PRACTICAL

WORKSHOP

FROSIO TRAINING BODY

HARVISH TECHNICAL SERVICES
No:5, Vellalar Street, 3 rd Main Road,
Ambattur Industrial Estate,
Chennai-600058, Tamilnadu, India
Mobile: +91-9176618930
Email: [email protected]
FROSIO PRACTICAL EXAMINATION
(PRACTICE MODULE)

STATION-1
 AMBIENT
CONDITIONS Sling Psychrometer:

Using Psychrometer to Measure Ambient Conditions 


The most common (and most economical) method of
measuring
the am bient conditions on a project site is by
using either a sling or battery-powered psychrometer, in
conjunction with the US Weather Bureau Psychometric Tables.
The psychrometer is used to measure the air temperature and
to assess the latent heat loss caused by water evaporation
from a wetted sock on the end of a bulb thermometer. The
psychometric tables are used to look-up the relative humidity
and dew point temperature (based upon temperature readings
from the psychrometer and the barometric pressure). For
now, it is more 
 important that we know how to obtain the
information. We will discuss what the information means later
in the module.
Obtaining Temperature Readings from the
Psychrometer
Sling and the battery-powered psychrometer are each
equipped
with two bulb thermometers. The two
thermometers are identical, except that one has a wick or
sock covering the end of the bulb. This thermometer is called
the wet bulb. The thermometer without the wick is called the
dry bulb thermometer. Follow Steps 1 through 4 below to
obtain the dry bulb and wet bulb temperatures.
Step 1: Verify wick cleanliness
Prior to each use, verify that the wick surrounding the wet
bulb thermometer is relatively clean. If the wick is dirty, the
pores of the wick may be clogged, which can prevent proper
contact of the water with the thermometer bulb.
Wick or sock
Step 2: Saturate the wick
Saturate the wick with clean water, or fill the water reservoir
at the end of the sling
ps y chrom eter . You m ay 
 us e dis tilled
or deionized water, but this is usually not necessary. In fact, it
is more important that the wick remain clean, than it is to use
purified water.

Step 3: Obtain the wet bulb temperature

If you are using a sling psychrometer, whirl the instrument

through the
air ( aw ay from y our body ) fo r approximately 20
or 30 seconds. Be careful not to “whip” the instrument
through the air, but whirl the gage at a moderate speed, such
that
the am bient air pas ses ov er both bulb therm om eters . After 20
or 30 seconds, obtain a reading from only the wet bulb
thermometer.
Remember or write down this temperature. Without re -
wetting the wick, whirl the instrument for another 20 or 30
seconds and obtain another temperature reading from the wet
bulb thermometer. Repeat this process until two consecutive
readings of the wet bulb are within 0.5° of one another.
Record the wet bulb temperature after it stabilizes.
Step 4: Obtain the dry bulb temperature
Independent of whether you are using a sling or battery-
powered psychrometer, the dry bulb temperature is read
directly from the bulb without the wick on the end. This
temperature stabilizes rather quickly, and only needs to be
read one time (after the wet bulb temperature stabilizes).
Steel Thermometer

Dial type surface temperature thermometers contain a

bi-metallic, temperature-sensing spring on the back
of the thermometer that expands and contracts with the
temperature of the surface. Since the spring is attached to the
indicator needle on the front side of the thermometer, the
needle increases and decreases on the temperature scale,
indicating the surface temperature. Magnets attached to the
back of the thermometer enable self-attachment
to vertical steel surfaces, although this thermometer can be
used on almost any surface.

Measuring surface temperature using dial type

thermometers
Step 1: Place the thermometer in the desired location.
Surface temperature can vary considerably and should be
measured in the area where surface preparation and/or
painting work is scheduled to take place. In some cases,
multiple readings are required to assess the range of surface
temperature in a given area.
Step 2: Allow the thermometer to remain undisturbed for at
least 3 minutes before recording the temperature. Lightly tap
the face glass before reading the dial, and make sure to read
the thermometer dial straight on to eliminate a misread due to
parallax.
Dew point Calculator

Dew point Calculator provides accurate values of Dew point

and Relative Humidity (RH) from the wet and dry bulb
temperatures measured by a Whirling or Sling Hygrometer.
Use of the IX diagram

On the left-hand side of the diagram you will find the

horizontal lines for the dry bulb temperature. On the right-
hand side, the lines coming up at a 45° angle are the wet bulb
temperatures.
At the point of intersection between a read dry bulb
temperature and wet bulb temperature, you will find the
relative humidity.
Example:
You have determined the following conditions using the
slinghygrometer: Wet bulb temperature (WBT): 20 °C Dry
bulb temperature (DBT): 24 °C

Determine the relative humidity, RH and the Dew point

temperature (DPT).

The relative humidity can be determined at the intersection

point of the DBT and WBT. Here the DBT= 24 °C and WBT =
20 °C, the intersection point, presents RH= 70 %.

As you already know, when lowering the temperature, the

humidity increases. Since the Dew point temperature is the
temperature where the RH is JOO%, we must try to locate the
temperature where air at (24 °C and 70 %RH) has been
cooled to condensation.

