Correlating laboratory tests with service life performance of marine coating systems

Abstract

Accelerated tests have been commonly used by the marine coating industry to evaluate the performance of a coating in a short duration of time. Replicating natural exposure in an artifi- cially simulated manner is a challenging task due to the various factors that induce corrosion in the natural environment. Continuous salt spray testing is a popular accelerated test, but it does not replicate the actual exposure scenario as intensifying the factors inducing corrosion does not produce the same result as natural exposure. However, it was found that alternating between wetting and drying of the coating correlates well with natural exposure. ISO 12944- 9, a standardized accelerated test for corrosion protection in the marine environment, is one such test which alternates between different exposure conditions. This is performed in order to replicate the exposure conditions that a marine structure experiences. This ultimately aids in understanding the performance and durability of the coating within a shorter period. Besides, accelerated tests can be used to correlate with the natural exposure, in order to circumvent the issue of testing coatings in the natural environment for years to understand the coatings performance and durability. This thesis aims to correlate the performance of a commercial marine vinylester coating re- inforced with glass platelets named Ecospeed, when exposed in a natural service life envi- ronment versus that when tested in an accelerated environment. For accelerated ageing, the standard ISO 12944-9 was used, which is the standard exposure conditions for coating sys- tems undergoing extreme conditions in the marine environment. For the natural exposure, two in-service vessels coated with Ecospeed were selected to test its performance. Both vessels were coated with Ecospeed for 10 and 15 years. The coating’s performance is evaluated using electrochemical impedance spectroscopy (EIS) in both the natural and accelerated environments. EIS measurements were performed at peri- odic intervals of 1000 hours until 3000 hours for the accelerated exposure. EIS measurements were obtained on the 10 and 15 years old ship at multiple locations on the hull. This was done to check the uniformity of corrosion protection and variation of coating performance across the ship. Pull-off adhesion tests were also conducted after 2000 hours of accelerated exposure and the strength was reduced to more than half its initial strength prior to exposure in ISO 12944-9. The results of the accelerated test indicated gradual reduction in the impedance of the coating over 3000 hours of accelerated test exposure. The magnitude of impedance at the lowest frequency of 10 ́1 Hz was 4.23 x 1010 Ω cm2 after 3000 hours of accelerated exposure and for the 15 year field exposure the magnitude of impedance was 4.27 x 109 Ω cm2, which is well above the minimum industry standard of 107Ω cm2. Considering the impedance values for both the accelerated and natural exposure, it can be said that the impedance of Ecospeed is atleast 2 orders of magnitude higher than the minimum industry standard requirement even after 15 years of natural exposure. The accelerated results of 1000 hours had good correlation with the impedance measurements performed on the 10 year old ship. The magnitude of impedance of the 15 year old ship was lower than the magnitude of impedance obtained from 2000 and 3000 hours of accelerated exposure. This means further exposure in the accelerated environment is needed to correlate with a 15 year old ship.