Wednesday 3 December 08 - 04:00
 

Paints And Coatings

A copper-bottomed investment

The coatings industry chemists have been searching for many years for non-toxic biocides, says Phil Pickin. Now it seems good old-fashioned copper may give the antifouling and environment protection needed
Wallstrom: substitute the most dangerous substances
Wallstrom: substitute the most dangerous substances

It's assumed that most boat owners are aware of the need to antifoul a hull but it isn't until you look into the issue in some depth that you begin to see some of the major reasons for this routine chore.

Although most of the data available refers to the shipping industry it's not difficult to see what the impact of marine growth on a hull can make, even leisure craft. To give some idea of the problem here are a few figures.

A 260,000 DWT crude oil carrier can burn an extra 24 tonnes of fuel per day if heavily fouled. This is not just an economic problem, with increased fuel costs and drydock time, but an environmental one as a totally fouled world fleet would burn an extra 70.6 million tonnes of fuel. This would add an extra 210 million tonnes of CO 2and 5.6 million tonnes of SO 2to the atmosphere.

So the answer is to antifoul?

Yes; but that too has its impact on the environment.

In 1996 evaluation results found that some 70% of the world's commercial fleet used tributyltin (TBT) based antifoulings. (TBT) was eventually found to be highly toxic - particularly to shellfish and at very low exposure rates - with the result that sale and application of TBT antifoulings was banned under the 2001 IMO Antifouling System Convention. Application of TBT based antifoulings was banned on January 1, 2003 and the total prohibition of TBT on hulls comes in on January 1, 2008.

The industry reacted swiftly and most major suppliers ceased to supply such products after January 2003. And so began the move towards copper that continues today.

But, says International Paint's Dr Julian Hunter, whatever products are used in antifoulings, they will need to comply with the legislation that began in 2001 when the European Commission adopted a white paper setting out the strategy for a future community policy for chemicals.

The main objective of the new chemical strategy is to ensure a high level of protection for human health and the environment, while, in their words: "ensuring the efficient functioning of the internal market and stimulating innovation and competitiveness in the chemical industry". Commenting on the announcement environment commissioner Margot Wallstrom said: "This is one of the most important initiatives the commission has taken in the context of sustainable development. We have decided on a step-by-step approach to phase out and substitute the most dangerous substances - the ones that cause cancer, accumulate in our bodies and in our environment and affect our ability to reproduce. This decision is crucial for future generations".

Crucial decision The enterprise commissioner Erkki Liikanen added: "The decision is crucial to get good and reliable information on the basis of which we can start analysing the many chemicals on the market on which we have no knowledge of their effects on the environment and our health. At the same time the decision is important to create a proper internal market for chemicals products - and thus a level playing field for our industry."

The result of this is that now, not only will the biocide elements within antifoul coatings be covered by an EU directive (likely to be in place by 2007-8), but all other chemicals will also have been scrutinised. The time scale for this procedure is also likely to be 2007-8 by which all companies making chemical products will have to have applied for and been awarded a licence. Acceptance of this application will be on the basis that they adhere to EU wide laws on the ingredients and manufacture of the end product.

The outcome of this will be, it's hoped, a cleaner and healthier environment to use and work in.

Although it would seem that most companies are looking to develop more chemical based products to meet the needs of the marine community there may be other options. China, as with most areas of commerce, would seem to be making considerable strides with what can only be described as natural based alternatives.

These "greener" options include the use of vegetable based compounds and even a type of mud that contains a naturally occurring growth inhibitor. These not only reduce the likelihood of marine growth but in some cases actually repel these microscopic invaders.

Some of these ideas may seem to be pie in the sky concepts but many are taking them seriously. Patents have been taken out on many of these products in both the US and China and a number of well respected universities are involved in the research.

All of this activity must have come to the attention of some major names as it's reported that contacts have been made with shipyards and paint companies. So it may not be too long before we see a truly green method of antifouling.

Let's hope that these alternatives are more effective than some of the more environmentally friendly domestic products on offer which can sometimes leave something to be desired.

I expect we'll see more and more of copper in the immediate future, starting with one of the major names in the industry, Awlgrip, which recently updated its formula of Awlstar Gold Label Antifouling and introduced it at the recent London Boat Show.

New formulation The new formulation uses the latest boosters against fouling growth and its copper-based structure has now been further optimised to act as a fouling deterrent for cruising vessels in warm and cold waters. In addition to the changes in formulation the Awlstar Gold Label colours have also been improved, and faster application times have been achieved, which cuts time spent in the yard. In addition the product can also now be sprayed at a high film thickness without runs or sags, they say.

Awlstar Gold Label is designed to be applied over Hull-Gard Epoxy Primer, which will ensure a strong bond between the two coatings. This epoxy-based water barrier can be directly applied to clean, prepared hulls. The company suggests that to provide a built-in indicator of when the coating needs to be replenished that the first coat be applied in a different colour from the remaining coats. It will be time to renew as soon as this layer starts showing through.

