MIL-STD-2199.pdf

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MIL-STD-2199(SH)

11 May 1990

SUPERSEDING

January 1964

NAVSEA 0283-LP-224-2201

MILI'I'ARY STANDARD

GLASS REINFORCED PLASTIC COVERINGS

FOR.PROPELLER S m I N G (METRIC)

AMSC N/A FSC 9330

DI!SI'RIBUTION STATEMENT k Approved for public release; distribution is unlimited.

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CHANGE

NOTICE OF

METRIC

NOTICE 1

5 OCTOBER 1993

MIL-STD-2199(SH)

MILITARY STANDARD

GLASS REINFORCED PLASTIC COVERINGS

FOR PROPELLER SHAFTING (METRIC)

TO ALL HOLDERS OF MIL-STD-2199(SH):

1. The following attached pagcs of MIL-STD-2199(SH) havc been revised and supersede the pages listed.

New Page Date

2 11 May 1990

4 11 May 1990 5 11 May 1990

7 11 May 1990

6 ""

Superscded Page

Da te 11 May 1990

11 May 1990

REPRINTED WITHOUT CHANGE

REPRINTED WITHOUT CHANGE

REPRINTED WITHOUT CHANGE

REPRINTED WITHOUT CHANGE

11 May 1990

11 May 1990

2. RETAIN THIS NOTICE AND INSERT BEFORE TABLE OF CONTENTS.

3. Holders of MIL-STD-2199(SH) will vcrify that page changes and additions indicated above have been entered. This notice page will be retained as a chcck sheet. This issuance, together with appended pagcs, is a separate publication. Each notice is to bc retained by stocking points until the military standard is complctcly reviscd or cancclcd.

Preparing Activity:

(Project 9330-NO61) Navy - SH

AMSC N/A FSC 9330

Distribution Statcmcnt A: Approval for public rclcase, distribution unlimited.

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MIL-STD-2177 73 m 7.9777LL 0070671 2 m

1. This Military Standard is approved for use by the Naval Sea Systems Command, Department of the Navy, and is available for use by all departments and agencies of the Department of Defense.

2. Beneficial comments (recommendations, additions, deletions) and any pertinent data which may be of use in improving this document should be addressed to: Commander, Naval Sea Systems Command, SEA 5523, Department of the Navy, Washington, DC 20362-5101 by using the self-addressed Standardization Document Improvement Proposal (DD Form 1426) appearing at the end of this document or by letter.

3. Glass reinforced plastic (GRP) coverings as described in this standard, and vulcanized rubber coatings conforming to MIL-R-15058, type II are specified as alternative'corrosion prevention materials for wajerborne propulsion shafting on Naval ships.

4. This standard provides requirements and guidance in application procedures in sufficient detail to allow personnel with limited experience to apply an effective GRP shaft covering.

5. This standard is intended for the use of contractor, shipyard, and ships' force personnel who install or repair propeller shaft coverings on Naval ships.

ii

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Paragraph

1 .

1.1

2 .

2.1 2.1.1 2.1.2 2.2 2.3

3 .

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20

4 .

4.1 4.2

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Page

SCOPE

Scope

APPLICABLE DOCUMENTS

Government documents Specifications Other Government dr*awing and publications Non-Government publications Order of precedence

D E m N ~ O N S Abrasive-blasting Accelerator (promoter) Air-inhibited (air-inhibited resin) BARCOL (BARCOL hardness) Catalyst Cure (or Curing) Fair Gel Glass reinforced plastic (GRP) Hardener Infusible . . . . . . . . . ...................... :

Insoluble

Fot life (working life) Resin Sleeve Tacky Thixotropic Viscous Wet-out

Milled glass fiber

GENERAL REQUIREMENTS

Personnel Facilities, tools. and equipment

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MIL-STD-2397 73 7777733 0070b93 b

Paragraph Page

5 .

5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.3 5.3 5.3.1 5.3.2 5.3.2.1 5.3.2.1.1 5.3.2.2 5.3.3 5.3.4 5.4 5.4.1 5.4.2 5.4.3

5.4.3.1 5.4.3.2 5.4.4 5.4.4.1 5.4.4.1.1 5.4.4.1.2 5.4.4.2 5.4.4.2.1 5.4.4.2.1.1 5.4.4.2.1.2 5.4.4.2.2 5.4.4.2.2.1 5.4.4.2.2.2 5.4.4.2.3 5.4.5

DETAILED REQUIREMENTS

Basic materials Resin Glass reinforement Auxiliary materials Thixotropic filler (thickening agent) Fairing compound Coatings for flange coupling areas Chemical types of resins Epoxyresins Polyester resins Polyester resin curing Peroxide catalyst. handling and storing

. Polyester resin classification

Application procedures

Preparation of shaft flange coupling

Shaft flange

Fiberglass tape

Preparation of fiberglass tape

Example. calculation for epoxy resin

Cure Fillers

General description

Preparation of GRP shaft covering in way of shaft sleeve end and

Sleeve

Estimation and preparation of the basic materials required (see 5.1)

Example of calculation for fiberglass tape

Resin Epoxy

Preparation of epoxy resins Polyester Example, calculation for polyester resin Preparation of polyester resin Thixotropic filler Safety precautions iv

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Paragraph

5.4.5.1 5.4.5.2 5.4.6 5.4.6.1 5.4.6.1.1 5.4.6.2 5.4.6.3 5.4.6.4 5.5 5.5.1 5.6 5.6.1 5.6.1.1 5.6.2 5.7

6 .

