PAINTING INSPECTION GRADE 2/3

1. IN A CORROSION CIRCUIT, WHICH WOULD CORRODE THE ANODE OR CATHODE?

 ANODE

2. WHY ARE ETCH PRIMERS USED?

 Etch primers are used to give good adhesion to the next layer of paint. It is used on new galvanized
surface to bring out the surface preparation for the next layer to be coated. It leaves zero microns.

3. DESCRIBE THE TEST CARRIED OUT TO DETERMINE FLASHPOINT.

 Put the solvent in a closed able cup. fix a thermometer, agitator and external source of igniter in it.
Then cup is sealed and kept in a bath of water. The water bath is gently heated which in turns heats
the solvent. For every ½ deg rise in temp at which the blue sparks appears is known as flashpoint.

4. DESCRIBE FLOCCULATION, CISSING, CHALKING, GRINNING AND BLEEDING.

 FLOCCULATION
 The development of loosely coherent solid aggregates in pigment vehicle dispersion.

 CHALKING
o The formation of a chalky or powdery layer on the surface of the paint film caused by the
disintegration of the binding medium due to disruptive factor during weathering.

 CISSING
o The formation of small areas of the wet film of a coating material where coating material has
recorded leaving holidays in the film caused by inadequate preparation. A difference in surface
energy cause local lack of adhesion.
 GRINNING
o The showing through of the underlying surface due to inadequate opacity of the paint film
which has been applied to it.

 BLEEDING
o The action of a material in penetrating and discolouring a coating applied on top of it. Brown
for bitumen and yellow for coal tar.
5. NAME 3 METHODS OF MEASURING DFT IF PAINT CONTAINS FERROUS MATERIAL?
 Electronic gauge (elcometer )
 Destructive gauge (pig )
 Comb gauge to determine WFT with wft and volume solids DFT can be calculated.

6. WHAT IS THE AVERAGE STAND OFF DISTANCE REQUIRED FOR ABRASIVE BLASTING?
 450MM

7. WHICH TEST ARE CARRIED OUT FOR MARINE SALTS?

 TEST FOR CLORIDES
 Silver Nitrate Test –qualitative test
 Merkoquant –quantitative test
 Bresle sample patch –quantitative test

8. DESCRIBE THE CALIBRATION AND USE OF A SUFACE PROFILE NEEDLE GAUGE?

 Surface profile needle gauge is used for profile measurement calibration as follows
 Place the needle gauge on a glass, loosen the locking screw and bring the bezet to zero and tighten the
locking screw .the gauge is now calibrated. Take a minimum of ten readings in random position over the
substrate. The average of the readings is surface profile reading.

9. DESCRIBE THE PARAMETER FOR THE USE OF A WHIRLING HYGROMETER?

 Check the reservoir is filled with distilled water or deionised water.
 Check if the wick is clean, wet and fastened around the bulb.
 Check if the thermometer scale graduations are clear.
 Check if the mercury is in an unbroken continuous stream, if not make it an unbroken continuous stream
by pulling back the mercury with a magnet.
 Check if there is any mechanical damage.
 Other names are aspirated hygrometer or psychrometer.

10. LIST THE SAFETY EQUIPMENT REQUIRED FOR AN ABRASIVE BLASTING OPERATION ON SITE?
 Carbon impregnated hoses
 Hoses to be short as much as possible.
 Safety in accordance to IGE SR 21
 Earthling the pot
 Use reinforced hoses
 External bayonet coupling
 Deadmans handle indirect control with the blasting operator.
 Scaffolding with safe tags
 Barriers and warning signs.
 Air fed helmet with adequate visors.
 Ear protectors, leather, apron, gloves and boots.

11. WHAT IS THE DEFINATION OF THE BARRIER PRINCIPLE?

 Barrier principle is to provide a physical impermeable coating to protect the underlying substrate. the
coating system physically prevents the electrolyte from making contact with the substrate.

12. WHAT TYPE OF SEALER IS USED FOR TSA AND IZS?

 Silicones

13. WHAT IS A PROHESION TEST?

 It is a test to check for protective adhesion.

14. DESCRIBE THE USE OF BANANA GAUGE ON ALUMINIUM AND GALVANISED SUBSTRATE?
 Banana gauge cannot be used on aluminum .If used on galvanized substrates; thickness of zinc coating
should be deducted (100microns).
 Note; can also be used on ferritic stainless steel.

15. WHAT IS A PYKNOMETER?

 Pyknometer is used for measuring density of a paint other names are
 Density cup
 Relative density cup
 Specific gravity cup
 Weight per liters cup
 Weight per gallon cup

16. WHAT ARE THE ADVANTAGES AND DISADVANTAGE OF VENTURI NOZZLES AND STRAIGHT BORE
NOZZLES?
 VENURI NOZZLE
 ADVANTAGES
 Large area coverage
 450 mph
 Large blast pattern
 DISADVANTAGES
o Expensive
o Cleaning and maintenance
o Safety.
 STRAIGHT BORE NOZZLE
 ADVANTAGES
o Cheaper
o Better accuracy
o Less wear
 DISADVANTAGES
 Longer time needed
 Work required
 Operator fatigue
  Smaller blast pattern.

