PROTECTIVE COATING

Understanding Inspection and control of

painting

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 PROTECTIVE COATING

Inspection and Control

 The human factor is an important element in the process to ensure the
specified quality of the paint system. It is therefore very important to inspect
and control all work performed in connection with surface treatment.

 During the painting of a structure, inspections and control should be performed

at the following critical phases:
 Steelwork
 Pre-treatment
 Before, during and after application.

 For all activities, the inspector should verify and document that the work
complies with the specification and has been performed professionally, and
that the paint supplier's instructions for use of the product have been followed.
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 PROTECTIVE COATING

Inspection and Control :

Steelwork
 Steelwork

 The inspector should verify that the steelwork has been performed according to
specification or ISO 12944-3.
 This includes:
 rounding of edges,
 grinding of welds,
 removal of weld spatters and
 grinding of laminations.

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 PROTECTIVE COATING

Inspection and Control :

Pre-treatment
 Pre-treatment
 The inspector must check and ensure that the structure is free from oil, grease
and salt and that the washing procedure has been followed.

 Standards ISO 8501-1 or ISO 8501-2 (for repair work) apply.

 Before and during pre-treatment, the atmospheric conditions are checked

according to ISO 8502-4.

 Other checks to be performed usually include inspection for invisible

contamination on the surface such as salts (ISO 9502-6 and 9), dust (ISO
8502-3) and specified roughness (ISO 8503).
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 All data and records shall be entered in a daily log
 PROTECTIVE COATING

Inspection and Control:

Application of paint
 The inspector's task during application of the paint is to ensure that all work
proceeds in the specified manner.
 Check technical data sheets and check for use of the right thinners, the right
curing agent for the base, mechanical agitators and a good mix when using
two-component paints.
 Check the specified pre-reaction time if given in the technical data sheet.
 Check that stripe coating has been performed properly before application of the
full coat by spraying.
 Ensure that the painter carries out careful checks with using wet film gauge so
that the specified wet film thickness is applied.
 The atmospheric conditions should be monitored during the painting work.
Ensure adequate ventilation to remove solvents.

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 PROTECTIVE COATING

Inspection and Control :

Drying / curing
 After drying / curing, the dry film thickness is checked as per ISO 2808.

 Pay particular attention to areas where access with an airless spray gun is
difficult, and ensure that the dry film thickness lies within the specified limits.

 Check that the over painting intervals are observed for the paints, and that the
surface is clean before over painting.

 Individual specifications also require adhesion testing for example to ISO 4624,
or holiday detection to ASTM G62-85.

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 PROTECTIVE COATING

Inspection and Control

What is QA - QC ?
 What is QA – QC?

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 PROTECTIVE COATING

Inspection and Control

An inspector’s work includes:
 Be capable of interpreting the specifications

 Understand the objective of the inspection

 Inspect all structures to be painted

 Ensure that all specified requirements are met

 Document the results from the inspections

 In case of non-conformance: Issue written reports

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 PROTECTIVE COATING

Inspection and Control

Daily logs
 Steel temperature
 Air temperature
 % Relative Humidity
 Dew point
 Object no. and name
 Exact specification
 Pre-treatment, specified and actually conducted.
 Film thickness (to be measured also at spot repair)
 Non conformance report
 Other comments

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 PROTECTIVE COATING

Inspection and Control

An inspector needs to know:
 All paints that will be used
 • All relevant inspection methods and inspection tools
 • Relevant standards
 • Relevant TDS and MSDS
 • Methods involved in cleaning, pre-treatment and paint application
 • The equipment used for pre-treatment and application: Benefits and
limitations

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 PROTECTIVE COATING

Inspection and Control

What needs to be inspected ?
 Shop-priming of the steel
 The steel work (Pre-blasting preparation)
 Cleaning and surface preparation prior to paint application
 Application of paint
 The applied paint film and its curing/drying conditions.

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 PROTECTIVE COATING

Inspection and Control

Pre-blasting preparation
 Rounding of sharp edges.
 Smoothing of rough welding seams.
 Removal / grinding of weld spatter and beads.
 Cracks and pittings.
 Surface faults like laminates etc.
 ISO 12944 - 3 , or ISO 8501 - 3

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 PROTECTIVE COATING

Inspection and Control

Inspection of cleaning and surface preparation prior to application
 Cleanliness (salt, oil, grease and dust/dirt)
 Evaluation of present condition (rust grade)
 Surface preparation (e.g. blast cleaning)
 Cleanliness of prepared surface (salts, oil, grease, dust and dirt)
 Climatic conditions (temperature, relative humidity etc.)