6.1 6.2 6.3 6.4 6.5

Figures

1 .

2 .

3 .

4 .

S .

6 .

Page

General Specific precautions Application of covering Temperature

Detailed procedure Cure (hardening) Painting Quality control Gel time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -19 Inspection After application Corrective action Drydock inspection and repair Reports

NOTES

Intended use Issue of DODISS Data requirements Subject term (key word) listing Changes from previous issue

Humidity

Navy current standard sleeve . suggested resin fairing detail (see 5.4.3.1) . . 24 Bearing sleeve (modified) - suggested resin fairing detail on some older ships (see 5.4.3.1) Bearing sleeve (typical configuration) - suggested resin fairing detaiI on some oIder ships (see 5.4.3.1) Resin being applied to shaft Schematic of tape wrap Fiberglass tape being applied to shaft

V

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5 OCTOBER 1993

1. SCOPE

1.1 Scope. This standard defines requirements for the materials to be used and provides detailed instructions for guidance on surface preparation, resin preparation, and application of fiberglass reinforced plastic coverings on waterborne propulsion shafting.

2 APPLICABLE DOCUMENTS

21 Govcrnmcat documcnk

21.1 Specifications. The following specifications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DODISS) and supplement thereto, cited in the solicitation (see 6.2).

SPECIFICATIONS

FEDERAL

P-D-680 Dry Cleaning and Degreasing Solvent

MILITARY

MIL-C-9084 Cloth, Glass, Finished, for Resin Laminates

MIL-R-17882 Repair Kits, Metallic Pipe and General Purpose, Damage Control

MIL-P-23236 Paint Coating Systems, Fuel and Saltwater Ballast; (Metric)

MIL-R-23461 Resin Compound, Thermosetting, Room Temperature Curing, For Metal Coating

DOD-C-24176 Cement, Epoxy. Mctal Repair and Hull Smoothing; (Mctric)

(Unlcss otherwise indicated. copies of federal and military specifications and standards are wailable from the Naval Publications and Forms Center. (ATTN: NPODS), 5S01 Tabor Avenuc, Philadelphia. PA 19120-5099.)

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5 OCTOBER 1993

212 Other Government drawing and publicatioos. The following other Government drawing and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation.

DRAWING

NAVAL SEA SYSTEMS COMMAND (NAVSEA)

NAVSHIPS 803-2145807 Shafting, Propulsion and Components

PUBLICATIONS

NAVSEA

09O-LP-430-Oo12 NSTM Chapter 9430, Shafting, Bearings and Seals

0943-LP-017-1010 Submarine Propulsion Shafting Main Technical Repair Standard

0943-LP-017-2010 Propulsion Main Shafting for Surface Ships, Technical Repair Standard

S9086-VD-STM-000, Preservation of Ship in Service (Surface Preparation and Painting) Chapter 63 1

S9086-VG-STM-000, Deck Covcrings Chapter 634

(Application for copies should be addressed to the Naval Publications and Forms Center, (ATIN:

NPODS), 5801 Tabor Avenue, Philadelphia, PA 19120-5099.)

2 2 Non-Govcmmcnt publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents which are DOD adopted are those listed in the issue of the DODISS cited in the solicitation. Unless otherwise specified, the issues of documcnts not listed in the DODISS are the issues of the documents cited in the solicitation (see 6.2).

SOCIETY OF AUTOMOTIVE ENGINEERS ( S M )

A M s 3824 Cloth, Glass Finished for Resin Laminates; (DOD adopted)

(Application for copies should be addressed to the Society of Automotive Engineers, 400 Commonwealth Drive, Warrendale, PA 15096.)

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MIL-STD-Zl%(SH)

5 OCTOBER 1993

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

D 2583 Standard Test Method for Indentation Hardness of Rigid Plastics by Means of a Barco1 Impressor; (DOD adopted)

(Application for copies should be addressed to the American Society for Testing and Materials, 1916 Race Street, Philadelphia, PA 19103.)

(Non-Government standards and other publications are normally available from the organizations that prepare or distribute the documents. These documents also may be available in or through libraries or other informational services.)

23 Order of precedcnce. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this documcnt.

however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. DEFINITIONS

3.1 Abrasive-blasting. Abrasive-blasting is a more all-inclusive term for the procedure known as sandblasting. Many abrasive materials other than sand are often used and are suitable f o r shaft surface preparation. In fact use of sand may not be permitted by some locnl environmental and safety regulations. e

3.2 Accelcrator (prornotcr). An additive for polyester resins which pronlotcs curing o f the resin at room temperature.

3 3 Air-inhiiitcd (air-inhibited rcsin). A characteristic of some types of polyester resin which results in incomplete cure of the surface which is in contact with air; the surface remains tacky.

3 . 4 BARCOL (BARCOL hardness). A measure of surface hardness of a covering system and used to indicate the degree of cure. The method involves applying a hand-held impressor to the surface, following ASTM D 2583 for the procedures and the instrument.