17. WHAT INFORMATION NEEDS TO BE RECORDED ON A SITE PAINTING REPORT?

 Time ,dry bulb temperature, wet bulb temperature, dew paint, steel temperature, relative humidity,
areas inspected, rust grade ,abrasiveused,size of abrasive, abrasive supplier, pressure applied, grade of
surface preparation, type of paint applied, batch no, paint supplier, method of application,conctractno,
date, signature.

18. WHAT IS BS4800 AND WHAT IS ITS PURPOSE?

 BS4800 Schedule of paint colours for building purposes
 It is a method by which all manufacturers can make exactly the same colour
 It is used to identify existing colours when maintenance painting.

19. NAME THREE PRIMARY COLOURS?

 Red, Yellow, Green, Blue.

20. WHAT PRODUCT SHOULD BE USED FOR REPAIRS TO PIPE COATING IN DAMP CONDITIONS?
 Moisture curing polyurethane. To be applied only by brush.

21. WHAT TYPE OF MACHINERY IS USED TO PRODUCE LARGE PRODUCTION RUNS OF POPULAR PAINTS?
 Sand mill or Pearl mill or Bead mill.

22. WHAT IS THE NAME OF THE MILL USED TO PRODUCE MASTICS, FILTERS, AND PATTIES?
 Triple roll mill.

23. WHAT SPECIAL SURFACE PREPARATIONS ARE REQUIRED FOR COATINGS ON CONCRETE?
 On concrete, surface is prepared by scrapping with the help of scrabblers.

24. WHICH MATERIALS ARE USED FOR THE MANUFACTURE OF POWER BRUSHES AUTHORISED FOR USE ON
BGAS/TRANSCO SITES?
 Phosphor bronze
 Beryllium bronze

25. WHAT VOLTAGE SETTINGS ARE COMMONLY USED FOR SPONGE TEST HOLIDAY DETECTION?
 9 Volts for DFT below 300 micron
 67.5 Or 90 volts for DFT above 300 micron.

26. WHAT SAFETY FACTOR SHOULD BE OBSERVED WHEN USING SOLVENTS?

 Toxicity should be checked.
 Flashpoint
 Eye hand protection
 No naked flames
 Ventilation
 Coshh document should be available
 Binder compatibility
 MSDS

27. DESCRIBE HOW ROGUE PEAKS ARE CAUSED?

 Blasting in one area for a long time

28. WHAT ACTION SHOULD BE TAKEN IF IT IS NOTED THAT A CONTRACTOR HAS SUPPLIED A COAT OF
PAINT OUT OF SEGMENT?
 Raise a Non – conformity report
 Inform the corrective action to the concerned engineer; recommend reblasting and recoating in correct
sequence in accordance with PA 10.

29. WHAT FACTORS INFLUENCE THE RATE OF CORROSION?

  Temperature
 Hygroscopic salts ( iron,chlorides,and iron sulpates )
 Aerobic conditions
 Presence of bacteria on surface (sulphur reducing bacteria )
 Acids and Alkalis
 Bimetallic contact

30. NAME 5 ADDITIVES WHICH CAN BE USED TO IMPROVE A PAINTS PERFORMANCE OR SUITABILITY FOR
USE?
 Anti setting agents – thixotropicagents eg bentene ,wax
 plastics eg non drying oils
 Driers eg. Octoates or naphthanates of cobalt, manganese and zirconium.
 Anti –skinning agents eg methyl ethyl ketoxince
 Extenders eg. China clay,chalk,slate flour

31. WHAT IS THE DIFFERENCE BETWEEN A CONVERTIBLE AND NON- CONVERTIBLE COATING?
 Convertible coatings are that which undergo chemical reaction on drying and upon drying does not get
softened or damaged when it comes into contact with its own solvent. It is non –reversible, ex alkids,
phenolics, natural oil.
 Non – Convertible coatings are those which dry by solvent evaporation only. no chemical reaction takes
place and after drying the paint would be softened or damaged if it comes into contact with its own
solvent .It is reversible eg. Vinyl, chlorinatedrubber, cellulose.

32. NAME 6 OPAQUE PIGMENTS AND THEIR COLOURS?

 CARBON Black
 Compounds of cobalt Blue
 Compound of chromium green ,yellow ,and orange
 Compound of iron Brown , red ,and yellow
 Compound of calcium Red and yellow
 Titanium dioxide White

33. WHAT ARE STRIPE COAT AND MARKING COAT?

 A Stripe coat is a coat of paint applied by brush to welds and edges which guaranties minimum DFT of
the system in these areas.
 Marking out is to protect areas during preparation and painting in particular to prevent the malfunction
of the plant. E.g. of areas are Fire protection equipment , weld end preparation ,atmosphere sensing
heads , name plates ,spray heads , vents on control equipment , flame traps , lubrication points etc.

