Surface Preparation General Theory

1. Why is correct surface preparation vitally important ?

Answer.------ Because it governs the service life of the applied coating.
2. What action should be taken if cracks or surface laminations are discovered during
surface preparation operations.
Answer.----Report to the engineer.
3. Name and briefly describe two theories of adhesion.
Answer.----Molecular attraction and molecular interference,( the force that
two surfaces in touch ).

resists the seperation of

4. What is 1 micron in relation to 1mm ?

Answer. ----1/1000
5. What do you understand by the term sliver. ?
Answer. ----A surface lamination.
6. What is the title of B.S. 7079. ?
Answer---- Preparation of steel substrates prior to the application of paint and related products.
7. What are the two main factors that govern blast quality.
Answer----Blast particle velocity and time taken to do the area ( the longer you
spend on an area the higher degree of cleanliness achieved )
8. What is the shape of a cross sectioned blast finish known as ?
Answer. ----Surface profile & anchor pattern.
9. What is the approximate speed of the particles leaving a pressure blast nozzle.
Answer.----220 mph straight nozzle & 450 mph for a venturi nozzle.
10. What are the four characteristics of abrasives which govern the surface roughness ?
Answer.------ Size, hardness, density and shape.
11. Abrasives provide a key for coatings, what is meant by the term key ?
Answer----An irregular profile.
12. For which situations would steel or chilled iron grit be used rather than mineral abrasives ?
Answer----When blasting can be carried out giving the possibility of reclaiming
factory blasting with closed blast units.

grit , ie :-

13. Which British Standard would be used for determining the size of copperslag
expendable abrasive ?
Answer.-----BS 410
14. Which British Standard would be used for determining the size of chilled iron or steel grit ?
Answer.----BS 2451?
15. Why is sand containing free silica not used nowadays for blasting purposes ?
Answer.----COSHH regs. Risk of silicosis.
16. What is the most common cause of rogue peaks ?
Answer.----Overblasting in one area or using irregular size grit.
17. What could be the cause of flash rusting on a primed blasted surface ?
Answer.----Rogue peaks , that have a higher profile than the DFT of the primer
coat .
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18. Other than degree of surface roughness , what else is partially governed by the abrasives characteristics.
Answer.----Cleanliness & surface hardness.
19. Name three methods of assessing the amplitude of a surface profile.
Answer.---- Testex tape,surface comparator, surface profile needle gauge.
20. Which type of abrasive would work harden a steel surface the most.
Answer.----Shot
21. In mill blasting operations, why is metallic shot and grit mixed ?
Answer----In order to obtain the best profile & because it can be recycled up to
around 20 times
as long as it is checked for contamination and hasn't broken down to below its effective working size.
22. What would be regarded as an ideal shot/grit mix ?
Answer. -----70-80% shot & 30-20% grit.
23. What is another term for anchor pattern ?
Answer. ----Key & Surface profile.
24. What do you understand by the term hackle ?
Answer.----A small surface lamination that sits upright.
25. What is another term to express peak to trough height ?
Answer. ----Amplitude.
27. What profile range can be measured with X-coarse Testex.
Answer. ----1.5 to 4.5 thou
28. What are the advantages of the Testex method of profile measurement ?
Answer.----Because it provides a permanent record.
29. What are the three profile assessments obtained by using BS 7079 Part C ?
Answer.----1.Fine profile :-equal to or rougher than 1, but not as rough as 2.
2.Medium profile:-rougher than 2, but not as rough as 3.
3.Rough profile:-rougher than 3, but not as rough as 4.
30. If the final profile measurement on an imperial dial micrometer was 4.4 thou", what would be the profile
in microns. ?
Answer. ----113 microns
31. If the final profile measurement on a metric dial micrometer was 113 micron, what would be the reading
in thou" ?
Answer.----4.44 thou.
32. Define what is meant by the grade of a blast finish ?
Answer. ----Amount of surface contaminant remaining.
33. What are the factors governing the grade of blast finish.
Answer. ----Time spent blasting & velocity of particles leaving blast nozzle.
34. Is it possible to determine the grade of a blast finish by using a BS 7079 surface comparator. ?
Answer.----Yes.
35. Is it possible to differentiate between ASa2 and BSa2 ?
Answer.----No.
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36. According to BS 7079 is it possible to achieve an A Sa1 ?