3.5 Catalyst An organic peroxide additive for polyester rcsin which initiates the curing of the rcsin and accelerator mixture at room temperature (see 5.3.2).

3.6 Cure (or Curing). The chemical reaction process by which epoxy and polyester rcsins change from a liquid to a solid mass having characteristic properties. Cure implies more than solidification alone. Cure continues for a period of time after initial solidilication and results in thc finill physical and mechanical properties of the reacted resin.

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MIL-STD-ZI99 CHG N O T I C E I W 9999931, 0470b22 988 W

5 OCTOBER 1993

3.7 Fair. The condition of a surface, either flat or curved, when it is smooth and free of irregularity, unevenness or abrupt change in curvature. It is the condition in which the ends of thc glass reinforced plastic (GRP) covering blend smoothly into the shaft or sleeve without roughness, projection or abrupt change in thickness or curvature.

3.8 G e L A step in the cure cycle in which the resin thickens to a semi-solid consistency. This thickening progrcsses to such a degree that the resin can no longer be applied effectively.

3.9 Glass reinforced plastic (GRP). Fiberglass reinforced epoxy or polyester resin.

3.10 Hardener. An additive component which for epoxy rcsin causes the curing of the resin.

3.11 Infusible. The condition in which the cured, solid resin-coating will not melt under application of heat.

3.12 Insoluble. The condition in which the cured, solid resin-coating will not dissolve or soften in a solvent (such as water).

3.13 Milled glass fiber. An additive, composed of short lengths of glass fiber (approximately

1.6 millimeters (mm) (U16 inches), which thickens resin.

3.14 Pot life (working life). The length of time tha t the mixed resin is of thc workable consistency rcquired for proper application. It is the length of time after the catalyst or hardener has been added, to the point that gelling or thickening of the resin has progressed to the degree it can no longer be applied effectively to the shaft.

3.15 Resin A liquid epoxy or polyester type of plastic which may be cured to a n infusible, insoluble solid.

3.16 Sleeve. In most cases as used herein a (copper-nickel) cylindrical tube or band sccurcd to the shaft by shrink-fit and uscd in way of bearings, coupling covers, and fairwaters.

3.17 Tacky. The condition of a coated surface which remains sticky to the touch.

3.18 Thixotropic. A characteristic of resins to which a fincly dividcd silica (fumed silica) has been added, which thickens resin to the degrce that it will not llow or move unless spread by hand or brush.

3.19 Viscous. A term describing the resistance of a liquid to flow. The thick, syrupy, consistency of resin would be a relatively high viscosity.

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MIL-STD-2199(SH)

5 OCTOBER 1993

3.20 W c t a k . The ability of a resin to "wet" or saturate the reinforcing fibers. Good wet-out implies complete wetting. Also, the process of applying resin to reinforcement.

4. GENERAL REQUTREMEESIS

4.1 Personnel Before being assigned the task of applying a glass reinforced plastic propeller shaft covering, personnel shall have background and experience with regard to the following:

a. Materials. General knowledge of the characteristics of the particular resin system being used, determining the mass of proper proportions of resin, accelerator, catalyst or hardener, and mixing the components thoroughly without entrapping air.

b. Shafi and sleeve preparation. An understanding of the need for the proper shaft and sleeve surface preparation, including abrasive blasting and degreasing, for obtaining acceptable resin adhesive bond.

c. Covering application. The skill required for uniformly applying fiberglass tape and resin to the shaft, detecting and eliminating air entrapment, and thoroughly wetting-out the tape with resin.

d. Quality control and inspecfion. Experience in determining. by visual inspcction and the tests specified herein, whether the covering has been properly applied, is void free, and has continuous adhesive bond to the shaft and sleeve.

4.2 Facilitics, t o o l s , and equipment. Facilities are required to provide a clean. dry environment and the temperature range required in 5.4.6.1 of both the shaft and surroundings. To ensure the safe and proper application of the shaft covering as described herein, equipment and tools shall be required to perform the tasks of abrasive grit blasting, mixing and applying the resin.

and performing specified tests.

5. DETAILED REQUIREMENIS

5.1 Basic materials. The basic materials as specified in 5.1.1 and 5.1.2 shall be used.

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5.21 Thixotropic filer (thickening agent). The addition of a small amount (2 to 4 percent by mass) of a thixotropic filler to the basic resin may be necessary to minimize or eliminate resin drainage. The amount required depends on the ambient temperature and resin viscosity. More filler will be required in warm temperatures when the resin flows more freely. Some manufacturers will provide the basic resin with the filler previously added, if required.

5.2.2 Fairing compound. One of the following thickened or paste type resin materials shall be used:

a. Hull smoothing cement in accordance with DOD-(2-24176

b. Repair kit paste resin in accordance with MIL-R-17882 (sometimes prcfcrred due to its fast cure time)

c. Basic resin thickened with milled glass fibers (see 3.13) (recommended for use with polyester type resins).

5.23 Coating for flange coupling areas. Coating for flange coupling areas shall be coal tar epoxy conforming to MIL-P-23236, class 2, or the basic resin thickened with milled glass fibers and thixotropic filler (see 5.4.3.2).

