requirements Being Developed

High priority specification creation work of interest to SEA 00, SEA 05, & multiple Flags.

TSN Fielding

Vital to Amphibious Ships

& Fleet Operations

FY-18 New

NAVSEA

Standard Item

New military

specification

MIL-PRF-XX704

for TSN wire

material.

Update Naval Ships

Technical Manual

Chapter 634

Material Installation Process / Qualifications In-service

Update current

MIL-STS-1687A

to Technical

Publication


Update MRC

for TSN Inspection

and Repair

by Ship’s Force

Under review by

SEA 05P

Process: SEA 05S SSRAC SEA 05S SEA 05S NSWC-PD

Status: SEA 05P2 review SEA 05P2 SEA 05P2 review NSWC-PD 1st Draft of Maintenance

complete to comments complete to Action Card for TSN Inspection

SEA 05S on 1st Draft, SEA 05S to CNSP on 17 May 2016

19 May 2016 complete 19 May 2016

19 Aug 2016 1-5 Aug 2016 12 Aug 2016 29 Jul 2016 SEA 05P2

SEA 05S concurs Presented to SEA 05S suggests Delivers FINAL draft cards

with need for QPL SSRAC. Revision as Technical to USFF N43 Flight Deck

Publication. Readiness Working Group

30 Aug 2016 29 Aug 2016

SEA 05S edits SSRAC edits done NSWC-PD to include in new

complete NRL to set up MRC deck.

Reading Session

Background:

Develop MIL-PRF-XX704 to define the wire material used with

twin-wire arc spray process & equipment as demonstrated on LHA/LHD.

Key Material Specification Provisions:

Coating to be formed over SSPC-SP 5 white metal level of cleanliness

by automated twin-wire arc system.

Multiple coats of TSN acceptable to build final coating system.

Wire material Type/Class to specify allowable hazardous heavy metals.

Wire material Type/Class to define whether wire is solid or cored.

Qualification Tests:

Conformance tests (e.g., metals levels, lubricants, packaging) to be

conducted on wire feed stock.

Coating conformance tests to exclude silicate color topping (another specification).

Qualification testing on coating with application parameters demonstrated on LHD

and LHA.

Status:

12 Aug 2016 - SEA 05S approved document as requiring a QPL.

30 Aug 2016 - SEA 05S completes draft document with revisions based on QPL listing, including updated references,

current “phraseology,” deleting data reports that cannot be required.

New military specification is to have qualified products list for wire feed materials that can form TSN coatings.

Action Item - NEW TSN Material Specification

MIL-PRF-XX704


● LHA 6 TSN installed using solid wire that is 97% Al / 3% Ti.

● LHD 1 and LHD 5 TSN installed using cored wire that is 5054 Al jacket / aluminum oxide (400 grit) core.

Cross Section: solid core aluminum wire

with elemental Ti.

Cross Section: hollow core aluminum alloy wire

with discrete aluminum oxide particles.

Transfer Efficiency: 68% Transfer Efficiency: 57%

Application Rate: 84 - 112 ft2/hour Application Rate: 84 - 112 ft2/hour

No reportable chromium on MSDS. Chromium reported as 0.15 – 0.35%

New MIL-PRF-XX704 to address Types or Class for both solid and cored TSN wire.


Action Item - NEW TSN Material Specification

MIL-PRF-XX704 Wire Type

Plan: Update MIL-STD-1687A to include requirements for personnel training and qualification to apply

wire material with the twin-wire arc spray process & equipment demonstrated LHA/LHD.

Key Update Provisions:

Defines required applicator training.

Outlines safety requirements.

Defines applicator qualification process and audit

For Quality Assurance/

Guides the applicator through the entire process

Including containment, legacy nonskid removal,

surface preparation, TSN application, color topping,

legacy nonskid tie-in and repair/

maintenance procedures.

May reference a CID to define the kind of robots used in the process.

Status:

12 Aug 2016 - SEA 05S completed Project Initiation Review (PIR) and determined document

must be modified to a Technical Publication.

Update to Technical Publication will leverage existing thermal spray training and certification requirements for TSN.

Action Item - Update to MIL-STD 1687A

Qualifications


NAVSEA Guidance

Surface Profile Measurement Validation – As-found Condition

ISSUE: As-found decks include multiple surface conditions that will influence ability to collect

representative surface profile data.

GUIDANCE:

1. Before nonskid removal, define scope of areas requiring abrasive blasting based on observed

SSPC-VIS 1, Rust Grade C or D (as shown in red).

2. After nonskid removal, collect representative, as-found surface profile data from areas with intact,

adherent nonskid (as shown in green). Data may be collected from exposed “black staining.”

3. Report required data on Standard Item 009-32 Appendices.

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Action Item – Develop Supporting Documentation

Standard Item 009-32 - Nonskid Profile Assessment


NAVSEA guidance slide for NST Center website to clarify data collection intent. NSRP input needed on clarity and content.