Answer.----Yes.
37. Is it possible to differentiate between A and B rust grades blasted to Sa3 ?
Answer.----No
38. Is it possible to differentiate between C and D rust grades blasted to Sa3 ?
Answer.----Yes
39. What is a typical maximum time lapse from blast cleaning to painting /coating ?
Answer.----4 hours , but can be shorter , the main governing factor is that at the
time coating starts , the desired finish of the substrate shall be met , ie
if Sa3 is stipulated , then that is what has to be achieved .
40. Which solvents are commonly recommended prior to blasting ?
Answer.----Aromatic , due to its 100% evaporation without leaving any mark on
substrate( xylene, benzene & tolulene).

the

41. Name four advantages of centrifugal blast units over air blasting ?
Answer. ----Takes less time, less labour, safer, more uniform profiles
achieved , more environmentally friendly& abrasive can be re claimed
42. What would be the typical speed of abrasive leaving a wheel abrator ?
Answer.----160 to 220mph.
43. What is the method of cleansing the abrasive leaving a wheel abrator ?
Answer.------Air/wash separator.
44. What is a knock out pot ?
Answer.----Liquid remover / filter.
45. Why are blast hoses carbon impregnated ?
Answer----To prevent static shock.
46. What is meant by a dead mans handle. ?
Answer----Lever on the blasting gun which kills the sytem, if pressure on it is released.
47. What is considered to be the optimum pressure for grit blasting ?
Answer----100psi.
48. What is the % efficiency drop for every 1psi pressure loss in a pressure blast system. ?
Answer. 1.5 %.
49. Name the gauge used for measuring pressure at the blasting nozzle ?
Answer----Hyperdermic needle gauge.
50. What is meant by BS 7079 St 2 and St 3 ?
Answer----ST 2 is a thorough hand or power tool finish , removing all
loose paint rust , millscale, oil ,& grease . By Manual means
ST3 is a very thorough hand or power tool finish removing all
debris as above & leaving a grey matallic finish prior to coating - By Mechanical means
51. What would be the equivalent to St 2 in Sa grading.
Answer----Can't be compared.
52. Which two alloys are used for wire brushes to render them spark free. ?
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Answer.----Phosphor bronze & beryllium bronze.

53. What is meant by burnishing and how is it caused .
Answer. ----Over wirebrushing in one area ,leaving a shiny surface which will not
acceptable key/profile for paint to adhere to.

provide an

54. Why should burnishing be avoided ?

Answer----End up with lack of adhesion on applied coatings due to lack of
profile or key on substrate surface.
55. What is a Jason's hammer ?
Answer----Needle gun.
56. What are the disadvantages of using a needle gun ?
Answer---- Can cause peening & can push impurities into substrate.
57. On what areas would needle guns be typically used ?
Answer. ----Welds & rivet heads .
58. In the pickling process , what would be the typical H2SO4 temperature and concentration.
Answer. ---- 5-10% & 65 to 70 degrees C.
59. What is the duplex process of surface preparation. ?
Answer.----It is the phosphating of the steel prior to coatings being applied .
(See below for details of process)
60. Describe the use of phosphating steel components ?
Answer.-----The technique involves initial degreasing & washing of the
component then a final treatment in a 1 to 2 % phosphoric acid
`
solution , held at 80 degrees for 1 to 2 hours .
This leaves a rust inhibitive phosphate coating on the steel surface , onto
which the coating should preferably be applied while substrate is still
warm .
Note:-Salts produced should be left in place as they are rust inhibitive .
61. What is meant by pH.
Answer.----Potential hydrogen .
62. What is the neutral figure on the pH scale ?
Answer. ----7. "Distilled water".
63. Which pH range covers acids ?
Answer. -----below 6 through to 1.
64. Which pH range covers alkalis ?
Answer. ----above 8 through to 14.
65. What is the usual pH requirement after phosphating prior to coating ?
Answer. -----5 to 7.
66. How is pH usually measured ?
Answer. ----m/Mols /litre.or indicator papers that determine pH by means of colour changes to strip.
67. What are the advantages of wet blasting compared to dry blasting ?
Answer.----Good for removing toxic coatings as no dust is produced .

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68. What are the disadvantages of wet blasting ?

Answer.----Large amounts of water & sludge produced , expensive inhibitors required very high
pressures sometimes utilised & substrates have to be dried before coating can commence
69. What would be a typical maximum pressure for high pressure pure water blast ?

Answer. ----35000 PSI

70. What are the main disadvantages of high pressure pure water blasting compared to other methods of wet
blasting.
Answer.----High pressures , so process is extremely dangerous .
71. In wet blasting , why are inhibitors sometimes added. ?
Answer.----To stop the formation of rusts where water is left on substrates .
72. Name five methods of wet blasting ?
Answer.High pressure water , ultra high pressure water , water plus abrasive, steam cleaning & low
pressure water blasting with abrasive .
73. How are flame cleaning standards defined in BS 7079 ?
Answer. -----AFl , BFl , CFl & DFl.
74. What are the three operations involved in flame cleaning ?
Answer.------ Flame clean, wire brush, prime.
75. Name two typical areas where flame cleaning should not take place ?
Answer. -----Near anything flammable , high pressure gas lines or near anything
damaged by heat e.g instrumentation or electrical
components.

Surface Preparation

which could be

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