53 Chemical types of resins. .The resins which are used in the GRP coverings are viscous liquids which can be cured at room temperature into hard, insoluble, and infusible plastics by incorporation of curing agents (accelerator and catalyst or hardener). The type and quantity of curing agents shall be in accordance with recommendations of the resin manufacturer. The resin used shall meet the performance requirements of MIL-R-23461 which specifies either of two different types of resin systems; epoxy or polyester. Working characteristics of the two types of resin are described in 5.3.1 and 5.3.2.

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53.1 Epoxy resins. Epoxy resins have been most widely used for shaft coverings because of their superior adhesive characteristics and this type of resin system is recommended. Epoxy resins are cured by the addition of a specific amount and type of curing agent or hardener. The amount of hardener added shall be in accordance with the recommendations of the epoxy resin manufacturer and shall not be varied over a wide range for pot life control. Pot life of an epoxy resin and associate hardener depends on the ambient temperature (see 5.3.3).

53.2 Polyester resins. Isophtalic-type polyester resins are generally preferred because of their improved toughness. Polyesters are cured by the addition of an accelerator (promoter) and an organic peroxide catalyst (in liquid or paste form) as required in 5.3.2.1 and 5.3.2.2. Pot life of the mixed resin is affected by ambient temperature and may be varied within limits by adjusting proportions of the accelerator and catalyst in accordance with the resin manufacturers instructions.

5.3.2.1 Polyester resin curing. An accelerator shall be mixed into the polyester resin either by the user or pre-mixed by thc rcsin manufacturer; the curing reaction can then be activated by mixing in a small amount of an organic peroxide catalyst. The type and amounts of these materials shall be in accordance with the recommendations of the resin manufacturer. Cadion shall be taken to ensure that the accelerator and catalyst are not directly mixed together as this will rcsult in a violent reaction. It is common practice and vcry dcsirable to acquire the resin premixcd with the accclerator to avoid this dangerous possibility.

CAUTION

NEVER MIX ACCELERATOR AND CATALYST TOGETHER DIRECTLY!!

53.2.1.1 Peroxide catalyst, handling and staring. Care shall be takcn in handling and storing the organic peroxide catalyst. It is flammable in nature and will decompose violently under certain conditions. It should not be exposed to heat such as direct sunlight, steam pipes, open flames, or sparks. Consult the manufacturer’s data sheet for spccific details on safe handling and storage conditions.

5.3.2.2 Polyester resin classification. Polyester resins may be classificd as “air-inhibited” or “non-air-inhibitcd“ (resins which cure tack free). Some air-inhibited resins frequently contain an additive such as wax which enables the resin to cure to a tack-frcc surface. This type of resin shall not be used since the wax additive interfere with adhesion between plies of reinforcement. The resin supplier shall furnish either a resin that is naturally non-air-inhibited or an additive (prcfcrably non-wax) which can be added to the resin for the final tack-free layer coating application.

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5.3.3 Cure. Once the hardener or catalyst has been added, the resin will remain liquid for a limited period of time after which it will begin to gel or thicken and bccome unworkable. The rcsin should cure at room temperature (or according to the manufacturer’s instructions). However, optimum properties can be developed in a shorter time by post curing or heating at moderate elevated temperatures. Infrared lamps and strip heaters are convenient sources of heat. Post curing may be used to obtain optimum cure particularly for coverings applied in cold weather or coverings that must be put in service as soon as possible.

5.3.4 Fillcrs. Resin flow from the freshly applied covering shall be minimized or eliminated by assuring the proper viscosity, or if necessary, increasing the resin’s viscosity by the addition of thixotropic filler material (see 5.2.1). This will probably be necessary if the shaft cannot be rotated continuously during application and cure. The- addition of filler may have the disadvantage of obscuring visual inspection for voids and trapped air. Clear, unfilled resin shall be used on shafts which are rotated during application.

5.4 Application procedures.

5.4.1 General dcEcription. After proper shaft surface preparation, a coat of resin is applied uniformly to the shaft. The first ply of glass tape is then wound spirally on the shaft, butting the edges. After working out entrapped air and ensuring that the glass tape is wet-out properly, a coat of resin is applied over this ply. A second ply of glass tape is then wound on the shaft, reversing the direction of the spiral wrap. This process is continued until four plies of tape have bcen applied. Safety precautions (see 5.4.5) shall be observed in the handling and application ot‘ these materials.

5.42 Preparation of shaft The shaft surface shall be prepared immediately prior to application of the covering in accordance with the following procedures to ensure a maximum degree of adhesion:

a. lhe existing covering on shafts and sleeves which have been in service shall be removed by mechanical means.

b. Remove any oil or grease from the surface of the shaft by washing with suitable solvents (for example, petroleum distillate type solvent in accordance with P-D-680, Type II, or other solvent that provides suitable cleaning and degreasing capability without leaving a residue. Solvents shall not be ozone depleting types and must be acceptable under local, State and Federal regulations, as required.

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MIL-STD-2177 7 3 7777733 0070703 5

C.

d.

e.

f.