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 PROTECTIVE COATING

Inspection and Control

ISO 8501 – 1 Surface preparation
 Visual assessment of surface cleanliness after blast cleaning, hand or power
tool cleaning or flame cleaning
 Rust grades and preparation grades of uncoated steel
 Photographic examples of steel when blast cleaned with different abrasives

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 PROTECTIVE COATING

Inspection and Control

ISO 8501 – 2 Surface preparation

As for ISO 8501-1

For steel where previous coating has been removed locally, not completely.

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 PROTECTIVE COATING

Inspection and Control

ISO 8501 – 2 Standard for deciding preparation grades

PSa : Localised blast cleaning

(grades 2, 2 ½ and 3)

PSt : Localised hand and power tool

cleaning
(grades 2 and 3)

PMa : Localised machine abrading (one

grade)

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 PROTECTIVE COATING

Inspection and Control

ISO 8502 Assessment of surface cleanliness
 Part 1: Field test for soluble iron corrosion products
 Part 2: Laboratory determination of chloride on cleaned surfaces.
 Part 3: Assessment of dust on steel surfaces prepared for painting (pressure-
sensitive tape method)
 Part 4: Guidance on the estimation of the probability of condensation prior to
paint application.
 Part 5: Measurement of chloride on steel surfaces prepared for painting. Ion
detector tube method.
 Part 6: Extraction of soluble contaminants for analysis. The Bresle method.
 Part 9: Conductometric measurements of soluble salts

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 PROTECTIVE COATING

Inspection and Control

Atmospheric conditions. Requirement during blasting and painting
 Surface temperature of the structure must be minimum 3 °C above the dew
point of the surrounding atmosphere

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 PROTECTIVE COATING

Inspection and Control

Ambient temperature and steel temperature
 Ambient temperature will influence:
 shelf life
 pot life
 viscosity/sprayability
 steel temperature

 Steel temperature will affect:

 speed of cure
 degree of cure
 recoating interval
 service life of the coating

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 PROTECTIVE COATING

Inspection and Control

ISO 8502 – 6 The Bresle method.
 A method for extraction of soluble contaminants on
 steel substrates for analysis:
 The Bresle method - This is a quantitative test

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 PROTECTIVE COATING

Inspection and Control

ISO 8502 – 9 Conductometric measurement of soluble salts.
 Field method for measuring soluble salts by conductivity (μ S) of
solutions containing water soluble salts

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 PROTECTIVE COATING

Inspection and Control

Calculation of salt level on the substrate

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 PROTECTIVE COATING

Inspection and Control:

Checking Surface Profile
 Comparing Standard coupons
 Replica Tapes

 Dial gauge to measure the depth

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 PROTECTIVE COATING

Inspection and Control

ISO 8503 Surface roughness
Example of a reference comparator
• Surface profile comparator
comprising four segments.
• Grit (G)
• Shot (S)
• Check if the profile is according to specification
and the paint manufacturer’s recommendation

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 PROTECTIVE COATING

Inspection and Control

ISO 8503 Surface roughness
Example of a reference comparator
•

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 PROTECTIVE COATING

Inspection and Control : Surface cleaning

Dust on blast-cleaned steel surfaces may reduce the adhesion of applied coatings and by
absorbing moisture, may promote the corrosion of the blast-cleaned steel surface. •

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 PROTECTIVE COATING

Inspection and Control : Surface Profile Gauge: ASTM D 4417-B

 Place the Profile Gauge on the glass plate and zero the instrument.
 Now place the gauge on the blasted profile. The foot sits on top of the peaks and the
sharp stylus travels to the bottom of the valleys allowing the gauge to display the peak-
to-valley height.
 In addition to blasted profile evaluation, this gauge can also be used for pitting and
cavity depths caused by corrosion.

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 PROTECTIVE COATING

Inspection and Control

Inspection during application
 The following must be verified, inspected or tested:
 Record name of coating and batch no.
 Ensure proper mixing of 2-pack paints
 Ensure use of the correct thinner
 Measuring the wet film thickness (WFT)
 Number of coats as given in the specification
 Cleanliness between coats (salts, dust, oil etc.)
 Drying time / recoating intervals
 Control of equipment: Pressure, nozzle etc.
 Climatic conditions (Ventilation, Air and steel
 temperature and the relative humidity)
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 PROTECTIVE COATING

Inspection and Control

Information to be found from the technical data sheet, TDS
 Product description – Generic type etc.
• Recommended use – Where to use the product
• Technical information – Solids by volume, WFT, DFT
• Application data – Methods, mixing, potlife
• Surface preparation – Different methods given
• Conditions during application
• Drying and over coating time at different temperatures
• Typical recommended system
• Storage
• Handling
• Packing control
• Health and safety – Details in MSDS
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 PROTECTIVE COATING

Inspection and Control

ISO 2808 – 97 Determination of film thickness (1 of 2)
 Method 1: Determination of wet film thickness.