34. WHAT WFT WOULD HAVE BEEN MEASURED, IF A COATING OF 88 MICRONS WAS ACHIEVED WITH A 66%
VS PAINT?
 V.S. % DFT /WFT X100
 66 =88/wft ANS =133.33MICRONS

35. CALCULATE THE DFT OF PAINT VS IS 44%AND WFT OF 234 MICRONS?

 FORMULA V.S % =DFT/WFTX100
 ANS =102.96Microns

36. NAME A DESTRUCTIVE DFT MEASURING EQUIPMENT?

 PIG ( Paint inspectors gauge )

37. NAME A NON DESTRUCTIVE DFT MEASURING EQUIPMENT?

 Banana gauge
 Electronic gauge (elcometer )
 Tinsley pencil or pull of gauge
 Magnetic horshoe gauge
 38. NAME 4 ARTIFICIAL WEATHERING DEVICES?
 Humidity cabinets
 Salt spray cabinet
 Water soak test
 Temperature recycling
 Prohesion testing

39. CALCULATE THE DENSITY OF A TWO PACK MATERIAL OF PART A IS 1.5 g/cm3 AND PART B IS 0.5g/cm3
(assuming mix ratio of 1.1 )
 Part A =1.5
 Part b =0.5
 Total weight =2
 Total volume for weight =2
 Density =2/2=1 gm/cc

40. NAME 3 ADHESION TESTS?

 V cut test
 Cross cut (cross hatch test )
 Dolly test

41. NAME THE DUTIES OF PAINTING INSPECTOR?

 The job of an inspector is to inspect and report. He must act with integrity at all times and be true to
the specification requirements. A list of his duties are
o Learn the specification ( he cannot deviate without written permission )
o Attend site meetings as necessary.
o Become familiar with the plant and equipment being used.
o Strike working relationship with colleagues
o Agree work programme with contractor.
 PRACTICAL DUTIES
 Visually inspect paint finish.
 Assess condition of substrate.
 Check correct material have been obtained for use.
 Check dew point, relative humidity and steel temperature daily as required.
 Inspect surfaces after blast cleaning (grade of cleanliness and amplitude )
 Wet film thickness checks.
 Dry film thickness checks.
 Witness all preparations and paint procedures.
 Make reports as required (daily , weekly , summary etc )

AT THE BEGINNING OF DAY.

 Check the environment/
 Check the equipment.
 Check the materials.
 Check the previous days work.
 Agree the days work programme with the site contractors’ senior personnel.
DURING THE DAY
 Check the environment
 Check the equipment
 Check the material usage.
 C heck the operators work
 Check the standards

ON COMPLETE OF THE WORK AT EACH STAGE

 Ensure that system meets the specification by carrying out or witnessing tests.
 Check for any application faults.

AT THE END OF EACH DAY

 Check the days work
 Check the housekeeping
  Complete reports.

ON COMPLETION OF EACH JOB

 Make the final check on integrity of the work.
 Write the summary report

42. LIST OF CONTRACTOR MALPRACTICES?

 Using unqualified personnel
 Using unsafe plant and scaffolding
 Using equipment which is in a poor condition
 Using a compressor at above 100 psi
 Using incorrect paint
 Using a paint which is out of date

 Using solvents other than those approved by manufacturer.

 Using incorrect solvent for degreasing
 Using cotton clothes for cleaning
 Preparing and painting when weather conditions are unsuitable
 Painting and coating over areas of inadequate surface preparation
 Attempting to re use expandable abrasives
 Attempting to skip a coat
 Applying low thickness coating
 Applying too much solvent to a paint
 Apply a coating system in a wrong sequence
 Carryout further work before inspection has taken place
 Not observing indication and pot life times
 Not observing recommended overcoat times
 Insufficient attention paid to awkward areas
 Incorrect storage of paint.

43. SKETCH THE WARNING SIGNS FOR HARMFUL OR IRRITANT, TOXIC, AND CORROSIVE
SUBSTANCE?
 SYBOLS TO BE DRAWN.REFER TEXT BOOK

44. WHICH DRYING /WRING TEST INVOLVES THE USE OF GLASS BEADS?
 Ballotini test

45. DESCRIBE HOW WOULD YOU CARRYOUT A CHECK ON AIR PRESSURE OF A BLASTING OPERATION?
 Air pressure in the blasting machine is measured using hypodermic needle gauge. Before using it,
alert the operator, check for earthling shut off the abrasives .Insert the needle through the hose
towards the hose towards the nozzle at an angle of 45.