Metal surfaces to be covered shall be abrasive blasted with clean abrasive grit to approximately 3 mil profile. (Experience has shown that a satisfactory covering can be applied to a freshly machined shaft (not abrasive blasted) if solvent washing procedures and time limitations herein are carefully followed. Covering freshly machined shafts is permitted. though not encouraged. Abrasive blasting is a more reliable method of surface preparation).

Wash with solvent as required in 5.4.2(b) after abrasive blasting, assuring that no residue remains.

Pits or cracks in the shaft shall be treated as specified in NAVSEA 0943-LP-017-1010, NAVSEA 0943-LP-017-2010, NAVSEA 0901-LP-430-0012 Chapter 9430. Irregular surfaces may then be faired using paste resin (see 5.2.2). Also, this is a good time to fill and fair the shaft to sleeve junction as specified in 5.4.3. Cure of the paste resin can be accelerated by warming the repaired area with hot-air guns or infrared heat.

When the filled-in areas are fully hardened they shall b e sanded to conform to the contour of the shaft but left roughened for better adhesion of the covering. These areas and any affected surrounding areas shall be washed with solvent as specified in 5.4.2(b).

GRP covering of the shaft shall b e started as soon as possible (within 8 hours) after the abrasive blasting, although shafts protected by plastic film or vapor phase inhibitor (VPI) paper can be held a maximum'of 24 hours before coating. If covering of the shaft cannot be started within 24 hours, or if there is evidence of oxidation, the shaft shall b e re-abrasive blasted.

5.4.3 Preparation for GRP shaft covering in way of shaft sleeve end and flange coupling. In cases where specific details of the covering are described on the shafting drawing, as on new construction, these details shall be followed in the application of the GRP covering. Similarly, requirements in accordance with NAVSEA 0943;LP-017-1010, NAVSEA 0943-LP-017-2010, NAVSEA 0901-LP-430-0012 Chapter 9430, whichever is applicable, shall be observed and shall govern in the case of conflict with this standard.

5.4.3.1 Sleeve. There are at least 13 different sleeve end details which may be encountered on Naval ships. Each of these details may require different preparation in order to provide a configuration which facilitates application of the shaft covering. Figure 1 shows the Navy current standard sleeve which is found on new construction and some older ships which have been modified. Figure 2 shows the configuration of a bearing sleeve used previously which has been modified to facilitate application of the GRP covering. Figure 3 shows a bearing sleeve with typical configuration which may be found on some older ships. -Experience has indicated that application of the GRP covering is most critical in the area of the sleeve and at the junction between the sleeve and the shaft. Many failures seem to initiate in this area which could be due to improper preparation of the surface in way of the sleeve. Figures 1,2, and 3 show some possible'approaches

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. M I L - S T D - 2 1 9 9 9 3 m 9999911 009070LI 7 m to preparation of the shaft-sleeve junction and sleeve. As shown, any grooves, hollows, shoulders or steps on the sleeve or between the sleeve and shaft are filled out with paste resin (fairing compound (see 5.2.2) to form a smooth surface and a gradually tapered junction between shaft and sleeve. Fairing compound shall be mixed according to the instructions for the particular material and the surfaces prepared as specified in 5.4.2. As specified in 5.4.2(e) cure of the resin may be accelerated by warming and after cure the surface shall be sanded fair and solvent washed. The objective is to provide a firm, faired, clean, and roughened surface on which to apply the GRP covering. Care shall be taken to ensure that the steel shaft is protected by a watertight seal in this area.

5.43.2 Shaft flange. Since 1967, rotating coupling covers are required on all Navy multisection, waterborne shafting. Treatment of the shaft sleeve for the fair-water and coupling cover shall be as required in 5.4.3.1. For older Navy ships which may have exposed couplings, the flanged couplings, sides of sleeve couplings, as well as bearing sleeve areas and other discontinuities in the shafting (such as coupling bolts and nuts) which cannot properly be covered with glass tape shall be sanded or sandblasted, solvent cleaned and coated with two coats of a coal-tar epoxy conforming to MIL-P-23236, class 2 to a minimum dry film thickness of 1.5 mils or coated with resin formulation containing 10 percent by mass of milled glass fibers (the same resin that has been used to coat the straight runs of shafting is used) after the straight run coverings have been applied. Any resin remaining from the latter operation may be used or new batches of resin may be prepared. In the latter case, 10 percent milled glass fibers shall first be added to the resin followed by the addition o f the curing system (accelerator and catalyst for polyesters and hardener for epoxies). A thixotropic filler (see 5.2.1) may'also be added to limit resin drainage (up to 4 percent by mass depending on temperature). Four coats of resin may be- sufficient but the total thickness shall not exceed 60 mils. Separate batches of resin shall be prepared for each coat since gelation (partial hardening) must occur before the next coat may b e applied. In 'coating flanged cauplings, care shall be exercised with regard to areas around and between bolts in order to avoid holidays or porosity.

5.4.4 Estimation and preparation of the basic materials requircd (see 5.1). This section covers the calculation of the amount of fiberglass tape and resin required for a fourilayer (ply) covering and their preparation for application.

