Since 1982, there has been a move to Thermal Sprayed Aluminum (TSA) coating in the “splash zone” of offshore structures. Our experience indicates that an experience applicator, good surface preparation and quality of wire combined to achieve required thickness and apply the sealer to seal the entire surface.
This NACE/EFC standard is considered as the basis for the cleaning, surface preparation, and application of paint and coating systems to Navy ships used in marine environments for New Build, and during Life Cycle maintenance and permanent repair. It is intended for use by naval corrosion control personnel, coating applicators, and coating manufacturers. It covers coating materials, coating test protocol and acceptance criteria, surface preparation, coating application, quality assurance and control, and repair methods. Its purpose is to facilitate more effective corrosion protection of Navy ships and support inter-operability requirements by presenting reliable information and providing guidelines for coating manufacturers and shipyards to develop more durable specifications.
This standard replaces NATO Allied Engineering Publication (AEP) 59.
During the construction of a 56km long 16 in. carbon steel sour gas pipeline, repetitive surface
preparation failures were detected during visual inspection of pipeline girth weld internal surface prior to
coating application. Such failures represented 67% of the total pipeline girth welds and were manifested
by excessive sharp-edges at the root pass. To identify the failure causes, an investigation was
performed through reviewing the pipeline, fabrication and coating application specifications and
procedures, quality control records and performing an extensive visual inspection through an advanced
video robotic crawler on all pipeline girth welds made. Upon investigation analysis, the failures were
caused by sharp-edges in the root pass which were attributed to improper practices during
manufacturing, field fabrication and pre-coating quality control. The failure analysis indicated that the
mechanized Gas Metal Arc Welding process, with the parameters used, was not suitable for internal
girth weld coating application. In addition, a more stringent requirement should be applied to the
acceptable pipe-end diameter tolerance and pre-coating quality control to ensure absence of similar
premature surface preparation failures. The pre-coating quality control can be improved through
utilization of robotic laser contour mapping crawler for precise detection and sizing of unsatisfactory
surface weldment defects, including sharp edges.