This tin-free antifouling is self-polishing and is recommended for use on GRP, steel and wood and is not to be used on aluminium: the company's Awlstar Aluminium Label antifouling is designed for this purpose. The new formulation is available in 1 gallon and 15ltr units.

Aquarius Marine Coatings (AMC) say Coppercoat is the original, longest running copper based antifouling product produced in the UK.

Manufactured and distributed by AMC in Dorset, the team behind Coppercoat, Jayson Kenny and Ewan Clark, have been involved with the product since its launch in 1990 and, they say, are just as passionate about it today.

Claimed to be long lasting, low cost and easy to apply, the copper based antifouling is environmentally kind. It has been thoroughly tried and tested, with customers enjoying their 13th season without the hassle of annual reapplication.

Developed in the 1980s Coppercoat is the combination of specially formulated solventfree epoxy resin and high purity (99%) copper: the company says it's the strongest copper based antifouling available, with each litre of resin impregnated with 2kg of ultra fine spherical copper powder, the maximum allowed by law.

Tests show that when antifoulings use less pure copper or weaker alloys the performance is substantially reduced.

Natural reaction Coppercoat works through the natural reaction between copper and water. On immersion the exposed copper powder degrades to produce cuprous oxide. This highly effective anti-fouling agent deters growth until the surface degrades to become cupric hydrochloride.

This then washes away, automatically exposing a fresh copper rich surface and the process begins again.

With an average of thickness of 250 microns per treatment, and a typical corrosion rate of less than five microns a year, AMC says this coating offers effective and long lasting protection.

Jotun Coatings also recently released its new FRC SeaLion silicone-based, elastomeric coating, which is said to provide a smooth, non-stick, waterrepellent and self cleaning surface. The product, or system, is made up of three parts; an anti-corrosive bridge coat - Safeguard Universal ES, a high adhesion tie-coat - SeaLion tie coat and a smooth top coat - and a SeaLion top coat .

The system is dependent upon these three products working to combine the features of the anti-corrosive and the smooth topcoat linked by a tie-coat. It would seem that the ability of the tie coat to provide good levels of adhesion between the two is critical and to provide this Jotun has developed the SeaLion tie coat.

This acts like an epoxy type seal on the inside and a silicone like seal with the SeaLion top coat and no biocides are released.

Sea Lion's smooth surface is designed to reduce the fouling of hulls, propellers and rudders, and the company is highlighting that this will lead to improved vessel performance and fuel benefits.

Jotun's data compares the Sea Lion with most TBT-free antifoulings products and, over a 10 year perspective, fuel savings are estimated to be 1.5%. In addition we are told the vessel also needs less paint as up to 40% of a silicone FRC can be lost into the atmosphere on application.

SeaLion is said to reduce volumes lost due to surprisingly little dry spray.

Generally it is said silicone based elastomeric coatings are less hard than traditional TBTfree antifoulings. However although SeaLion dries faster than other similar coatings that reduce the risk of damage, it would seem care must be taken to avoid scraping or scratching. SeaLion, does however, seem to provide a cushion effect that offers good protection against bumps.

Toxic-free SeaLion is a toxic free coating but is primarily for use on high speed vessels although it can be used on propellers and rudders of slower moving vessels.

It would seem this new product is costly and there are some application concerns so, for the moment, it is being targeted at the commercial marine market rather than the leisure market. But its high speed credentials will be of interest to the race yacht sector.

The introduction of SeaLion helps fill a gap in Jotun's products: the company already has a range of tin free antifoulings and it now has a coating to cover vessels of all speeds and trading patterns.

The inland waterways market is one that has some particular needs unique to canal boats.

One area is the need for a good range of colours. For many this is not a major issue but for canal boat owners a wide range of colours, for areas above the waterline, is important. Colour schemes need to be in keeping with the traditional styles and to meet this need paint manufacturer Rylard has been progressively introducing a range that specifically targets this area of the market.

Products for this sector are quite unique in not only needing to meet these specific colour requirements but also certain application techniques need to be taken into account as does the enamel top coat finish.

In many ways the coatings for the hulls, especially below the waterline, of inland waterways boats needs to combat the somewhat specific problems boats in this part of the industry encounter.

Not only do they need to take into account the construction materials but also the environment in which they are used, which brings fairly unique wear patterns.

Hire fleet craft can encounter harsh treatment in locks when crewed by the inexperienced.

As a result, surface coatings take a battering. To demonstrate the range of products on offer Rylard has teamed up with Price Fallows to develop the Justfashow brand that uses all the 27 colours in the company's paint range as well as its varnishes and hull blacking.