5.4.4.1 Fiberglass tape. The length of fiberglass tape shall be calculated using the following equation:

W

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MIL-STD-2377 9 3 W 7777733 0070705 7 W

Where:

L = Length of tape required for each ply in meters (feet) D = Diameter of the shaft in centimeters (inches) H = Length of the section of straight run of shaft to be covered in meters (feet) W = Width of the fiberglass tape in centimeters (inches).

The factor 3.5 in the above equation is used instead of the extract factor (z = 3,14) to allow for some excess tape and some overwrap at terminations.

5.4.4.1.1 &ample of calculation for fiberglass tape. Calculate the length of 15.24 cm (6 inch) wide glass tape required for each ply of a covering for a 3.05 meter (10 feet long section of a

17.78 cm (7 inch) diameter shaft.

D = 17.78, H = 3.05, W = 15.24

L = 3.5 x 17.78 x 3.05 - - 189-8 = 12.45 meters

15.24 15.24 of tape for each ply. The length in feet can be similarly calculated by using the English dimensions given in parentheses. The total length of tape required for the four plies is equal to four times the length of a single ply as calculated above.

5.4.4.1.2 Preparation of fiberglass tape. Determine the amount of tape on each roll furnished to be sure there is sufficient material for accomplishing the task. The mass of all four plies of tape shall be determined to provide a basis for calculating the amount of resin required (see 5.4.4.2).

5.4.4.2 Resin. This section describes calculation of the mass of resin, thixotropic filler (see 5.2.1), and curing agents for typical polyester and epoxy resin coating formulations.

5.4.4.21 Epoxy. The total amount of resin (including hardener) required can be estimated by using the guide 1 liter of resin for every 2 square meters of tape (1 gallon for every 81.5 square feet) per layer of tape plus a finish coat (four layers of tape requires five layers of resin). The 2 square meters per liter is based on resin requirements per layer of fiberglass tape to provide thorough wet-out. The total amount of resin (including hardener) can also be estimated on a mass basis by multiplying the total mass of tape (all four plies, as determined in 5.4.4.1) by a factor of

2. This factor will provide an excess of mixed resin required for coating the shaft and thoroughly wetting-out the fiberglass tape.

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5.4.4.21.1 Fxample, calcu la1 ion for epoxy resin Four 12.5 meter (41 feet) lengths of 15.24 cm (6 inch) tape would have a mass of approximately 2.52 kilograms (kg) (89 ounces (oz)).

Total mass of resin plus hardener = 2.52 kg x 2 = 5.04 kg (89 oz x 2 = 178 oz or 11 pounds - 2 oz)

The mass of resin hardener (separately) may be estimated, but the proportion (percent) of resin and hardener required shall first be obtained from the resin manufacturer, since this can vary greatly, depending on the hardener used. Assuming that 60 percent of resin by total mass is required to be mixed with 40 percent of hardener then:

Mass of resin = 0.60 x 5.04 kg = 3.02 kg (0.60 x 178 oz = 196.8 oz)

Mass of hardener = 0.40 x 5.04 kg = 2.02 kg (0.40 x 178 oz = 71.2 oz)

Total mass (resin and hardener) = 5.04 kg (178 oz).

WARNING

The resin and hardener shall not be mixed together until immediately prior to use, since the mixture will have a limited working life.

5.4.4.21.2 Preparation of epoxy resins. Since epoxy resins have limited pot or working life, especially in warm temperatures, separate batches of resin may need to be prepared for each of the four layers of glass tape. The appropriate amount of hardener shall be added to each batch separately just before wie. In warm weather the resin may be cooled to extend the pot life of the resin-hardener mixture. Pot life may also be extended by preparing the resin in the shade, avoiding direct exposure to the sun, and by keeping the mixed resin in a shallow pan to slow its heat buildup. Information on resin pot life may be obtained from the resin manufacturer. The mass of the resin and the hardener, each separately, shall be weighed out in four equal parts (for each ply of tape), and placed in separate metal or plastic containers. One part each of resin and hardener shall be thoroughly mixed prior to application of each ply, taking care not to beat or whip in any air.

5.4.4.2.2 Polyester. The amount of resin required is estimated as described in 5.4.4.2.1. Unlike epoxy resin, however, the amounts of accelerator and peroxide catalyst required are so small (on the order of 1 to 2 percent) they need not be considered as part of the total mass.

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MIL-STD-2177 73 W 77777L1 0070707 2 W

5.4.4.2.2.1 m p l e , calculation for polyester resin. Four 12.5 meter (41 foot) lengths of

15.24 cm. (6 inch) tape would have a mass of approximately 2.52 kg (89 oz). Total mass of resin:

2.52 kg x 2 = 5.04 kg (89 oz x 2 = 178 oz or 11 lbs - 2 oz)

Assuming that 1 percent of accelerator and 1-1/2 percent of peroxide catalyst by mass are required in order to obtain^ the desired working life, then:

Amount of accelerator = 0.01 x 5.04 kg = 50 grams (0.01 x 178 oz = 1.78 oz)

Amount of catalyst = 0.015 x 5.04 kg = 75 grams (0.015 x 178 oz = 2.67 oz)

The resin may b e supplied with the accelerator premixed. The accelerator and catalyst shall not be directly mixed together. If the accelerator is supplied separately, it shall be thoroughly mixed into the resin first and then the catalyst shall be added to the resin and accelerator mixture immediately before use.

