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MARINE TOPSIDE PAINTS: BALANCING BEAUTY AND ENDURANCE

 * Topic: Coatings Xperience, CoatingsTech Update, Marine Coatings



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Editor’s note: This is the second in a series. Read Part One in the
September-October CoatingsTech.

By Cynthia A. Gosselin, Ph.D., The ChemQuest Group

As discussed in Part One of this two-part series, it is quite the technical feat
to develop marine coatings and methods that keep the submerged portion of the
hull free from sea creatures and corrosion without also destroying everything in
the vicinity. The many efforts underway to accomplish this are represented in
the fact that 64% of the $8.7 billion marine paint market is dedicated to this
endeavor. The complex underwater scenario is rarely seen by spectators watching
yachts, fishing boats, sailboats, and commercial shipping vessels sail
majestically away to their maritime adventures.

What is seen is the part of the boat that is above the waterline. The beauty and
majesty associated with boats is represented by topside coatings that impart
gleaming paint jobs that are the icon of yacht-quality maintenance—and the goal
of all boat owners. Aesthetics are very important and affect the ranking and
resale value of a vessel.

Topside paint is, technically speaking, not considered “as important or complex”
as bottom boat paint, but it does provide corrosion resistance and significant
protection against UV rays. Weeks of sun exposure without “sunscreen” can damage
the surface of boat hulls and gunwales just as dramatically as skin can sunburn
and blister.

Topside coatings are formulated specifically for the substrate to be painted.
Many modern boats have fiberglass hulls, but there remains a significant market
for wooden boats among enthusiasts, classic boat owners, and traditionalists.

From Air to the Sea

The genesis of modern topside boat paint occurred in 1973 when two Eastern
Airline pilots persuaded Merritt Boat & Engine Works to paint their boats with a
coating called Alumigrip that, until now, had only been used on planes flying at
450 knots (517 mph). The coating seemed immune to UV degradation and was
extremely hydrophobic. The results were so stunning that US Paints decided to
market the product for the marine industry.

Through a series of bar discussions and poor handwriting, Alumigrip became
Awlgrip —perfectly (albeit accidentally) named for the marine industry. The new
coating process consisted of an epoxy primer and a sprayed linear-polyurethane
coating. Ted Turner, winning the 1977 America’s Cup in a record four-race sweep
sporting a beautiful Awlgrip topcoat, propelled this coating technology to the
top of the marine world. Since then, polyester and acrylic-modified polyurethane
topcoats have been added to the product line, providing the same UV and
corrosion resistance and hydrophobicity of the original experiment. In the 50
years since the inception of this product, it has become the go-to paint system
for the marine and yacht market.1

Liquid Coatings

Today’s maritime world still has expensive yachts, wealthy boat owners, and
less-than-handy boat enthusiasts that commission commercial painting and
maintenance for their vessels using only the top-of-the-line coatings. But
similar to other industries, the Do-It-Yourself (DIY) philosophy has taken root
because of the wildly fluctuating and increasing prices (much to the dismay of
boat refurbishing companies).

Paint companies have responded to the DIY demands by simplifying paint systems
that provide glossy finishes and decent durability. One-part modified alkyd
enamels, urethanes, and two-part simple mix products line marina supply and big
box store shelves. If properly applied, the aesthetics are excellent. With some
routine maintenance, durability is good enough.

In addition to aesthetics and durability, ease of application is a prime
consideration of the DIY consumer. Of course, while the roll-and-tip finish will
never rival a PRO-sprayed finish, the results from today’s formulations can be
very good.

Several of these formulations generate little sagging and dripping, which is the
bane of  improperly applied high-end coatings. The caveat is that the
instructions for surface preparation must be carefully followed, the owner has a
modicum of sanding and buffing skill with the requisite amount of patience. Boat
refurbishing companies hide their grins when someone comes in for a full paint
repair because they “knew how to paint and didn’t need directions.”

In fact, many PROs that mentor DIY novices suggest first painting oars with the
paint system that will be used on the boat hull. This provides insight into the
behavior of the paint and more importantly, the actual skill and ability of the
painter.

The chemistries used to either commercially or DIY paint new or refurbished
boats include alkyds, epoxies, and polyurethanes for interior and exterior
surfaces. Table 1 provides the typical paint systems used for various boat
locations with the projected maintenance intervals.

Powder Coatings

Powder coatings are used in a huge variety of applications, including boating
and marine equipment. These types of coatings are not as widely used as liquid
systems, primarily because they are more difficult, if not impossible to repair
without completely removing the existing coating. However, there are some
advantages to using powder coatings on metal surfaces—particularly for ladders,
stairs, rails, flag poles, and such items. Metal, unlike fiberglass or wood,
tends to corrode if there is a poor barrier layer between the surface and the
environment. The higher powder coating film thickness, together with complete
coverage, provides this advantage.

Salt particles are highly corrosive to common powder coatings. If not formulated
specifically for marine applications, salt will permeate the coating over time,
causing it to powder and break down. Marine powder coatings are typically made
from specialized resins and additives that provide for durability, flexibility,
water resistance, UV resistance, and even antifouling properties. In addition,
these powders use different media—glass beads, coarse and medium sand, etc.—to
generate a variety of textures. Powder coatings also have good chemical
resistance to most of the types of exposures that boats can encounter even in
relatively clean water.