We find this going vertically down from the initial condition

(24 °C and 70 %RH) to the saturation line (100 % RH). Here
the dew point temperature can be read, DPT= 18 °C
IX-diagram

°
IX-Diagram
Temp.. S°C- +70 C. Fuktig luft av 101 kPa. Moist air at 760 mm Hg.
kg, moistu re cont ent lbs/lb O 020 0,025
n·,n nehill kg/
Vatte 0 o,91� • I
Ii I I I IJ
I
g9-, I I ,O,� I
0,01

u.. ,...
0
' " I ' '

I ,,

''
,;,

' ,,.
'

....
0 I'- I ,.... '
8 ..,. r,. ,_.
' ' /

0
Q)
STATION - 2
INSPECTION OF THE SUBSTRATES
ISO Surface Cleanliness

Standards ISO standard 8501-1:

 Two degrees of Hand & Power Tool Cleaning (St 2 & 3)


 Four degrees of Abrasive blasting Cleaning (Sa1,
Sa2, Sa2.5 & Sa3)

 One degree of Flame cleaning (F1)

Assessing Surface Cleanliness

Grade A: Steel surface largely covered with adhering mill
scale but little, if any rust
Grade B: Steel surface, which has begun to rust, and from
which the mill scale has begun to flake
Grade C: Steel surface on which the mill scale has rusted
away or from which it can be scraped, but with slight
pitting visible under normal vision.
Grade D: Steel surface on which the mill scale has rusted
away and on which general pitting is visible under
normal vision
Standard notation usually, but not always, includes the
original condition of steel before blasting i.e. “B Sa3”. Pictorial
standards of cleanliness (Sa1, Sa2, Sa2.5 and Sa3) are
depicted overleaf.

ISO 8501-1

Select “BEFORE” photo of Initial surface condition

- A, B, C, D
-
Determine level of Cleanliness required by specification
- St2, St3, Sa1, Sa2, Sa2 ½, Sa3
-
Select “AFTER” photo
-e.g. B Sa2

ISO St2: Thorough Hand and Power Tool Cleaning

“When viewed without magnification, the surface shall be free

from visible oil, grease and dirt, and poorly adhering mill
scale, rust, paint coatings and foreign matter.”

ISO St2: Very Thorough Hand and Power Tool Cleaning

“(Same) as for St2, but the surface shall be treated much

more thoroughly to give a metallic sheen arising from the
metallic substrate.”

Assessing Surface Cleanliness

 ISO Sa 2 ½

 The Images in ISO guides rarely “match”

 actual conditions.
 Establish a project specific surface
cleanliness standard/test section
 Use ISO 8501-1 visual guides to “calibrate” the eye

 Preserve with clear sealer or photograph
Blast-cleaning to Sa Standards
Blast cleaning to ISO 8501-1 Sa standards is a commonly
used specification with pictorial and written guidelines as
follows:

Sa 1 Sa2

Sa2.5 Sa3
STATION - 3
ISO Visual Comparators

 Grit or Shot prepared surfaces

 Used with 5-10X magnifier
  Surface roughness “graded” as
 Fine
 Medium
 Coarse

Grit comparator


ISO Comparator G

Comparator with surface profiles corresponding to (or simulating)
surfaces obtained by abrasive blast- cleaning with metallic or mineral
grit
Shot comparator


ISO Comparator S

Comparator with surface profiles corresponding to (or
simulating) surfaces obtained by abrasive blast- cleaning with
metallic shot
Using 8503-1 for determining roughness
The comparator is placed onto the surface of the blast-cleaned
steel. The surface profile is seen through the center of the
comparator and in turn compared with the segments of the
comparator. In accordance with ISO 8503-1 the roughness is
characterized as fine, medium or coarse. If you find it difficult
to make the comparison, a 7 X magnifying glass can be used.
Avoid using the fingertip for control, as it may leave traces of
grease and salts on the surface.
The ISO comparators are widely used. But also other methods
for checking the roughness are available.
Table 1 — Nominal values and tolerances for the surface profiles of
the segments of ISO surface profile comparators

ISO comparators for steel, blast-cleaned with

grit abrasives

a
Segment Nominal reading μm Tolerance μm
1 25 3

2 60 10

3 100 15

4 150 20

ISO comparators for steel, blast-cleaned with shot

abrasives

a
Segment Nominal reading μm Tolerance μm
1 25 3

2 40 5

3 70 10

4 100 15

Where using the microscope method (see ISO 8503-3),

the nominal reading refers to hy. Where using the stylus
method (see ISO 8503-4), the nominal reading refers to
Ry5.

Each ISO comparator shall be accompanied by a calibration certificate stating the

method for determining the surface profile, the estimated tolerance and the
calibrated surface profile, in micrometers, of each segment.

Table-2 - Limits of Profile Grades

ISO comparators for steel, blast-cleaned
with grit abrasives
Profiles equal to segment 1 and up to
Fine (G)
but excluding segment 2

Medium (G) Profiles equal to segment 2 and up to

but excluding segment 3
Coarse (G) Profiles equal to segment 3 and up to
but excluding segment 4
ISO comparators for steel, blast-cleaned
with shot abrasives
Profiles equal to segment 1 and up to
Fine (S)
but excluding segment 2

Medium (S) Profiles equal to segment 2 and up to

but excluding segment 3
Coarse (S) Profiles equal to segment 3 and up to
but excluding segment 4
STATION - 4
 PAINT INSPECTION GAUGE (PIG GAUGE)
MICROSCOPE WITH SCALE

MEASURING FILM THICKNESS

1. Mark the surface to be tested with a stroke of the black
marker pen provided with your gauge. Note that there
should always be a distinct contrast between the colour
of the pen ink and the coating; different pen ink colours
may therefore be required for dark coatings.
2. Fit/select the appropriate cutting tool
3. Cut the coating at right-angles to the pen mark as
follows: 

Place the gauge on the specimen with both guidance
wheels in contact with the surface of the specimen (this
ensures that the knife blade produces an exact vertical
cut with no tilting to one side).

Pull the gauge towards you and apply a little pressure.

Slight pressure is normally sufficient to penetrate
through to the substrate. Heavier pressure may be
required for very thick coatings and very hard surfaces.

