TECHNOLOGY AREAS: Materials/Processes

ACQUISITION PROGRAM: NAVFAC Pollution Abatement Ashore Program

OBJECTIVE: Provide for creative and innovative technology to remove coatings from Navy platforms (including ship hulls) that does not utilize and generate residual media as part of the coatings removal process.

DESCRIPTION: Coatings removal using media including abrasives and pressured water results in relatively large and somewhat problematic waste streams that must be managed. Additionally, use of abrasives is usually accompanied by large and expensive containment utilized to avert release and to treat airborne debris and contaminants. The Navy and other DoD services have been investigating the use of corn hybrid polymer and other environmentally friendly media that can be recycled and reused. Technology that can eliminate the need for media, associated air handling and containment and can be utilized for a broad range of substrates and coatings would reduce the generation, management and cost of coatings removal operations. Coatings used on and aboard ships are particularly difficult since they span multiple substrates, coating types and applied thicknesses. Use of lasers for removing coatings has advanced but their use on Navy shipboard coatings has not proven sufficiently capable or has not been embraced for production use. Additionally, use of lasers requires application of exhaust fume treatment. Eliminating media, containment and by-product processes associated with these technologies is a more global and environmentally friendly approach that may significantly reduce the cost of coatings removal and by-product waste management. A successful method might be incorporated into the Navy's Automated Paint Application, Containment and Treatment System (APACTS) or similar concept that would enhance its potential for integration as both a coatings removal and application system for ship hulls in dry-dock. Recent advances in cryogenic, ultrasonic or other media-free techniques are targeted and may be of benefit for application beyond Navy ships. The technology/device must be capable of removing several layers of dried paint as described in detail below:

a. Coatings to be removed:

Five (5) layers of paint typically applied to below waterline hull:

Two (2) layers of 5 � 1 mil dry film thickness (dft) Epoxy Anti Corrosive paint (Zinc-Based, typically 70-80% solids)

Three (3) layers of 5 � 1 mil dft Cuprous-Oxide Based Anti Fouling Paint, typically 60% solids.

Above waterline, Silicone Alkyd Paint applied:

2-layers of 3 � 1 mil dft on top of the two layers of epoxy A/C paint.

Substrate is steel, typically sand-blast profiled to 2.5 � mils.

b. Coatings Removal Technical Requirements:

It is desired, but not required, that the removal technology/device not touch the coated surface and be applicable to other than UW applied coatings and steel substrates (e.g. aluminum, composite). The technology/device should be capable of preparing the substrate for subsequent coating and not negatively impact substrate condition or profile, be capable of achieving production rates similar to or better than achievable using existing technologies, be deployable in a Navy industrial environment, allow/enable other work to occur in the vicinity of the technology application, not generate or be susceptible to interference from other technologies, enable multiple or select coatings layer removal in air and/or underwater, be amenable to capture technology integration that could be employed to manage the coating(s) removed, be amenable to manual and automated application, generate, by it�s nature, no inherent waste streams to manage other than the removed coatings, present no environmental or occupational safety and health concerns or hazards that would limit its broad application or usefulness. Targeted use is in air, underwater or in both environments (most desired).

Laser technology is not targeted. Cryogenic methods are considered a viable approach if no residuals or by-product constituents of concern are generated and require subsequent management to address environmental or occupational safety and health concerns.

PHASE I: Investigate/develop/design an innovative media-free coatings removal technology approach that is capable of removing Navy ship hull coatings under the conditions shown above and that can be applicable for use on or with automated systems. Preliminary laboratory measurements should be obtained to defend and justify further development. Prepare concept documentation that will demonstrate the selected technology and provide estimates of eventual production cost and size of final package.

PHASE II: Based on the results and proven feasibility/ suitability documented in Phase I, design, develop and test a prototype media-free coating removal device. Working with the Navy Acquisition sponsor, conduct laboratory evaluation of the prototype device and subsequently, conduct field tests in conjunction with Navy surface preparation and painting operations to demonstrate the technology. The media-free coatings removal device will be evaluated for performance, operational compatibility, and ruggedness appropriate for field use.

PHASE III: The final media-free coatings removal device "product" will transition to the Naval Sea Systems Command and the Naval Facilities Engineering Command for implementation and further advanced development and integration. Based on the evaluations completed under Phase II, the contractor will make further modifications, improvements optimizations as required and conduct full scale field evaluations in a Navy/marine engineering environment (dry dock) or commercial facility in conjunction with the Navy customer. Additional opportunities for application to other DoD coatings removal operations are envisioned.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The commercial marine and dry dock industry will be a primary recipient of the technology. Other commercial surface preparation and painting companies and industries may also benefit.

REFERENCES:
1. S9086-VD-STM-010/CH-631 - Naval Ships' Technical Manual Chapter 631, Volume 1, Preservation Of Ships In Service - General

2. S9086-VD-STM-020/CH-631 - Naval Ships' Technical Manual Chapter 631, Volume 2, Preservation Of Ships In Service-Surface Preparation And Painting

3. S9086-VD-STM-030/CH-631 - Naval Ships' Technical Manual Chapter 631, Volume 3, Preservation Of Ships In Service - Surface Ship/ Submarine Applications

KEYWORDS: Coatings Removal Technology; Surface Preparation; Ship Hull Painting

** TOPIC AUTHOR (TPOC) **

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