46. GIVE THE REASONS WHY DIFFERENT SURFACES REQUIRED DIFFERENT PAINT SYSTEMS?
 Temperature, surface conditions, service life expectancy cost, compatibility, environment.

47. WHAT CONSIDERATIONS SHOULD BE MADE BEFORE CARRYING OUT A MAINTENANCE PROJECT?
 Knowledge of previous coating, extent of damage, operating temperature ,service condition ,removal
of toxic salts, safety requirement,colour,cost,type of abrasive required or used ,environment
,durability and longer life are the existing coatings compatible to the new system in terms of
adhesion, possibility of solvent stripping and possibility of bleeding where adhesion problems, solvent
stripping or bleeding might occur a tie coat would be employed to prevent the problems arising.

AIRLES SPRAY
 ADVANTAGES
 High rate of paint flow
 Can apply high viscosity fluids
High transfer efficiency
Versatile
Large area coverage
Low wastage
 DISADVANTAGES
 Poor atomization
 Expensive nozzles
 Narrow fan pattern
 Coating limitation
 Increased maintenance
 High skill required
 Increased safety risk
 Lower quality finish
CONVENTIONAL SPRAY
 ADVANTAGES
1. Inexpensive nozzles
2. good atomization\
3. more accuracy
4. Better finish achieved
5. Less cleaning after use
6. Lower working pressure
7. Concentrated spray patter

 DISADVANTAGES
1. Heavy hose lines
2. operator fatigue
3. Specialized container
4. Slow application rate

ELECTROSTATIC SPRAY
 ADVANTAGES
1. High transfer efficiency
2. Good edge cover
3. Good wrap around
4. Uniform film thickness
5. Low wastages
 DISADVANTAGES
1. Bulky ,delicate guns
2. Requires extra cleanliness
3. Fire /safety hazard
4. Compound must be conductive
5. High maintenance cost

48. DESCRIBE THE USE OF DRAGER BELLOWS AND WHAT COLOUR CRYSTAL CHANG WOULD YOU EXPECT, IF
CARRYING OUT A TEST FOR XYLENE?
 Drager tube and dragger bellows is used to measure the toxicity of the air. Using a special fitting
situated on the bellows the nipples are snapped off both ends of the tube, which is then inserted
into the aperture. The crystals should be adjacent to the bellows. The bellows then depressed and
released according to the tube. Each depression and release slowly draws 100cc of air through the
opened of the tube, through the crystals and into the bellows.
o For xylene n=5, therefore 5 depressions, so 500cc of air is the RAQ, The colour change
is form white to reddish brown. it is mainly used to test air quality when using solvents
varying crystal for different solvents.
o Thermosetting is where a coating is heat cured and after safety cannot be softed if heat
is applied. Convertible thermoplastic is opposite and become soft when heated and hardens
when cooled non convertible.

HYGROSCOPIC SALTS
  A HYGROSCOPIC SALT IS ONE, WHICH WILL ATTRACT WATER AND
DISSOLVE IN IT. When salts are present on a substrate and a coating is
applied on them, water will be drawn through the film and the resulting solution
builds up a pressure under the film and forces up to form blisters. These blisters
are called Osmotic or Hygroscopic blisters and are defined as Pinhead sized filled
blisters.

GALVANIC LIST OR ELECTRO MOTIVE SERIES OR ELECTROCHEMICAL SERIES

 GRAPHITE +0.25V
 TITANIUM 0.0V
 SILVER - 0.1V
 NICKEL 200 -0.15V
 LEAD - 0.2V
 ADMIRLTY BRASS - 0.3V
 COPPER - 0.35V
 TIN - 0.35V
 MILLSCALE - 0.4V
 LOW ALLOYSTEEL - 0.7V
 MILD STEEL - 0.7V
 ALUMINIUM ALLOYS - 0.9V
 ZINC - 1.0V
 MAGNESIUM - 1.6V

GALVANIC LIST
 Metal and metal compound carry an order of nobility which determines their ability to corrode or not
.this nobility is found by testing in sea water at ambient temperature.

SURFACE PREPARATION
 Involves removing contamination, roughens, the substrate to give good adhesion. Factors to be
considered when inspecting a surface preparation are degree of cleanliness (min –sa2.5) and surface
profile (degree of roughness).

ADHESION
 The force required to separate two surfaces in touch abrasive blasting roughens the surface and
increases the actual area, thus increasing adhesion.
 Dial micrometer and replica tape ( also called TESTER or CORNPLASTER method )
 Coarse grade -0.8 to 2 thou or 20 – 50 microns
 Extra coarse grade -1.5 to 4.5 thou – 40 -115 microns
 1mm =1000 microns
 25.4microns =0.001inch (1 thou )
 40 thou =1mm
 25.4mm =1 inch

NATURAL RESINS
 Copal’s, dammers, coumarones, amber and lag natural resins are not soluble in water.