4. Position the gauge vertically so that the microscope

 lens is over the cut.
5. Press and hold the light switch to illuminate the cut.
6. Look through the microscope lens and rotate the focus
adjuster until the cut is visible clearly.
7. Rotate the graticule scale until it is at right angles to
the cut and the scale divisions are parallel to the cut.
Note that one side of the cut will have a straight edge
and the other side is likely to be ragged.
8. Measure the width of the cut coating (or coatings) by
counting the number of graticule divisions. To convert
the width of the cut coating into coating thickness,
either:
Multiply the number of graticule divisions by the graticule
scale factor shown in Table 1.
Table 1: Graticule Scale Factor
Practical Maximum thickness Graticule scale factor
Cutting Cutting
Inch scale
Tool# (μm) (Mils) angle Mm scale (μm)
(mils)
1 1600 64 45° 20 1
4 800 32 26.6° 10 0.5
6 160 6.4 5.7° 2 0.1

a. Based on using 80% of cutter width


In the example shown overleaf, the coating thickness using cutting tool #4 is:

42 divisions x 10μm per division = 420μm or;


33 divisions x 0.5mils per division = 16.5mils


Or alternatively, calculate the coating thickness using the Table 2,

“Additions Table,” on page 9.

In the example shown, the coating thickness using cutting tool #4 is:


42 divisions= 40 divisions; 400μm plus 2 divisions 20μm = 420μm


33 divisions = 30 divisions; 15mils plus 3 divisions; 1.5mils = 16.5mils

STATION - 5
 DETERMINATION OF WATER
SOLUBLE SALTS

  Specific Ion (Salt-specific)

 Chloride
 Sulfate
 Ferrous Ion
 Conductivity (non salt-specific)
  ISO 8502-9
 Specification may prescribe methods of
sample retrieval and analysis.

 Retrieval methods include:
 Swabbing
 Latex patches
 Latex sleeves

 Methods of analysis include:
 Chloride strips and tubes
 Drop titration for chloride
 Ferrous ion strips
  Conductivity meter (non ion-specific)
 Turbidity meter (sulfate)

Latex Patch/Cell Sample Retrieval Steps

Adhesive patch, the body of which is made of ageing-
resistant, flexible material with closed pores, e.g. polyethylene
foam, and with a hole punched in the center. The punched-out
material is kept in the hole as reinforcement until the patch is
used. One side of the patch is coated with a thin elastomer
film. The other side is coated with adhesive and covered by a
removable protective sheet made of paper.
NOTE: The hole and the outer edge of the patch may be any
shape, e.g. circular, rectangular, elliptical, etc.
The thickness of the patch shall be 1,5 mm ± 0,3 mm. The
width of the adhesive rim between the hole and the outer
edge of the patch shall be at least 5 mm.
Reusable syringe:
max. cylinder volume: 8 ml

max. needle diameter: 1 mm
max. needle length: 50 mm

Solvent, chosen as a function of the surface contaminants to

be determined. For the determination of water-soluble salts or
other water-soluble contaminants, use distilled or deionized
water.

Procedure for Salt Extraction (ISO 8502-6)

1. Take an adhesive patch of a suitable size. Remove the
protective paper and the punched-out material.
2. Press the adhesive side of the patch against the test
surface in such a way that the minimum amount of air is
trapped in the compartment in the patch.
3. Fill the syringe with solvent.

4. Insert the syringe needle at an angle of about 30° to the
 test surface near the outer edge of the patch, so that it
passes through the adhesive foam body of the patch into
the compartment formed between the elastomer film and
the test surface.
If the patch is in a position, which makes access to the
patch compartment difficult, bend the syringe needle as
required.
5. Inject the solvent, ensuring that it wets the whole of the
test surface. If necessary to avoid air remaining trapped
in the patch compartment, carry out the injection in two
steps as follows:
Inject half of the solvent. Evacuate the air through the
needle by reverse operation of the syringe. Remove the
needle from the patch. Holding the syringe with the
needle pointing upwards, expel the air. Re-insert the
needle into the compartment and inject the remainder of
the solvent.
6. After a suitable period of time, to be agreed between the
interested parties, suck the solvent back into the syringe.
During this period of time, without removing the syringe
needle from the patch, re-inject the solvent into the
compartment and then suck the solvent back into the
syringe cylinder at least four times.

NOTE On unpitted blast- cleaned areas, a period of 10 min

has been found satisfactory, as by then more than 90 % of
the soluble salts have usually been dissolved.
7. Transfer the solvent to a suitable vessel for analysis.
8. During steps 3 to 7, it is essential that no solvent be lost
from the patch or syringe, due for instance to inferior-
quality materials or improper handling of the materials. If
any solvent is lost, the solution obtained shall be rejected.
9. On completion of step 7, clean and rinse the syringe so
that it can be re-used. A bent needle is best left as it is
 until it becomes necessary to straighten it or bend it
further.
Test report
The test report shall contain at least the following information:
a) A reference to this part of ISO 8502 (i.e. ISO 8502-6); 

b) The solvent used; 

c) The volume of solvent injected; 

d) The total time of contact between the solvent and
substrate, i.e. the time agreed in 6 multiplied by the total
number of cycles carried out; 

e) The temperature during steps 3 to 7 of the procedure; 

f) The manufacturer's batch number of the patch used; 

g) The date of the test. 


Procedure for Salt Analysis (ISO 8502-9)

Preparation of water and blank test

Pour into the beaker an amount of water that is just large
enough for the operation of the conductometer. Usually a
volume between 10 ml and 20 ml is needed. To prevent
foreign matter inside the beaker and syringe, and on the
conductometer probe, from influencing the result, carry out
the following blank test.
Completely fill the syringe with water from the beaker. Then
empty the syringe back into the beaker.
Immerse the electrodes of the conductometer fully in the
water in the beaker and agitate gently. Record the
conductivity (γ1) and the units in which it is expressed, for
example μS/cm.
Removal of salts from the steel surface. Follow the procedure
specified in clause 5 of ISO 8502 -6:1995, subject to the
following specific requirements. Fill the syringe with about
one-quarter of the water contained in the beaker. 
 After 1
min, suck the water back into the syringe cylinder (see 5.6 of
ISO 8502-6:1995).
Without removing the syringe needle from the patch, re-inject
the water into the patch compartment and then suck the
water back into the syringe cylinder. Repeat until 10 cycles of
injection and sucking have been completed (see 5.7 of ISO
8502-6:1995).
At the end of the 10th cycle, retrieve as much as possible of
the water from the patch compartment and transfer to the
beaker, thus restoring its content to nearly the original volume
in (see 5.8 of 8502-6:1995).
Conductometric measurement
Immerse the electrodes of the conductometer fully in the now
contaminated water in the beaker, and record the conductivity
(γ2) expressed in the same units as μS/cm.
Expression of results