Veneziani re-establishing The Italian coatings company Veneziani is re-establishing itself in the UK paint and antifouling business through its UK distributor, Yacht Systems.

Claiming to be the oldest manufacturer of antifouling in the world, Veneziani started manufacturing cold applied antifouling in 1863 from its factory in Trieste and points to being a supplier of varnishes to the Riva Factory to emphasise the quality of its products.

The company is launching new products this year, including Raffaello, an antifouling for the cruising sail and motorboat market.

Using technology from its race antifoulings, Raffaello now includes carbon, giving it hydrophilic properties that reduce laminar drag on a hull.

The company's one and two pack enamel and varnish systems have been reformulated making them even easier for DIY application, while professionals will also get the highest quality finish as well.

Gummipaint is, they say, a unique paint with elastomer binders designed for painting hypalon, neoprene and PVC.

Ideal for restoring old ribs and inflatables, they say the paint is extremely flexible and will not crack on bending.

With sales growing fourfold in 2005, and a string of winning results on the club and professional race circuits by boats using their products, Veneziani is aggressively marketing to users of premium quality products.

Yacht Systems has also been appointed sole European distributor of Sea-Slide, a new coating manufactured by Hydromer Inc.

A transparent hydrophilic coating applied to reduce drag, Yacht Systems tell us tank tests by the University of Rhode Island have proved that drag is reduced by 7-12%, giving higher top speeds, quicker acceleration and fuel savings for motorboats between 15-20%.

What's more, they say the coating can be applied over antifouling, which will continue to work through it.

Derived from technologies used in the medical industry, the product is available in 1 litre containers retailing at £49.99, which is enough to coat the hull of a 30ft powerboat.

Family owned Marclear International says in an industry dominated by huge international companies, many of the advantages of being a family owned and run business have disappeared.

But, they say, not all of them.

They say the company's continued expansion has been based on high quality products and services at sensible prices backed by meaningful guarantees and made available to the boating community through a network of more than 60 carefully selected and fully supported official application centres and distribution points.

The company's application centres offer antifouling application work priced by the square metre at the same price in all its centres throughout Europe.

It also offers an easy to use and totally fair and transparent pricing formula on its website that enables the owner to calculate the quotation for his own boat. He or she can also book through the centralised booking system on the website.

"All work is carried out strictly in accordance with our own rigorous manufacturer's specifications, " said Marclear's Bill Robinson, "and we give a full written guarantee that even covers the lift out and hard standing costs."

Robinson told BB Marclear has plenty of opportunities throughout the UK for companies or people with either marine paint application or marine sales experience.

Flag Paints Ltd, manufacturer of FLAGship and contract self eroding and hard antifoulings, as well as specialist anti-mould coatings, tell us it has just launched a new low friction PTFE thin film, low toxicity antifouling.

They say the new product, FLAGship High Performance PTFE, is extremely quick drying, so extra coats and re-launching can be achieved well inside a day. The low friction hard finish is also easier to scrub, they say, and being "thin film" will not create build-up as with conventional antifoulings. It can also simply be applied over any PTFE based antifouling product.

Contact details

Aquarius Marine Coatings T: 01202 888802 F: 01202 882100 E: info@coppercoat.com W: coppercoat.com<$>Awlgrip Europe Elenor Ekman T: 0191 4022665 F: 0191 4012310 E: Elenor.Ekman@ukakzonobel.com W: awlgrip.com<$>Flag Paints Ltd T: 01621 785173 F: 01621 785393 M: 0797 0660290 E: sales@flagfinishes.co.uk W: flagfinishes.co.uk<$>International Paint T: 023 8022 6722 F: 023 8033 2090 E: boris. webber@ukakzonobel.com W: yachtpaint.com<$>Jotun Paints A C Pawsey T: 01342 870078 F: 01342 870070 E: pawseyadmark@zoom.co.uk W: jotun.com<$>Marclear International Note new address: Apartado de Correos 183 07150<$>Andraitx Mallorca, Baleares, Spain T: (+34) 971 137781 M: (+34) 609 231654 F: (+34) 971 235995 E: info@marclear.com W: marclear.com Rylard T: 0121 7022485 F: 0121 7784338 E: sales@indestrctible.co.uk<$>W: rylard.co.uk<$>Yacht Systems T: 023 8023 8200 F: 023 8023 2582 W: baremarine.com

Images for this article - click to enlarge

Wallstrom: substitute the most dangerous substances
Liikanen: level playing field for our industry Marclear - new packaging and new address
Veneziani: handled in the UK by Yacht Systems Flag Paints has launched FLAGship High Performance PTFE antifouling
Awlgrips Awlstar Aluminium Label antifouling: specifically for aluminium surfaces
Coppercoat changes colour to green a few months after immersion

Unless otherwise stated, all images copyright © Mercator Media 2008. This does not exclude the owner's assertion of copyright over the material.

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