NATURAL OILS
 Linsed oil,tung oil (also known as china wood oil ),Soya oil ,tall oil , safflower oil , olive oil ,coconut oil
,castrol oil

OLEORESINOUS
 A mixture of oils and resins.

PHENOLIC RESINS
 Good adhesion properties, resistance to heat and chemicals, used instead of chlorinated rubber where
temperature grater than 65deg.commonly called hot dry oils.

PIGMENT PROPERTIES
  Gives cohesive strength
 Gives abrasion resistance
 Gives durability
 Gives opacity
 In some cases, gives impermeability and resistance to ultraviolet rays.

MIO –MICCEOUS IRON OXIDE

 Purple grey in colour
 Retards permeation,uv A and B reflection
 Good adhesion to next layer
 Durability

PAINT MANUFACTURING -3 STAGES

 Premixing
 Dispersion or grinding or milling
 The letdown process

SAND MILL OR PEARLMILL OR BEAD MILL

 The sand mill is particularly suitable to long production runs on popular paint colours. The mill base is
pumped under pressure up through the vessel which is partly filled with sand or other grinding mediums.
Through the centre of the vessel runs a shaft with fixed discs, which causes the abrasives to be moving
constantly. As the paint exists at the top it passes through a fine screen which retains the abrasive in
the vessel .A cold water cooling jacket is needed because of the heat generated by friction.

HANGMAN GRIND GAUGE

 Also called as fineness of grind gauge ,is used to measure the degree of dispersion of paint

DYNAMIC VISCOSITY
 Measure in poise, si unit n.s/m2 (Newton-second per square meter )
o 1 poise = 10 centipoise
o 1 poise = 1 dyne second per cm2
o It is measured using rotational viscometer or rotothiner disc rotates at 200 rpm.

KINEMATIC VISCOSITY
 Measured using Krebs stormer viscosity units used are stokes and centistokes.

FLOW VISCOMETER (FLOW CUPS)

o Measured in seconds

ZAHN AND FRIKMAR

o Used for hot fluids.thixotropic paints cannot be measured using a flow cup.
o Eccentric wheel cannot be used UN curved surface .on pipes it can be used circumferentially on curved
surface. Comb gauges must be used longitudinally on curved surface.

DESTRUCTIVE TEST
o PIG PAINT INSPECTORS GAUGE
o ERICSON TEST DRILL
o SABERG THICKNESS DRILL

NON DESTRUCTIVE TESTGAUGES

 ELECRONIC GAUGE
 ELECOMETER –Electro magnetic induction and eddy current accuracy +-1/2%
 Magnetic
 Tinsley pencil or pull gauge or foreman’s gauge accuracy +-15%
  magnetic horshoe gauge for measured hot surfaces as metal spray ,accuracy +-10%
 Banana gauge or magnetic coating thickness gauge. accuracy +-5%

TESTS FOR MECHANICAL PROPERTIES ON PAINT FILMS

ABRASION RESISTANCE
o Tested using a taber rotary abraser disc painted with the material to be tested are rotated under special
abrading wheels. The abrading wheels can be of various compositions, depending on the degree of abrasion
required. E.g. sand paper or carborundum. Periodically the samples can be checked for thickness or damage
inflicted.

HARDNESS
o Test done by Koenig Albert method. A pendulum with two spherical fulcra is free to swing on a plate
painted with the material under test; the number of swings is counted electronically.

FLEXIBILITY
o Materials ability to withstand bending over mandrels, straight or tapered. Standard panels are coated
with material to be tested and bent around cylindrically mandrels of various diameters. The flexibility
of a coating is expressed as the smallest mandrel over which the paint will not crack when bent. A
conical mandrel with a uniform taper from 3mm dia to 37mm dia is used. The conical type needs only one
sample to achieve a result whereas straight mandrels need a flat for each mandrel.

IMPACT RESISTANCE
o Tubular impact testers are commonly used. They may be direct or indirect. Direct being onto the
painted side of the sample and indirect on the non – painted side. A weight typically 1kg is lifted up the
tube to the height required and held in place by a retaining colour. A painted sample is fixed under the
tube. By rotating a ring within the collar the weight is released and falls onto the sample, which is then
assessed for damage.

ACCELERATED TESTING OR ARTIFICIAL TESTING

o NORMALWEATHERING are a sample process of hanging out painted panels, facing south on an A frame
and periodically testing for colours retention, chalking, water absorption over a period of years.

o HUMIDITY CABINETS OR TROPICAL BOX

 For testing tropical conditions. Humidity is very high at 95% and elevated temperature up to
55deg.

SALT SPRAY CABINETS

o For checking paint ability to withstand salt laden environments.

WATER SOAK TEST

 Allowing painted panels to be submerged to test for water absorption, by weighing before
and after submission.

