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52 MARCH 2016 COATINGSPROMAG.COM Teir work would be done on a ship that is essential to Nav y operations. Te 22-year-old USS Boxer, which has a homeport in San Diego, was picked to be the fagship of a task force of ships from Australia, Pakistan, South Korea, Turkey, the United States, and the United Kingdom that fought pirates of the coast of Somalia. In fact, when Captain Phillips was kidnapped by Somali pirates from the container ship Maersk Alabama in 2009, he was brought to the USS Boxer after he was rescued. Unfortunately, when the actor Tom Hanks recreated the scene in the 2013 movie, the USS Truxtun was used in its place. Te USS Boxer has also been deployed as part of Operation Iraqi Freedom in 2003 and helped rescue the German container ship Hansa Stavanger in 2009. For this job, the stakes might not have been quite as high as during pirate rescues, but Sanchez took his work just as seriously. It was a military job, which meant every step of the process had to be documented and approved. "A nything w ith failures or out of the ordinar y — if there's an issue that arises, any defects, any questions — you do an investigation, a failure analysis on whether the coatings w ill adhere," Sanchez said. "It's my job to let the militar y know if the coating w ill be fine, if it w ill meet the life expectancy. T he militar y ensures a lot of research is done on any issue that might arise." On this job, the concer n was over the cond ition of the substrate on the black pitted iner t cor rosion cel ls that were scattered throughout the f light deck. T he wor r y was that those cor rosion cel ls wou ld af fect the substrate's prof i le read ings. "Te USS Boxer was put into service in 1993, which means this fight deck has been taking a beating in the most extreme corrosive atmospheric conditions being at sea for the past 21 years, and these inert corrosion cells are the result of that service," Sanchez said. "Tis class of ship has been receiving ultra-high pressure water jetting for the better part of the past 8 to 10 years." Sanchez recommended that the solution include abrasive blasting the fight deck to break down the porosity of the inert corrosion cells. Tis process would leave the indentions of the metal loss but still create an acceptable profle range and would mitigate the loss of coatings that are absorbed by the porous The South Bay crew did a lot of research to come up with a plan that would work for the Nav y. "No application could be started until we briefed a one-star admiral," Sanchez said. The team decided that the porous corrosion cell areas would best benefit from ultra-high pressure water jetting and steel shot along with an anti-skid coating system. The corrosion cells would get two coats of primer. Navy Ship Co m b at ting th e co r rosio n cell s wa s a p rio rit y. "Th e s e area s ten d to absorb the coating s , leaving these area s with les s mil s of paint versus the 'good' substrate, which results in less coatings coverage," Sanchez said. T h e cr e w p u t to ge th e r a s p e ci f i c s t u d y to te s t v a r i o u s t y p e s o f sur face prep for this corroded subs trate. Then, af ter te s ting them out, they'd work with the Nav y to decide on the best way for ward.