The total surface density ρA of the salts is given by the

equation:

ρA = m
A
Where
m is the mass of salts dissolved from that part of the
surface, which is covered by the patch compartment
A is the area of that part of the
surface. In this case, m is given by

m = c. V. γ
Where

–
c is an empirical constant approximately equal to 5 kgm
2 –1
S 

V is the original volume of water in the beaker

γis the change in conductivity, i.e. the difference between

the conductivity measured in (Υ2) and the conductivity
measured in (Υ1).
STATION - 6
 DETERMINATION OF DFT

Type 2 - Electronic Gages

“Electronic circuitry converts reference signal to

coating thickness”

Calibration & Verification of Accuracy

 Calibration
 Verification of Accuracy
 Adjustment

Steps are required to be completed before coating thickness

data acquisition to determine conformance to a specification

Gage Calibration

 Performed by the gage manufacture or

 qualified laboratory
 Certificate of calibration traceable to a National
Metrology Institute required
  No standard calibration interval (established based
 on experience & work environment)
 One year interval is common

Verification of Type 2 Gage Accuracy

 Verify accuracy per manufacturer instructions

 (use Traceable Standards)
 Verification can be done “beginning and end of each
 work shift (minimum)”
 During (e.g., hourly), if:
 Obtaining a large no. Of readings
 Gage is dropped or readings are suspect

 Record
• Serial no. of gage and standard
• Stated & measured thickness

  Single Point Verification

 Select one reference test block representing the
 mid-range of the anticipated coating thickness
 E.g., 4-6mils (100-150 microns), select 5 mil (125
microns) reference standard

  Two Point Verification
 Select a reference test block below and above the
 median anticipated coating thickness
 E.g. 5 mils (125 microns), select 3 mils (75microns) and
7 mil (175microns) reference standards

Adjustment of Type 2 Gages

 Aligning a gage’s thickness readings to those of a

known thickness value to improve gage accuracy on a
specific surface or within a measuring range
  Corrects for
 Surface roughness
 Substrate Properties
 Curvature
 Etc.,

 Follow the gage manufacturers step-by-step procedure
 for gage adjustments
 Instructions vary by gage manufacturer
 Adjustment is typically performed using plastic
shims (foils) of known thickness

Verification in accordance with ISO 19840

Table 1 — Sampling plan

Area/length of inspection Maximum number of

Minimum
area measurements allowed to be
number of
repeated
 (see 6.3 as per ISO
measurements
2
m or m 19840)
up to 1 5 1

above 1 to 3 10 2

above 3 to 10 15 3

above 10 to 30 20 4

above 30 to 100 30 6

add 10 for every

a 2 20 % of the minimum number of
above 100 additional 100 m
or 100 m or part measurements
thereof

a 2
Areas above 1 000 m or m should be divided into smaller inspection areas.
Adjustment of the instrument
Before use, it shall be ascertained that the instrument is in
good working condition and correctly adjusted. Verification
shall then be carried out on uncoated test plates at zero and
with verified foils/shims above and below the specified dry-
film thickness. Pre-coated test plates may be used instead of
verified foils/shims.
If the result of the verification is outside the range given by
the manufacturer, the instrument shall not be used.
NOTE: the user in most cases carries out Adjustment.
Calibration, on the other hand, is the process of setting and
recording the thickness values displayed on a dry-film
thickness gauge to known values of thickness across the
range of the gauge. The gauge manufacturer using traceable
thickness standards in most cases carries out calibration.
6.3 Measurement
Measurements on the dry film shall only be taken after
instrument accuracy has been checked in accordance with.
The measurement instrument shall then be used in
accordance with the instrument manufacturer’s instructions.
Following completion of a series of measurements, and
preferably during the measurements, the adjustment of the
instrument shall be re-verified. If this is not in accordance
with, the results of the measurements shall be rejected.
When, during a series of measurements, an individual dry-film
thickness value does not meet a criterion and, a repeated
measurement not more than 10 mm from the point of the first
measurement shall be carried out. The first value shall then be
rejected and replaced by the result of the repeated
measurement. This new measurement will then be the
individual dry-film thickness. If this individual dry-film
thickness does not meet the criterion, it shall not be replaced.
For maximum numbers of repeated measurements within an
inspection area see Table 1. The number of replaced
measurements shall be indicated in the test report.
The sampling plan shall be completed even if values do not
meet the criteria, unless otherwise agreed.

Correction values

If the surface profile is known and conforms to ISO 8503-1,

correction values given in Table 2 shall be used.
Table 2 — Correction values

Surface profile Correction

in accordance value
with ISO 8503-
1 μm

Fine 10

Medium 25
Coarse 40

The specification/contract might require the determination of a

specific correction value that is a correction value determined
on the abrasive blast-cleaned or otherwise roughened
substrate with the particular dry-film thickness instrument
being used. In this case, the correction value shall be
determined in accordance with Annex D.
If the surface profile is not known and an uncoated sample is
not available, a correction value of 25 μm shall be used.
If a sample showing the surface profile is available and the
profile is not in accordance with ISO 8503-1, the correction
value shall be determined in accordance with Annex D.
If a correction value is used, it shall be subtracted from the
individual reading to give the individual dry-film thickness in
micrometers.
NOTE 1: The correction value is applied once to every
reading, no matter if the coating consists of a single layer or
multiple layers (see illustration in Figure 1).
NOTE 2: For deviating surface profiles or in the case of
particular agreements between the interested parties, a
method for determining the correction value to be used is
given in Annex D.
Annex D
(normative)
Determination of a specific correction value

When a specific correction value is to be determined, proceed as

follows:
Adjust the instrument in accordance with the manufacturer’s
instructions. Check the adjustment for intermediate values following
the manufacturer’s specification.
Use the adjusted instrument on the blast-cleaned or otherwise
roughened surface to check a measured foil/shim of approximately 125
μm thickness (but not less than 115 μm or greater than 160 μm).
Using the foil/shim, take 10 measurements at different points on the
blast-cleaned or otherwise roughened surface and determine the
arithmetic mean value. From the mean value, subtract the known value
of the foil thickness. The value obtained is the correction value.