TEMPERATURE CYCLING
 Painted samples are subjected to constant temperature cycles from hot to cold .paints in common with
most materials expand and contract according to temp. Constant expansion and contraction can result in
cracking .max and min temp can be set and cycle, over a running period of thousand hours.

PROHESION TESTING
  Painted sample plates are cut with a pre damage in the form of an X, 50micron each incision length. A 3
% saltwater solution is sprayed onto the plate for 60 minutes and stopped for 60minutes, at a constant
35 deg. The cycles continues for 1000 hours .On examination after the 1000hours ,there shall be no
blistering or undercut outside of a 3mm boundary on each side of the predamage.

DRYING AND CURING TESTS

BALLOTINI TEST
 Ballotini, tiny spheres of glass or sometime sand are trickled onto a newly painted block graduated in
hour of traverse e.g. 24 hours for the block to traverse full length under the funnel. After a specified
time, the block is removed, tipped onto its side, tapped lightly and examined. The position of the last
grain of ballotini or sand sticking to the surface is recorded as the drying time at that temperature
( 20 +-0.5 deg )

BK DRYING RECORDERS OR STYLUS TEST

 The BK defines also the stages of drying .eg.Solvent evaporation time, SOLGEL Transition, surface
drying time and final dry time. Needles (stylus )are fixed to the motor driven wires which then traverse
over the full length of the painted glass strips 300mm x 25mm ,in preset times of 6,12,24 hours . the
needles can also be weighed if required when the paint is wet , the needle will penetrate through to the
glass. As the solvent evaporates the needle will start to cut a continuous track in the film, as drying
progresses it will cut an interrupted track, until finally dry when no scratch is visible

MECHANICAL THUMB TEST

 It simulates a thumb onto a surface and apply a twisting motion. A cam drives a weighted shaft with a
spherical rubber end cap, allows it drop onto the painted plate, rotate through 270 deg, and then lifts
it off again. The plate is visually inspected for tearing, pulling, wrinkling etc.

HARDNESS TESTS

PENCIL SCRATCH TEST (WOIFF – WILBORN)

 A Sharpened pencil is fitted into a special steel block and pushed along the surface, starting with e.g.
3h and working up 4H,5H etc.The first pencil to scratch the paint lends its hardness value to the paint
e.g. 5H.

MECHANICAL SCRATCH TEST

 A stylus with various added weights is drawn across the painted surface. The weight that causes the
surface to be scratched gives its value to the hardness .e.g. 500gm

THUNBNAIL TEST
 A Quick test for hardness is to try to penetrate the paint film with the thumbnail. If the thumbnail
penetrates the film is cheesy.

TEST FOR RESIDUAL ATTACK

GOLD LEAF TEST

 A Small square of gold leaf is lightly pressed onto the surface of paint. The gold leaf is then pealed off
and the area examined with a magnifying glass. No residual leaf should remain.

OPACITY
 Opposite of transparency or hiding ability. Commonly used crypto meters are P-FUND CRYPTOMETERS.
THEY ARE 2 TYPES
a. Trough Type
b. Black and white plate

TROUGH TYPE
 A Wooden block with a tapered sunken trough in the middle the bottom of which is formed by the
chequered black and white glass squares. Paint is added at the deep end and scrapped along to fill the
trough, looking perpendicular onto the trough, find the where the underlying square can just no longer
 be seen (look at the squares offering the biggest contrast to the paint colour) .A scale running along the
groove will indicate the depth of the groove at that point, and is recorded as a wet film thickness.
DEGREE OF GLOSS
 Is found using gloss meter 60 and 20 deg are used .60 angle is most commonly used.
ADHESION
 3 Main areas of adhesive failure
1. PRIMER TO SUBSTRATE FAILURE
 Surface contamination problem. Due to lack of adequate surface preparations, grease, oil,
dirt and dust.

2. INTERCOAT ADHESION
 Caused by problems above and others. Lack of observanic of recommended over coating
limits and expansion /contraction differences between materials.

3. COHESIVE FAILURE
 Over thickness of a layer can entrap solvent during the drying process and thus stop
polymerization and the correct formation of the film, reducing cohesive strength. Solvent
entrapment as well as incorrect ratio mix of a two pack can have cohesive failure.
V CUT TEST
 Cut through the paint, to the steel substrate, with two cuts forming an inclusive angle of
approximately 30deg, with leg length of 13mm.Insert the tip of the blade into the tip of
the V and try to lever off. The paint should chip across the tip of the V clearly and
cohesive without following the line if any of the faults described. It should not expose any
of the substrate.

CROSS CUT (CROSS HATCH TEST)

 Using a cross hatchcutter,cut through the paint 6 horizontal and 6 vertical cuts
approximately 2mm spaces giving a 25 squared grid. Apply an agreed tape to the area, rub
smoothly onto the hatched area and then snatch off. The resulting areas of disbandment
are then compared to diagrams. Showing BS 3900 pt EF and classified according to
percentage area of disbondment.