5.4.4.222 Preparation of polyester resin. As discussed previousIy (see 5.3.2), the working life of a polyester resin depends on the percentages of catalyst and accelerator in the resin and the ambient temperature. Catalyst and accelerator percentages may be adjusted to permit enough time for the coating operation before the resin gels. Information on the specific re sin^ shall be obtained from the manufacturer. The required quantity of resin (with acceIerator) and catalyst shall be mixed thoroughly, immediately prior to use, taking care not to beat or whip in any air. .A gel time (pot life) of 2 to 3 hours should be sufficient to permit three people to apply a fout-ply covering on a 3 meter (10 feet) length of 20 cm (8 inch) shafting. Two people can typically cover a 6 meter (20 feet) length of 50 cm (20 inch) shafting with one ply in 15 minutes.

5.4.4.23 Thixotropic H € e K Refer to 5.2.1 and 5.3.4 for use information. The amount of filler added to the resin shall be determined based on prior experience, trail, or the recommendation of the resin manufacturer. Particular care shall be taken to avoid beating air into the resin.

5.4.5 Safety precautions.

5.4.5.1 General. Caution must be observed when handling any chemicals or solvents. The application of the GRP shaft covering is no exception. When applying the covering, the following general precautions shall. b e observed:

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a. Th .e working area shall be properly and adequately ventilated to draw fumes away from the worker.

b. Avoid direct contact with the solvents, resins, and associated hardeners and catalysts

c. Keep -chemical containers clearly labeled, tightly covered when not in use, and stored in a cool, dry area

d. Do not work near hot surfaces or open flames. Do not smoke on the job or when handling chemicals.

e. Review the manufacturer's Material Safety Data Sheet for the specific resin system to be used

f. For further guidance on related safety procedures and equipment, refer to NAVSEA S9086-VD-ST"OOO, chapter 631.

5.45.2 Specific precautions. The following specific precautions shall be observed:

a. Wear disposable plastic gloves, protective clothing and goggles. The use of barrier cream on exposed skin which contact resiner hardeners is encouraged.

b. Wear a dust respirator when handling the finely divided thixotropic filter.

c. Avoid contact of resins and associated chemicals with eyes, skin or clothing. Absorption through the skin may be harmful. In case of contact with the skin, immediately wash with soap and water and flush with plenty of water for at least 15 minutes. If the eyes are. involved flush with water immediately and for at least 15 minutes. Medical attention must be obtained as soon as possible.

d. Avoid prolonged or repeated breathing of vapors. If ventilation is not adequate, wear and organic vapor respirator.

e. If clothes or shoes become contaminated, remove at once and clean thoroughly before reuse.

f. Always wash exposed skin areas thoroughly after completing the job.

5.4.6 Application of covering. Typical details -of waterborne propulsion shafting and components for Navy ships are shown on Drawing 803-2145807.

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MIL-STD-2199 9 3 7999913 0090709 b

5.4.6.1 Temperature. During the covering operation, the temperature of the shaft and the immediate environment ideally should be about 23 degrees Celsius ("C) (73 degrees Fahrenheit ("F)). Covering shall not b e attempted at temperatures below 16 "C (60 "F) since both cure of the resin and wet out of the fiberglass will be adversely affected. Covering may be done at environmental temperatures below 16 "C (60 "F) if a suitable heat controllable enclosure is used which enables all areas of the shaft to be covered and the covering to be maintained above 16 "C (60 "F).. At higher temperatures (for example, 24 to 32 "C (80 to 90 "F)), the gel time (pot life or working life) of the resin will be significantly reduced. The resin system may have a gel time of anywhere from 30 minutes to 6 hours a t 23 "C (73 "F) and 18 minutes, minimum, at 32 "C (90 "F) as permitted in a.mrdance with MIL-R-23461 (see 5.1.1)- The manufacturer's instructions shall be consulted for gel time or working life details for the specific resin system to be used. The required work shall be performed within the gel time limits for that resin system (see 5.5.1).

5.4.6.1.1 Humidity. High humidity can have an adverse effect on resin curing and also on resin wet-out of the fiberglass tape. The effects may vary the specific resin and tape combination to b e used. In general, humidity conditions above 85 percent relative humidity should b e avoided unless a trail application shows that the materials to be used will perform satisfactorily under the specific conditions.

5.4.6.2 Detailed procedure. The application of fiberglass tape and resin on the shaft shall be as follows:

a. Start the application as soon as possible and within 24 hours after shaft preparation (see 5.4.2 and 5.4.3). .If shaft has been wrapped with VPI paper, it shall be allowed to air for 1 hour or more to dissipate any inhibitor vapor.

b. Review and observe the safety precautions (see 5.4.5).

c. Prepare the required quantities of materials (see 5.4.4).

d. Pour or brush mixed resin on top of the shaft as it rotates (see figure 4). See 5.3.4 for application to stationary -shaft. It should be noted that the preferred method of application of the covering is ta a rotating shaft. Resin drainage is usually not a problem and overall quality is better. Recommended speed of the shaft rotation, in revolutions per minute (rlmin) may be determined as foHows: When shaft diameter (d) is in centimeters then 450 divided by d equals r/min (when d is in inches then 180 divided by d equals r/min). For- a 25 cm (10 inch) diameter the speed would be:

450/25 (180/10) = 18 r/min.