Acceptance/rejection criteria
For the acceptance of an inspection area, the following criteria
shall be fulfilled:
 a) The arithmetic mean of all the individual dry-film
thicknesses shall be equal to or greater than the nominal
dry-film thickness (NDFT); 

b) All individual dry-film thicknesses shall be equal to or
above 80 % of the NDFT; 

c) Individual dry-film thicknesses between 80 % of the
NDFT and the NDFT are acceptable provided that the
number of these measurements is less than 20 % of the
total number of individual measurements taken; 

d) All individual dry-film thicknesses shall be less than or
equal to the specified maximum dry-film thickness. If it is
not specified, see ISO 12944-5. 

NOTE: for verifying dry-film thicknesses as given in ISO
12944-5, acceptance criteria are given therein.
The criteria defined above include all measurement
uncertainties (for example instrument accuracy, operator
skill), provided that the requirements of this International
Standard have been met.
If the acceptance criteria above are not met, the inspection
area shall be rejected (see also ISO 12944 series).
 TEST REPORT
A BASIC INFORMATION (test is carried out in accordance with ISO 19840:2012)

A1 Name of project:
A2 Name of owner:
A3 Location of project/structure:
A4 Paint manufacturer(s):
A5 Corrosion protection work carried out by:
2
A6 Structure: Area: ....... m Estimated: D
Known: D
2
A7 Constituent element: Area: ....... m Estimated: D
Known: D
2
A8 Inspection area (if not A6 or A7): Area: ....... m Estimated: D
Known: D
A9
Drawing No.: Position No(s):
A10
Sketch for identification of inspection area:

B PROTECTIVE PAINT SYSTEM

B1 Surface preparation, relevant part of ISO 8501:

B2 Surface profile (roughness), ISO 8503-1:

B3 Substrate (e.g. steel, hot-dip-galvanized):

B4 Prefabrication primer: Nominal (specified) dry-film thickness: .... µm

B5 Priming coat: Nominal (specified) dry-film thickness: .... µm
Nominal (specified) dry-film thickness: .... µm
B6 Intermediate coat: Nominal (specified) dry-film thickness: .... µm
Nominal (specified) dry-film thickness: .... µm
B7
Top coat: Nominal (specified) dry-film thickness: .... µm
Nominal (specified) dry-film thickness: .... µm

C Measurement/adjustment

C1 Principle of measurement instrument:

C2 Measurement instrument: Serial No.:

Range of probe:

Calibration date:

C3 Date of measurement:

C4 Adjustment: Smooth surface D

Rough surface D
This report consists of pages No. .... to .... .
D Acceptance/rejection criteria:

Measurement 1st coat 2nd coat 3rd coat 4th coat

µm
NDFT (individual coat)
Cumulative NDFT
80% of the cumulative NDFT
Maximum cumulative dry-film thickness

E Results
Project:
Corresponding drawing No:
Number of measurements to be taken in accordance with ISO 19840:2012, Clause 6:
1 2 3 4 5
Measurement No. Individual reading Correction value used Resulting individual Individual dry-film
(see Table 2 of dry-film thickness thicknesses outside of
ISO 19840:2012) Column 2 minus column 3 the specification
µm
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
..
Arithmetic mean

Number of measurements:

Number of measurements between NDFT and 80 % NDFT:

Percentage of those measurements compared with the total number of
measurements:

Number of measurements less than 80 % NDFT:

Number of repeated measurements:
Ambient temperature during the measurements (°C):
Surface temperature during the measurements (°C):

Remarks:

Work conforms to the requirements? yes/no

Name(s) of the inspector(s):

Place and date: Signature(s):

STATION - 7
HIGH VOLTAGE SPARK TESTING (ASTM D 5162)
ASTM D5162, “Practice for Discontinuity (Holiday)
Testing of Nonconductive Protective Coating on Metallic
Substrates”

PINHOLE & HOLIDAYS

 Holidays/Discontinuity – skips or misses in the
 coating/lining system
 Pinholes – tiny voids in the coating or lining that
penetrate to the substrate

Caused by:
 Areas missed by the applicator (holidays)
 Outgassing of the coating; poor wetting of the
 coating/lining on the surface during application (pinholes)
 Typically found on difficult access areas/non-uniform
surfaces (behind angles, corners, welds, bolt threads,
inside holes, between back-to-back angles, etc.)
When Holiday detection is performed?