DOLLY TEST
i. Clean and degrease the surface to be tested
ii. Roughen the surface with final medium grade emery cloth.
iii. Mix regular araldite and stick dolly to the surface ,leave for 24 hours at 25deg
iv. Cut paint around the dolly down to the substrate using special cutter.
v. Attach pull off instrument and apply pull off force
vi. Examine the force of the dolly and apportion adhesive failure according to areas
exposed, at the pull off force indicated on the scale.

HYDRAULIC ADHESION TEST EQUIPMENT (HATE)

 Quicker test with a higher degree of accuracy.

COATING CONDITIONS
IT IS NOT PERMISSIBLE TO APPLY PAINTS.
 During rain, Snow or high winds
 When the air or metal temperature is down to within 3deg above the dew point
temperature.
 When the air or metal temp is below 5 deg
 When the relative humidity is more than 90 %
 Manufacturers’ recommendation.

WHIRLING HYGROMETER OR ASPIRATED HYGROMETER OR PSYCHROMETER

 Rotated at 4m/sec or as fast as possible
 Rotated for 30-40 seconds
 Always measure the wet bulb temp first
 Operation should be repaired until two consecutive reading should be within 0.2 dg wet
bulb to wet bulb and dry bulb to dry bulb.
  To measure steel temperature, limpet gauge or digital thermometer or thermocouple (touch
pyrometer) is used.

IMPRESSED CURRENT
 Transformer rectifier (TR) receives high voltage and high amperage and also AC.TR
converts AC into DC and transforms it to a low voltage and amperage
 MONITORING CD
o Half cell reference electrode is copper /copper sulphate half cell electrode.

HOLIDAY /PINHOLE
 9V – BELOW 300micron (DFT )
 67.5v or 90v –Above 300 micron (DFT)
 Sponges is wetted in water with a drop of detergent, excess Squeezed out, and then pass
it over the substrate. On vertical surface it is better to work upwards on contact with a
pinhole the wetting agent (detergent) allows immediate penetration of water so providing a
very low resistance circuit back to the control box. An alarm, a spark and a fluctuation in
the needle of gauge when pinholes or holidays are found.

PAINT APPLICATION
BRUSH
 The quality of the brush depends mainly upon the type of bristle or filling used.
ROLLER
 Mohair, lamb wool and sponge.
AIRLESS SPRAY
 Ratio 35.1, these systems are called airless because air is not used for atomization.

OTHER PAINT APPLICATION METHOD

 Dip coating, padding, and hot spraying, spin rotating, aerosols flow coating, curtain
coating.

GALVANISING
 The components are chemically cleaned (acid), washed and flushed, then totally
immersed in a vessel containing molten zinc at approximately 450deg. When drawn
out, the zinc solidifies at an average thickness of approximately 100 micron.

SHERADISING
 The tumbling of small steel fitting, fasteners etc in a hot zinc dust which leaves a
coating of between 15 micron -30 micron.

CALORISING
 Dipping the component into molten aluminum calorising can also be done by immersing a
component in a mix of fine sand and aluminum powder and heating.

COATING FAULTS
BITTINESS
 The presence of particles of gel flocculated material or foreign matter in a coating
material or projecting from the surface of a film.

BLEEDING
 The action of material in penetrating and discoloring a coating applied on top of it
o Bitumen –brown ,coal tar – yellow

BLISTERING
 The formation of dome shaped projections or blisters in the dry film of a coating
material by local loss of adhesion and lifting of the film from the underlying surface
such blisters may contain liquid ,vapour,gas or crystals.

BLOOM
 A deposit resembling the bloom on a grape that sometimes forms on the floss film of
coating causing loss of gloss and drilling of colours.
CHALKING
 The formation of a chalky or powdery layer on the surface of a film of a coating
material caused by the disintegration of the binding medium due to disruptive factors
during weathering.

CISSING
 The formation of small areas of the wet film of a coating material where the coating
material has recorded leaving holidays in the film, caused by oil or grease ,inadequate
surface preparation . If cissing large, it is known as fisheyes. If fisheyes join
together it is known as crawling.

CRACKING
THE Splitting of the dry film of coating material usually as a result of ageing
 HAIR CRACKING: Cracking that comprises of fine cracks, which may not penetrate
the top coat, they occur erratically and at random.
 CHECKING: Cracking that comprises of fine cracks, which do not penetrate the top
coat and are distributed over the surface giving the semblance of a small pattern.
 CRAZING: Cracking that resembles checking but the cracks are deeper and broader.
 CROCODILE /ALLIGATORING: A drastic type of crazing producing a pattern
resembling the hide of a crocodile or alligator.
 MUD CRACKING: A network of deep cracks that form as the film of a coating
material dries, especially when it has been applied to an absorbent substrate. Mud
cracking is associated with highly pigmented water borne paints.