NAVSEA Guidance

Surface Profile Measurement Validation – Abrasive Blasted Condition

ISSUE: Abrasive blasted decks have multiple surface conditions that will influence ability to collect

representative surface profile data.

GUIDANCE:

1. After abrasive blast cleaning, validate SSPC-SP 10 near white metal cleanliness and required surface

profile using ASTM D4417, Method B or Method C from areas without visible pitting or corrosion metal

loss (as shown in green).

2. After abrasive blast cleaning, validate SSPC-SP 10 near white metal cleanliness using SSPC-VIS 1 for

Rust Grade C or D in areas with visible pitting or corrosion metal loss (as shown in red).

3. Report required data on Standard Item 009-32 Appendices.

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Standard Item 009-32 – Abrasive Blasted Profile Assessment



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Standard Item 009-32 – Reuse of Nonskid Mixing Blades



NAVSEA Guidance

Nonskid Mixing Blade Cleanliness

ISSUE: Nonskid mixing blades that are free of previously applied paint/nonskid may be reused to

mix nonskid.

Reused blade that Blade contaminated with

is free of nonskid - with nonskid –

ACCEPTABLE for use NOT ACCEPTABLE for use

New blade that is

free of nonskid -

ACCEPTABLE for use

GUIDANCE:

1. Blades shall be 99% free of residual coating or corrosion staining when viewed without magnification.

2. Up to 1% cured coating or corrosion staining may be retained in corners, welds, corrosion pits,

and other irregular surface areas.

3. All retained coating and corrosion staining, when wiped with nonskid solvent applied to clean,

light-colored shall not leave any colored residue on the rag.

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Standard Item 009-32 – Tie Down Inspection



SSPC-SP 2 or SP 3

in these areas

NAVSEA Guidance

Surface Cleanliness & Coating Integrity Validation on Tie Downs

ISSUE: Interpretation of surface cleanliness and coating integrity validation requirements on

aircraft and vehicle tie-downs highly variable across RMCs & shipbuilders.

GUIDANCE:

1. Surface preparation to SSPC-SP 2 or SP 3 is authorized in

areas that are shielded or shadowed from abrasive blast or waterjet cleaning or power tool cleaning.

2. Required surface profile measurements to be taken in areas that can be abrasive blasted to SSPC-SP 10 or

waterjet cleaned to NACE/SSPC- WJ-2/L or power tool cleaned to SSPC-SP 15.

3. Tie-down coating coverage shall be validated without use of a mirror or flashlight on all fittings.

10% of all tie-downs in each work zone shall be inspected using a mirror and flashlight.

4. For tie-down installation, NAVSEA Drawing 803-1916300, Note T-1D requires that 100% of crossbars to be tested

to ensure proper fit of the TD-1 hook. Excessive coating runs, drips, sags, puddles, or inadequate removal

of old coating during surface preparation can interfere with fit of the TD-1 hook.



Standard Item 009-32 – Reuse of Nonskid Mixing BladesISSUE: Standard Item 009-32 update “lessons learned” that nonskid mixing is a manual process and that

inadequately mixed nonskid exhibits irregular cure.

SOLUTION: NRL completed project to develop effective, automated nonskid mixing equipment.

Inadequate nonskid mixing adversely affected nonskid deck installation.

Effective performance demonstrated on nonskid deck at Puget Sound Naval Shipyard.

Draft Commercial Item Description (CID) A-A-XX695 for nonskid mixing equipment

to SEA 05S on 17 Jun 2016 with authorization to proceed to Government & Industry review.

25 Jul 2016 - Project Initiation Review (PIR) initiated.

5 Aug 2016 - PIR complete and NAVSEA is adjudicating comments.

Mix all qualified nonskid Double vortex mixing blades

6,000 gal. mixed without repair Three blades per unit

One blade being used

1.7 hp pneumatic motor One blade free of nonskid

ready to be installed

1 to 175 rpm speed control

One blade being cleaned

with solvent, rags,

and wire brush

Blades for 5 & 6 gallon cans

NSRP SPC comments on CID A-A-XX695 needed . New equipment will speed production & reduce risk.

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Summary

• NAVSEA goal is to ensure all coating and nonskid applications satisfy performance requirements.

• NAVSEA transitioning new thermal spray nonskid to fleet service to support V-22 and F-35 operations and to reduce the risk of aircraft engine FOD.

• NAVSEA will publish FY-18, Standard Item 009-32 in Jan 2017.

• NAVSEA will publish DRAFT Standard Item 009-XX on TSN for industrycomment in Jan 2017.

• NAVSEA goal to work with NSRP SPC to streamline coating productionprocesses while ensuring coating durability and attain anticipated service life.


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Backup slides