 After final coat has been applied and after fully cured (i.e.
 6 to 8 days (refer PDS).
 Specifications may require holiday testing after the
 application of each coat
 Cannot use wetting agent in water for “between coat”
 pinhole detection
 Cannot perform pinhole detection on a coating already in
 service
 Coating must be nonconductive
 Substrate must be conductive
 High voltage (spark) testing requires voltage setting
100 to 125 volts/mil (per 25 µm)
Obtain recommended test voltage from coating
manufacturer ASTM D5162 provides voltage chart & formula

PROCEDURE
1. Attach ground cable to detector unit
2. Attach electrode cable to detector
3. Select test voltage
4. Verify accuracy of test voltage setting using a peak
reading voltmeter
5. Attach ground wire to bare substrate
6. Power-up detector
7. Test surfaces (move wand 30 cm [1 foot]/ second)
8. Mark holidays with chalk or other marker that is
removable
9. Only re-inspect repaired areas

DOCUMENTING HOLIDAY DETECTION

 Type of inspection (low or high voltage)
 Manufacturer, model No. and serial No. of detector
 If high voltage, the test voltage used and the method
used to verify test voltage
 Area of structure inspected
 Location of holidays/pinholes

 Methods used to repair coating/lining
 Results of retesting (if performed)
STATION - 8
LOW VOLTAGE WET SPONGE HOLIDAY TESTING
PROCEDURE
1. Attach ground wire to detector unit
2. Attach sponge wand wire to detector
3. Attach ground wire to bare substrate
4. Saturate sponge with tap water. May use wetting agent
in water if coating thickness is 250-500 µm (10-20 mils)
5. Power-up detector
6. Verify unit is operational (correct sensitivity)
7. Test surfaces (move wand 30 cm [1 foot]/ second)
8. Mark pinholes with chalk or other marker that
is removable

DOCUMENTING HOLIDAY DETECTION

 Type of inspection (low or high voltage)
 Manufacturer, model No. and serial No. of detector
 If high voltage, the test voltage used and the method
 used to verify test voltage
 Area of structure inspected
 Location of holidays/pinholes
 Methods used to repair coating/lining
 Results of retesting (if performed)
STATION - 9
ASSESSMENT OF PULL-OFF TEST
 Adhesion Break: A break between coating layers or
 between the substrate and first coating layer
 Cohesion Break: A break within a single coating layer

 Glue Break: Coating adhesion and/or cohesion strength
exceeds bonding strength of the adhesive

 If multiple locations of break occur, estimate the % of
 each
 E.g., 75% cohesion within primer; 25% adhesion between
primer and intermediate coats
STATION - 10
ADHESION TESTING BY THE CROSS CUT
METHOD (ISO 2409)

SELECTING THE CORRECT CUTTER BLADE

The cutter blade is selected based on the substrate type,
coating thickness and the test method being used, see table
below.

Coating
Test Method
Thickness
ISO ISO
Microns
(Hard Substrates) (Soft Substrates)
0-60 6 x 1mm 6 x 2mm
61-120 6 x 2mm 6 x 2mm
121-150 6 x 3mm 6 x 3mm

The crosscut test is not suitable for coatings of total

thicknesses greater than 250 μm.
NOTE: For coatings of total thickness greater than 250 μm,
the X-cut method described in ISO 16276-2 can be used.
TEST PROCEDURE: ISO 2409 (Cross Cut)
 Place the cutting edge on the sample. 


 Press down gently and pull the 
 adhesion tester towards
you in one steady movement to make a series of parallel
cuts approximately 20mm long. Apply sufficient pressure
to ensure you cut right through the 
 coating to the
surface of the substrate.

• If the substrate is wood or similar, make cuts at a 45°
angle to the direction of the grain.

1
2 3

 Place the cutting edge on the sample at a 90° angle to

the first cut and repeat Step 2 to create a lattice pattern
on the coating. 

 Brush the sample lightly several times, forward and
backwards along the diagonals of the lattice, to remove
debris.
  Inspect the sample to ensure that the cuts have
penetrated all the way through the coating.

 Remove and discard two complete turns of adhesive tape.
Remove an additional length of tape at a steady rate and
cut apiece approximately 75mm from this length. 


 Centre the cut piece of tape over the lattice and smooth
into place using a finger. Rub the tape firmly using a
finger nails or finger tip to ensure good adhesion between
the tape and the coating. 


 Within 5 minutes of applying the tape, remove the tape
by pulling in a single smooth action taking approximately
0.5 to 1 seconds at an angle of 60° to the surface. 


 To maintain a permanent record of the test, retain the
tape by applying it to a transparent film. 


 Assess the coating adhesion by viewing the lattice of cuts
in good light. If agreed, use an eyeglass to aid viewing.
Compare the lattice of cuts with the ISO 2409 standards
table shown in Section 5 ‘Assessing the results.
Test report
The test report shall contain at least the following information:
 All details necessary to identify the product tested;
 A reference to this International Standard (ISO
 2409:2013);
 Details of the preparation of the test panels, including:
• The material, the thickness and the surface preparation of
the substrate 

• The method of application of the coating material to the
substrate, including the duration and conditions of drying
between coats in the case of a multi-coat system 

• The duration and conditions of drying (or stoving) and
ageing (if applicable) of the coating before testing. 

• The thickness, in micrometers, of the dry coating and the
method of measurement used in ISO 2808, and whether
it is a single coating or a multi-coat system.

 The temperature and relative humidity during the test, if
different from those specified. 

 The type of cutting tool used and the method of operation
(manual or motor-driven); 

 Details of the method used to remove loose paint
 The results of the test

 Any deviations from the procedure specified; 

 Any unusual features (anomalies) observed during the
test; 

 The date of the test. 

Table 1 — Classification of test results

Appearance of surface of cross-

cut area from which flaking has
a
Classification Description occurred
(Example for six parallel cuts)

0 The edges of the cuts are

completely smooth; none of the
squares of the lattice is detached

Detachment of small flakes of the

1 coating at the inter- sections of the
cuts. A crosscut area not greater
than 5 % is affected.
The coating has flaked along the
2 edges and/or at the intersections of
the cuts. A crosscut area greater
than 5 %, but not greater than 15
%, is affected.
The coating has flaked along the
edges of the cuts partly or wholly in
3 large ribbons, and/or it has flaked
partly or wholly on different parts
of the squares.
A crosscut area greater than 15 %,
but not greater than 35 %, is
affected.
The coating has flaked along the
4 edges of the cuts in large ribbons
and/or some squares have
detached partly or wholly. A
crosscut area greater than 35 %,
but not greater than 65 %, is
affected.
Any degree of flaking that cannot
5 even be classified by classification —
4.
aThe figures are examples for a crosscut within each step of the
classification. The percentages stated are based on the visual
impression given by the pictures and the same percentages will
not necessarily be reproduced with digital imaging.
STATION - 11
 MEASURING MEK RESISTANCE OF ETHYLE SILICATE
(INORGANIC)