Powder coatings can be applied to a wide variety of substrates, which helps in
reducing corrosion on the metal parts throughout the boat. Epoxy and modified
epoxy powder coatings are the oldest and still most widely used for this
application. They are considered to be “surface tolerant” by many repair shops
because of good adhesion to minimally prepared surfaces.2 Many South Florida
boat owners choose powder coatings for their metal boat parts because the
surfaces maintain their luster and shine without needing constant attention.

Other structures located at or very near the coast or off-shore also benefit
from powder coatings. Reliability and durability are critical for metal
structures that are exposed constantly to the environmental attack of seaspray,
humidity, and sunlight. Powder coatings used for these applications provide
protection from these elements.

These coatings are governed by standards such as ISO 12944-5:2019. This standard
lists environment classifications and provides guidance as to the types of
coatings that have been proven to perform well within those boundaries.
Suggestions for testing are also provided. Powder coating chemistries and film
thicknesses for metal on boats, shoreline, near shoreline, and sea structures
are part of this standard.

Rigorous accelerated and real-time cyclic testing has verified long term
durability, corrosion resistance and extended surface aesthetics for marine
applications. Marine powder coatings must perform well in Corrosion
Classification C5M–Very High Marine, which encompasses on shore and offshore
areas of high salinity. Buildings in this classification are almost always
subjected to constant condensation and high environmental salt contamination as
well.3

Typical accelerated testing for marine products includes ASTM G85 Salt Spray and
Salt Fog Testing: Annex 1—Acetic Acid Salt Spray Test (non-cyclic) or Annex
3–Seawater Acidified Test (cyclic).

In addition, real-world testing is also required in order to ensure that the
corrosion mechanisms are not artificially test-induced, but actually occur in
the ascribed environment. Florida exposure testing includes 72 hours of
accelerated UV exposure, 72 hours of neutral salt spray exposure, and 24 hours
low temperature testing at -20 °C. This cycle is repeated 25 times (4,200 hours)
to ensure that the paint systems on metal substrates ultimately exhibit the
necessary durability.4

Deck Coatings

A necessary safety feature on boats is a skid-resistant deck. No boat owner
wants to take the chance that a purported non-skid deck paint loses gripping
power and someone ends up overboard. The substrate determines the decision to
prime the deck surface. If the deck is wood or bare metal, a primer is crucial.
If the deck is wood, a sealer is required. The best primer is a 2K epoxy because
it provides more durability and hardness than a one-part system.

The easiest topcoats to apply are one-part paints containing non-skid
additives—with the caveat that they be mixed well for an even application. The
2K linear polyurethanes will last longer and stay cleaner than textured paints
or one-part coatings. For higher-end paints to perform better, more care must be
taken during application. Professional boat refurbishing shops will generally
spray-apply polyurethane. Following the application of the textured layer,
multiple thin coats are applied to seal the surface. The 2K linear polyurethanes
last at least five years and, in the right environmental conditions (rainy and
cloudy versus constant sunshine) can provide good service for up to 10 years.

Wood Coatings

Aluminum is taking over as the preferred mast material for modern sailors. But
many classic boat owners, traditionalists, and boat enthusiasts love the
aesthetics of a wooden mast—even though it requires much shorter maintenance
intervals than all other topside paints. Most topside wood paints lose gloss,
color, and durability after only two years—but every sailor should check the
mast every year. Furthermore, because masts, spars, and tillers see the most
banging of any wood component on a boat, chip- and abrasion-resistance are also
important coating characteristics. In fact, clear coatings are preferred on
masts because cracks, fungus, wood rot, dings, and chips are visible very
early—helping to avoid significant damage or a sailing disaster. Paint tends to
hide cracks and seams where water can penetrate, causing unseen deterioration
due to moisture ingress. These spar varnishes also tend to be soft and flexible,
adapting to the expansion and contraction due to hot, dry, cool, and wet weather
cycles without cracking.5

There is a one-part, self-crosslinked system with outstanding weathering
properties. It is safe for application both above and below deck because there
is virtually no odor, it has low VOCs, and it is non-toxic. It contains three
UV-stabilizers, does not yellow, and is mold and mildew resistant. It flexes
with the wood to prevent cracking—providing longer durability. The formulation
allows for cleanup using only water.6 Heightened consumer environmental
awareness, especially relating to waterways, will spur coatings developers to
make more environmentally compatible coatings available in the future.

Topside coatings are a very well-developed genre of marine coatings because
serious boat owners understand that the eye-catching, gleaming appearance of a
well-maintained boat is really a beautiful cover for a tough preservation
imperative for long-lasting enjoyment in the ironically corrosive environment of
beautiful lakes and seas.

References

 1. Awlgrip website. “1973—From Planes to Boats.”
    https://www.awlgrip.com/fiftyyears/1973-from-planes-to-boats (accessed
    September 12, 2023).
 2. Coatings Systems Inc. Benefits of Marine Powder Coatings for Boats. November
    20, 2017.
 3. International Standards Organization. 2019. ISO 12944-5:2019 Paints and
    varnishes—Corrosion protection of steel structures by protective paint
    systems—Part 5: Protective paint systems.
 4. Northpoint Ltd website. Anti Corrosion. “What Is Marine Grade Powder
    Coating?” 
    https://www.northpoint.ltd.uk/2021/08/26/what-is-marine-grade-powder-coating/
    (accessed September 24, 2023).
 5. The Wood Whisperer.  “Difference Between Spar Varnish and Regular Varnish?”
    October 20, 2008.

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