CRATERING
 The formation of small bowl shaped depression in the film of a coating material.

CURTAINING /SAGGING
 A downward movement of a coat between application and setting that result in an
uneven area of coat having a thick lower edge. The resulting sag is usually restricted
to a local area of a vertical surface and may have the characteristic appearance of a
droped curtain .May be caused by incorrect angle during painting, over application.
1. Remove of fending excess material ,lightly abrade and re coat
2. RUN: A narrow downward movement of a coat that may be caused by the
collection of excess qualities of paint irregularities in the surface.
3. TEAR: A Small run resembling a tear drop.

DRY SPRAY
 The production of a rough or slightly bitty film from sprayed coating materials where
the particles are insufficiently fluid to flow together to form a uniform coat.

FLAKING
 Lifting of the coating materials from the substrate in form of flakes or scales.

FLOCCULATION
 The development of loosely cohesive pigment agglomerates in a coating material.

GRINNING THROUGH
 The showing through of the substrate due to the inadequate hiding power of the
coating material.

HOLIDAYS
 Missed or poorly coated areas of a painted surface due to faulty application
techniques.

LIFTING
 Softening, swelling or separation from the substrate of a dry coat as a result of the
application of a subsequent coat. Caused by strong solvent over weak binder.
ORANGE PEEL
 The uniform pock marked appearance, in particular of a sprayed film, resembling the
peel of an orange due to the failure of the film caused by paint viscosity problems or
application technique.

PINHOLING
 The formation of minute holes in the wet film of a coating material that forms during
application ,due to air or gas bubbles in the wet film which burst giving rise to small
craters that fail to coalses before the film has wet.

RESIDUAL TACK
 The degree of stick ness remaining in the film of a coating material which although
set does not reach the true tack free stage.

SAPONIFICATION
 The formation of a soap by the reaction of a fatty acid ester and an alkali.

WRINKLING /RIVELLING
 The development of wrinkles in the film of a coating material during drying, visually
due to the initial formation of a surface skin.

ROPINESS
 Pronounced brush marks that have not flowed out because of the poor lovelling
properties of the coating material.

Primary colours –red, yellow, and blue

BS 4800 – Schedule of paint colours for building purpose.

HUE – Refers to the basic colours .Varies from 00-neutral to 24 –even number only.
BRIGHTNESS – Refers to the amount of lightness or darkness of the colour.Varies from A (Max white) to E (max
black)
SATURATION – Refers to how vivid colour appears varies from
01 to 56 (higher number –stronger colours) .It is a method by which all manufacturers can make exactly the same
colour .it can be used to identify existing colours when maintenance painting.
EH 40 –Guidance notes, health and safety
MEL – Maximum exposure limit
OEL - Occupational exposure limit
OES - Occupational exposure standard
LEL – Lower exposure limit
UEL - Upper exposure limit
RAQ – Required air quality
COSHH – Control of substance hazardous to health

XYLENE – 100ppm
PA – 10

SPA IE PREFERRED SYSTEMS MIM

 Complaint solved based DFT
 High build epoxy aluminum primer -75
 Epoxy MIO -75
 High build epoxy undercoat – 75
 Epoxy or polyester acrylic finish _-40

Epoxy in chlorinated rubber will cause blistering, lifting etc.

With the use of inorganic zinc silicate, mud cracking of the coating may result if manufacturer s recommended film
thickness is exceeded.
Table spa 3c operation chart for hot duty surfaces operating above 340 deg
Mask, remove surface contamination, blast clean to SA3, max profile 75micron, apply thermally sprayed aluminum
(tsa) alternate to TSA.
Inorganic Zinc Silicate (tZS) appliy sealer (silicone) apply coat to cure sealer.
Polysiloxan inorganic coating does not need sealer.

SPA 4A, CHART FOR PAINTING DAMP METAL SURFACES

Remove all surface contamination, Blat clean to SA21/2.wash to remove grit and dust. Remove droplet and
standing water .Apply system.
Two types of coating available for damp metal surface
 Moisture curing polyurethane
 High solid multi-component epoxy paints

Any oil and grease shall be removed by swabbing with grease removing solvents. The surface shall be washed with 2 %
detergent solution. Then shall be blast cleaned and continued as above.

For stainless steel, aliminium oxide is used as blasting medium.

ETCH PRIMERS
 Primary use s to make etching on galvanizing surface 4% Phosphoric acid tinted with copper
phosphate (blue) . If applied successfully, blue turns black. Leaves 0 microns.
 PVB – POLYVINYL BUTYROL ARE USED FOR Aluminiums.This acid etches the aluminium surface
and leaves a DFT of 15 - 25microns. It also contains Phosphoric acid,