Reagents and Materials

• Methyl Ethyl Ketone (MEK), in accordance with
Specification D 740.
• Cheesecloth, 100 % cotton mesh size grade 28 by 24
approximately 300- by 300-mm (12- by 12-in.) and
contrasting in color to the coating being evaluated, or
other mutually agreed upon cloth.
• Squeeze Bottle.
• Proper Safety Equipment, as determined from the solvent
MSDS, for example, solvent resistant gloves, respirator.
Procedure
 Select areas on the primer surface at least 150mm (6in.)
long on which to run the tests. Clean the surface with tap
 water or dry cloth to remove loose material.
NOTE 1—Tap water may influence the cure of the zinc-
rich primer.

 Measure the dry film thickness of the primer in the
selected areas in accordance with Test Methods D1186, D
1400 or D 4138. Mark a 150- by 25-mm (6- by 1-in.)
rectangular test area on the undamaged cleaned surface
 using a pencil or other suitable solvent resistant marker.
 Fold the cheesecloth into a pad of double thickness and
saturate it to a dipping wet condition with the methyl
ethyl ketone. Do not allow more than 10 s to elapse
before proceeding to the next steps.
  Place the properly protected index finger into the center
of the pad while holding excess cloth with the thumb and
remaining fingers of the same hand. With the index finger
at a 45° angle to the test surface, rub the rectangular test
area with moderate pressure first away from the operator
and then back towards the operator. Complete each
 double rub (one forward and back motion) in about 1 s.
 Continue rubbing the surface with the MEK saturated pad,
wetting the pad as necessary without lifting it from the
surface, until either the metal substrate is exposed or 50
double rubs have been completed. If the former, record
 the number of rubs when the substrate is exposed.
 Select an adjacent area to be used as a control. Repeat,
except use dry cheesecloth to establish the effect of
burnishing without the influence of MEK. Use this area as
 the control to visually show the appearance of No Effect.
 Inspect the test areas and the cheesecloths. Rate the
results in accordance with below Table 1.
TABLE -1 Scale for Resistance Rating
Resistance
Description
rating

5 No effect on surface; no zinc on cloth after 50 double rubs

4 Burnished appearance in rubbed areas; slight amount on

zinc on cloth after 50 double rubs

3 Some marring and apparent depression of the film after 50

double rubs

2 Heavy marring; obvious depression in the film after 50

double rubs

1 Heavy depression in the film but no actual penetration to the

substrate after 50 double rubs
0 Penetration to the substrate in 50 double rubs or less
STATION - 12
DETERMINATION OF MAIN GROUPS OF

PAINT Groups of Paint

 Acrylic
 Epoxy
 Polyurethane
 Silicate
 Silicone
 Chlorinated rubber

Solvent Test

• Can be used to identify drying mechanism of unknown

old coating
• Expose the old coating to MEK solvent
• Place paper towel / cloth / rags soaked in the thinner
on the coating to be tested
• Observe how the coating react

Solvent test: Three samples

Solvent test: Three samples

Use paper towel to keep the solvent in contact with the sample

Solvent test: Three samples

Paper-towels wetted by MEK

Solvent Test: Acrylic (physically drying)

Paint sample is dissolved

Solvent Test: Alkyd (oxydatively curing)

Alkyd film “lifting”

 Lifting and loss of
adhesion,
solvent act as
paint remover.
Disregard blue
smear from paper
towel

Solvent Test: Epoxy (chemically curing)

No change in paint sample

Paint / Coating Failures

Paint Flakes
Description:

Paint flaking is a form of adhesion failure where paint literally

flakes from the substrate. A familiar sight on wood substrates and
on galvanizing.
Probable Causes:

Incorrect paint system used. Either none or incorrect pre-

treatment used for certain substrate. i.e. non-ferrous or
galvanized. Also poor application techniques. May also be
attributed to differential expansion and contraction of paint and
substrate e.g. wood. Can be the result of ageing of the paint
system.
Prevention & repair:

Always use correct coating system and pre-treatment. Remove all

flaking coating until a firm edge can be achieved. Abrade, sweep
blast and clean overall and apply suitable coating system to
coating manufacturer’s recommendations.
Delamination (also called adhesion failure and Flaking)
Description:

Loss of adhesion between coats of paint.

Probable causes:

Provided compatible paint materials have been used,

delamination defects are generally related to poor surface
preparation and application defects/such as contamination
between coats; exceeding overcoat times; application to a
glossy surface.

Prevention & repair

Ensure no contamination between paint coats, closely follow

intercoat times, light abrade and clean glossy surfaces
between coats.
Depending on extent, abrade and recoat or completely remove
the delaminated coating and reapply.

ADHESION FAILURE (also called delamination

and flaking)
Description:

Paint fails to adhere to substrate or underlying coats of paint

Probable causes:

Surface contamination or condensation

Prevention & Repair:

Ensure that the surface is clean, dry and free from any
contamination and that the surface has been suitably
prepared. Use the correct coating specification.

Depends upon the extent of adhesion failure. Removal of

defective areas will be necessary prior to adequate
preparation and application of correct coating system to
manufacturer’s recommendations.
STATION - 13
INSPECTION OF PAINTED SURFACES

“COATING DEFECTS”
PHOTOGRAPHS
Sagging
Sags are the downward movement of a coat of paint which appear soon
after application and before setting, which results in an uneven area with
a thick lower edge. They are usually apparent on local areas of a vertical
surface and in severe situations may be described as curtains.