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Spread the resin with gloved hands, brush or roller, to completely wet-out the shaft and sleeve surfaces and to provide a resin base to impregnate the first ply of the tape to be applied.

e. To start the wrap, wind one complete circumferential turn of tape around the shaft to completely cover the tape end. Then gradually, in two or three turns, decrease the tape overlap and work into a spiral with edges of the tape continuously butted as closely as possible to avoid gaps in coveragë (see figures 5 and 6). On rotating shafts, two people are generally required to handle a roll of tape; one holds and feeds the tape from the roll to the second person who guides the tape onto the rotating resin-coated shaft. The preferred method of application is to a rotating shaft. On a stationary shaft, this operation may be accomplished with two people, one on each side of the shaft, who pass the roll of tape to each other over and under the shaft. The tape shall be carefully butted and applied with .some tension so that the wrap is fairly tight, but not so tight as tö pucker or distort the tape; Apply additional resin to the surface, if needed to completely impregnate the tape. Effort should be made to apply enough resin initially to impregnate the tape without the need to apply additional resin on top of the tape. The glass tape shall be coated uniformly and thoroughly so that good wetting of the glass fibers is obtained. After allowing some time for wetting by the resin, work out entrapped air with a roller, squeegee or other convenient method.

f. If there is a flange, each ply of tape shall be started or ended by butting as close to the flange as possible. To provide complete shaft coverage, the tape, which is spiral wound around the shaft, shall end up normal (90 degrees) to the shaft axis at both ends of the coated length (see figure 5). Several tape widths from the end, begin reducing the spiral angle to achieve and increasing overlap, minimize wrinkles, and end with a circumferential turn.

g. If a ply begins at a tapered sleeve (see figures 1, 2, and 3), start spiral winding the tape with edges closely butted (see figure S ) , approximately 0.6 meter (2 feet) from the sleeve and wind toward the sleeve. The first turn may overlap to help. hold the tape in place. Tapered. ends of sleeves are always wrapped proceeding from the shaft up onto the sleeve taper. To end the wrap, the last several turns are taken with decreasing spiral and increasing overlap so that the final turn on the sleeve will end up normal (90 degrees) to the shaft axis (see figure 5). It may be necessary to use a ‘narrower tape or to slash the tape to eliminate wrinkles and air pockets. Additionil plies of tape may be interspersed with each ply of shaft covering as necessary to fair the covering and sleeve surfaces, as shown on figures 1,2, and 3. After completing this short section, complete the application of the first ply. This is done by going back to the starting

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Not for Resale, 11/01/2017 11:37:01 MDTNo reproduction or networking permitted without license from IHS point, applying a turn of tape over the first'turn which had been previously applied and proceeding to the opposite end of the shaft. (To maintain the same spiral for the continuation of the wrap, the shaft rotation must be reversed.) The tape is applied by spiral winding with edges butted as closely as possible to avoid gaps in coverage. As described previously, the wrap at the end shall begin to overlap on the last few turns and end up normal to the shaft &S.

h. On larger diameter shafting, the roll of tape may not be long enough to cover the entire shaft. In this event, cut the end of the tape square and start winding a second roll of tape. The first turn of the new roll shall overlap the last turn previously applied on the shaft. Some edge overlap may b e used to ensure that the tape ends are held in place. Alternatively, lengths of tape may b e measured out in advance and splicing as necessary may be done by overlapping tape ends 8 to 10 cm (3 to 4 inches) and securely stitching them together with fiberglass yarn. This procedure also has the advantage of permitting location and removal of any defects in the tape in advance of the winding operation.

i. After completing the first ply, allow the shaft to continue rotating while the fiberglass wets through which may take several minutes. The tape will be transparent and essentially invisible when properly wet-out. Work the resin through the tape and smooth any wrinkles with gloved hand, roller or squeegee. Add additional resin if needed to assure thorough wetting of the glass tape. Wrinkles and^ trapped air shall be removed.

j. Continue by pouring more resin over the shaft as needed to provide a reservoir of resin to wet out the.second ply. Apply the second ply in a similar manner, except begin at the opposite end of the shaft, using a reversed direction of spiral so that edges of this ply cross the first ply (see figure 5). Add additional resin as needed for complete wetting of the tape.

k. Work out entrapped air and wrinkles and proceed with two additional plies of resin and tape alternately reversing the direction of spiral wrap. Upon completion of the four ply wrap, one or two circumferential turns may be applied at each end to "tie down'' the covering, although this usually will not be necessary.

1. After fourth ply, the entire surface shall b e coated with additional resin t6 ensure complete wetting of the glass tape and to provide a smooth, resin-rich and glossy surface with no evidence of dry glass tape or protruding glass fibers. The surface shall be brushed smooth and excess resin dropleis or runs shall b e removed before the resin gels.

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.I L

M I L - S T D - 2 1 9 9 CHG N O T I C E I D 9999911 0470627 4bT m

MIL-STD-2199(…