Cost Saving Comparison in

Application of Polysiloxane
vs. Silicone Alkyd Topcoats
An NSRP Surface Preparation and Coatings Panel Project

J. Peter Ault, P.E. – Elzly Technology Corporation

Pete Lockwood, Robert Cloutier, and David Kinee – General Dynamics Bath Iron Works

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If it doesn’t move, paint it!

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How We Protect Steel from Corrosion

Coating

Corrosion allowance

Structural steel
 LSA Pigment LSA Pigment

Non-LSA Pigment Non-LSA Pigment

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Why do we paint so much?

 Culture of painting
 Prevents corrosion
 Desire to look good during certain events
 A fresh coat of paint is perceived to be
the quickest way to get the desired effect
 Integration of Low Solar Absorbance
pigments
 Significant energy savings
 Older resin technology more susceptible
to chalking
 Navy policy against isocyanates
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The Unintended Consequence of
Maintenance Painting for Aesthetics….
 Excessively thick coating
 Over 1/10th of an inch thick
 Suggests 20+ coats of paint

 Exacerbates peeling, cracking and

disbondment of coating
 Poorly prepared surface
 Adds weight

 Unnecessary cost

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Polysiloxane Coatings History

 1930’s – possibility of using silicone to

improve coating durability recognized
 1950’s – silicone alkyd coatings introduced for
industrial structures requiring exterior
durability
 1981 – First patent for polysiloxane coating
 1990’s – First commercially available
polysiloxane coatings
 Expanded use since 1990’s
 Storage Tanks, Offshore, Bridges…
 Generally favorable results
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Navy Interest in Polysiloxane

 Navy interest dates back to the 1990’s

 Improved durability
 Stain resistant
 Tested in Navy ship repair beginning in 2005
 Eliminate a coat of paint
 Improved color & gloss retention
 Varying stages of implementation
 Depot level maintenance
 Operational maintenance
 New shipbuilding

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MIL-PRF-24635D, COATING SYSTEMS,
WEATHER-RESISTANT, EXTERIOR USE
 Type V and Type VI – “High Durability”
 VOC content < 250 g/L
 Color (26270 haze gray)
 Semi-gloss (45-60 units)
 Low Solar Absorbance pigments
 Excellent resistance to UV/sunlight degradation
 Cleanable surface
 Three 2-component products approved in 2006
 One-component repair materials being developed

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Depot Maintenance Silicone Alkyd Topcoat (2-3 mils)
Epoxy Mid-coat (4-8 mils)
Epoxy Primer (4-8 mils)

 Estimated 20%+ cost reduction (installation)

Steel Substrate
 Eliminate coat of epoxy
 Anticipated life cycle savings
 Inserted in FY08 version of NSI 009-32
Polysiloxane Topcoat (5-8 mils)
Epoxy Primer (4-8 mils)

Steel Substrate

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Operational Level Maintenance

 Challenges for ships force to use 2 component coating

 Training (need to mix, how to mix, pot life limitations)
 Waste minimization (planning, workload)
 Logistics/inventory of matched material
 One component product for ships force use being developed by NRL to have
coating attributes similar to the 2 component siloxanes
 Single-component (all-in-one can) system, isocyanate-free and low in VOCs
 Brush, roll, or spray applied
 Better exterior color stability than 2 component polysiloxanes
 Adheres to high-solids (HS) epoxy primers and aged silicone alkyds

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Culture of Cleaning versus Culture of
Painting
 Naval Research Laboratories (NRL) developing alternative cleaning methods
for use by ships force
 Assembling tool kits/procedures
 Navy Corrosion Control Assistance Teams are field testing cleaning systems

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NRL Topside Coating Cleaning Kit

 Cleaning compound and tool kit developed for Ship’s Force to

remove rust stains from US Navy Polysiloxane Topside Coatings
 Cleaning Device & Cleaning Compound
 Fleet Benefits of Topside Cleaning:
 Eliminates HAZMAT and reduces VOC emissions from overcoat painting
 Eliminates peeling associated with recoating over contaminated
surfaces
 Reduces annual maintenance cost
 Reduces topside weight associated with cosmetic painting, thus
reducing its fuel efficiency
 Reduces maintenance time allowing sailors to work on fleet critical
tasks

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Navy New Build Challenges

 Construction sequencing does not always allow epoxy coat to be eliminated

 Cleanability has not been evaluated in a shipyard environment
 Concern regarding color matching during touch-up

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NSRP SPC Panel Project

 Simulate construction sequencing

 Apply each manufacturer’s system
to a section of the wingwall of
BIW’s drydock
 Various representations of unit
stage of construction

 Weather for several months

 Apply finish coat of polysiloxane
 Host workshops to discuss issues

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Polysiloxane Application Overview
Polysiloxane Repair Overview
SP1 / SP2 Vendor A /
Vendor A Various Touch Up Vendor A Cleaning & Tape
Coating Surface Prep with other Vendors Testing
over all 3

Nothing
V-A Continued
Weathering
SP1 As Is
V-A

SP2
V-A

SP1/SP2 V-C
SP1/SP2 1K

SP1/SP2 V-A
SP3 & SP11 to
Bare V-A
Fifty Shades of Gray?

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NSRP Project Observations

 All three approved polysiloxane coatings:

 Are easily applied in shipyard environment
 Retain color and gloss better than silicone alkyd after several months exposure
 Can be cleaned after several months exposure in industrial environment
 Outstanding concerns during new build:
 Whether touch up materials are sufficiently color-matched
 Whether various adhesives and coatings applied over topside coatings are
compatible with polysiloxane
 Net cost impact is shipyard & program dependent
 Is enough aesthetic painting & intermediate coat avoided to offset higher material costs?
 Life-cycle cost payback to Navy shortly after delivery

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New Build Cost Issues for Polysiloxane
Costs/Risks
 Increased material costs
 Costs associated with applying two-
component coating
 Potential compatibility concerns
 Adhesive materials
 Color-marking paints
 Color-matching is not perfect; still
need to extend re-work to a physical
boundary
 May need to identify alternative
masking tapes
Benefits
 Life-cycle benefit to the Navy
 No need for topcoat after PSA
 In some instances, intermediate
epoxy coat can be eliminated
 Reduced color shift (less pinking)
eliminates need for additional
coats during long build cycles
 Stain resistance reduces
contamination and makes cleaning
an option in lieu of re-painting
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Summary

 Polysiloxane coatings can save the US Navy considerable resources and

improve the overall condition of the fleet
 Life-cycle cost savings
 Improved performance
 Reduced environmental footprint
 There are different challenges for each phase of the life cycle
 Not a simple coating substitute
 Requires cultural and technical changes

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Acknowledgements

 The authors would like to acknowledge the support of:

 National Shipbuilding Research Program Surface Preparation and Coatings Panel
 Naval Research Laboratory
 Naval Sea Systems Command

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Questions?

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