Sags/ Curtains/runs
DRY SPRAY

FISH EYES
HOLIDAYS

ORANGE PEEL
PINHOLES

POPPING
WRINKLE / LIFTING

SOLVENT ATTACK/LIFTING (ALSO CALLED WRINKLING)

AMINE SWEATING / BLUSHING / CARBONATION

Blooming & Blushing

OSMOTIC BLISTERING

BLISTERING
PIN POINT RUSTING

CRACKING
DELAMINATION

CHALKING
BLEEDING

VACUOLES
RUST SPOTTING

MUD CRACKING
CRATERING

ADHESION FAILURE (FLAKING, DELAMINATIO

SAPONIFICATION

CHECKING
POOR SPRAY APPLICATION

INCOMPATIBLE COATING SYSTEMS OR

INCORRECT COATING SYSTEM

STATION - 14
 “CORROSION”
PHOTOGRAPHS

GENERAL CORROSION

GALVANIC CORROSION
CREVICE CORROISON ON FLANGE

Cavitation
EROSION CORROSION

Stress corroison
MICROBIOLOGICAL CORROSION
STATION - 15
 Painting Project Daily Data Log Book
Coatings: Inspection
Coating Inspector and Applicator - Verify Ambient Conditions:
• Measure & record the Surface Temperature of the substrate (object
• painted)
• Measure and record the Air Temperature within 2 ft of the part
• Measure and record the Relative Humidity within 2 ft of the part
• Measure and record the Dew Point Temperature within 2 ft of the part
• The Surface Temperature of the part must be 5º F ≥ greater than the Dew
• point Temperature or no painting can be performed.
• Shelf life Expiration Date: One year for most Epoxies (Check with Mfg.)
• Record the date, time, joint number, location, Etc. for the data book to
• protect all parties,

Coatings: Mixing, Thinning, Application

Coating Inspector and Applicator - Verify Coating Material Inventory:

• Condition of containers/storage: Damage?
• Storage: Are the coatings materials protected from the environment, are
• temps within Mfg. guidelines
• Number of components: 2 Part / 2 to 1 Ratio
• *Record Manufacturer, product no., color
• *Record Batch/Lot No.
• Shelf life Expiration Date: One year for most Epoxies
• Record this information for the data book to protect all parties

Coatings: Inspection: Final Visual

Inspection Critical last steps
• Perform visual and holiday inspection simultaneously if possible with
• applicator.
• Make all repairs in accordance with Specification
• No paint stick repairs.
• Two part epoxies or inner tape wrap followed by a water activated fiberglass
• wrap or two part epoxy followed by an H2O activated outer wrap are
• acceptable alternatives.
• Re-Inspected the all repaired areas.
 Date: / / M T W Th F S Su Pg. Of
Paint Inspection: Project #: COPY To:
Daily Coating Inspection Report Inspector:
QC Mgr Owner

Contr
Project/Client:
Location: Attachments:
DFT Sheet NCR/CAR
Description:
Requirements:
Contractor: Spec # Revision #
Description of Areas & Work Performed Hold Point Inspections Performed
1 Pre Surface Pep/Condition & Cleanliness
2 Surface Preparation Monitoring
3 Post Surface Preparation/Cleanliness & Profile
4 Pre Application Prep/Surface Cleanliness
5 Application Monitoring/Wet Film Thickness (WFT)
6 Post Application/Application Defects
7 Post Cure/Dry Film Thickness (DFT)
8 Nonconformance/Corrective Actions Follow-up
9 Final Inspection
Approved By:
Surface Conditions Ambient Conditions
New Maint Primer/Paint Age/Dry/Cure Time (Indicate AM or PM) : : : :
Steel Galvanize Concrete Other Dry Bulb Temp (C/F)0 o o o o
Hazard Sample Report # Wet Bulb Temp (C/F) 0 o o o o
Degree of contamination: % Relative Humidity % % % %
Test: Cl µg/cm2 / ppm Fe ppm pH Surface Temp0 (C/F) Min/Max / o / o / o / o
Degree of Corrosion: Dew Point Temp (C/F) 0 o o o o
Scale Pitting/Holes Crevices Sharp Edges Wind Direction/Speed
Weld Moisture Oils Other Weather Conditions:
Painted Surface Condition: Application
Dry to: Touch Handle Recoat Start Time : Finish Time : Est. Sq/ft.
Dry/Over Spray Runs/Sags Pinholes Holidays Primer Intermediate Topcoat Touch-up
Abrasion Fall Out Other Generic Type: Qty Mixed:
Surface Preparation Manuf.: Mix Ratio:
Start Time: Finish Time: Est Sq/ft: Prod Name: Mix Method:
Solvent Clean Hand Tool Power Tool Prod #: Strain/Screen:
HP Wash PSI Other Color: Material Temp: oF
Abrasive Blast Abrasive Type Sample Kit Sz/Cond.: Sweat-in Time: Min/Hrs

Blast Hose Size Nozzle Size / PSI Shelf Life: Pot Life: Min/Hrs

Air Supply CFM Air Supply Cleanliness Batch #'s Reducer #:

Water/Oil Trap Check Equipment Condition Check (A) Qty Added: Pt/Qt/Gal

(B) % by Vol: %
Surface Cleanliness & Profile Measurement (C) Specified WFT Avg: Mils

Job Specification SSPC/NACE - SP- Reducer: Achieved WFT Avg: Mils

SSPC/NACE Spec / Visual Stds Airless/Conv. Spray Brush Roller Other

Profile Check: Disc Tape Gauge Pump Pot Hose Dia. Air Check
Specified mils avg. / Achieved mils Ratio/Size Hose Lng. SEP/Trap
Surface effect on DFT Gauge/BMR mils GPM/CFM Spray Gun Filter
Dry Film Thickness PSI Tip Sz. Agitator
Gage Gage Calib. Spec Avg. Total Avg DFT Last DFT This
Gage Type / Coat
Model Serial # Verified DFT DFT Coat

Inspector's Signature Date