 Method 2: Determination of dry-film thickness by calculation from mass

 Method 3: Measurement of dry-film thickness by mechanically contacting

method

 Method 4: Measurement of dry-film thickness by the profilometer method

 Method 5: Measurement of dry-film thickness using microscope method

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 PROTECTIVE COATING

Inspection and Control

ISO 2808 – 97 Determination of film thickness (2 of 2)
 Method 6: Magnetic method

 Method 7: Eddy current method

 Method 8: Non-contact methods

 Method 9: Gravimetric method (dissolving methods)

 Method 10: Determination of dry-film thickness on blast-cleaned steel

substrates

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 PROTECTIVE COATING

Inspection and Control

Calculations : Paint Abbreviations)
 WFT = Wet Film Thickness
 DFT = Dry Film Thickness
 % VS = Percent Volume Solids
 LF = Loss Factor
 DV = Dead Volume

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 PROTECTIVE COATING

Inspection and Control

Formula for determining the DFT

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 PROTECTIVE COATING

Inspection and Control

Consumption of Paint with loss

 To be painted: Tank, area of 500 m2 , 40 % loss

 40 % loss implies that only 60 % will remain on the surface.
 The correction factor, Loss factor, will be 0.6

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 PROTECTIVE COATING

Inspection and Control

Dead volume increases the volume of paint required

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 PROTECTIVE COATING

Inspection and Control

calculation of paint consumption with loss

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 PROTECTIVE COATING

Inspection and Control

Inspection after application

 After application the following must be checked

 Climatic conditions (Ventilation, Temperature and humidity)
 • Curing / drying of the film
 • Dry film thickness (DFT)
 • Adhesion
 • Holiday detection (if required)

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 PROTECTIVE COATING

Inspection and Control

ISO 2808 – 97 Determination of film thickness

Method No. 10 - On blast cleaned steel substrates

Electromagnetic instruments
• Calibration on a smooth steel surface min. 1,2 mm thick
• For DFT measurement, not less than 25 and preferably above 50 microns
• Number of readings, as a guide:
– 1 reference area: At least 3 readings evenly
– 2 reference areas for every square meter for flat plates
– 4 reference areas for every length for a web
– 2 reference areas every metre length for a flange
– 2 reference areas every metre length for a pipe

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 PROTECTIVE COATING

Inspection and Control

ASTM D 3359-87 Adhesion testing by knife and adhesive tape

There are two test methods : The method to select depends on the DFT
Method A: DFT above 125 microns
Method B: DFT below 125 microns

(Above 125 if wider cuts are used)

Method A: X - cut. Tape test
Method B: Cross - cut. Tape test

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 PROTECTIVE COATING

Inspection and Control

ISO 2409 Cross-cut test

Cutting tool
Single bladed knife
or
Multi-blade cutting tool with 6 cutting
edges spaced 1 mm or 2 mm apart
Spacing of cuts
0 - 60 microns: 1 mm spacing, hard substrates
0 - 60 microns: 2 mm spacing, soft substrates
60 - 120 microns: 3 mm spacing, hard/soft substrates
121 - 250 microns: 3 mm spacing, hard/soft substrates

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 PROTECTIVE COATING

Inspection and Control

ISO 4624 Pull-off test for adhesion

Procedure:
• Test dollies glued onto the coating
• Adhesive: Cyano-acrylate or solvent free
epoxy
• Remove adhesive and coating around the
dollies
• Pull off test-dollies vertical to the surface
• Read adhesion value and report the type of
fracture
Fractures:
• Adhesion failure - fracture between coats or
substrate and
• Cohesion failure - fracture within a coat 41
 PROTECTIVE COATING

Inspection and Control

ASTM G 62 - 85 Method A Pinhole detection. Low voltage.

Low voltage: < 75 V DC

• To detect pinholes, voids or metal particles to be in the range of 25-250
microns.
• Effective for paint films up to a DFT of 500 microns if a wetting agent is
used in the water.
• This is a non-destructive test.

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 PROTECTIVE COATING

Inspection and Control

ASTM G 62 Method B Holiday detection. High voltage.

High voltage: 900 - 20.000 V

Used to detect pinholes, voids and areas with thin paint films
This is a destructive test.

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 PROTECTIVE COATING

Inspection and Control

ISO 12944 General standard for corrosion protection:

 Paints and varnishes - Corrosion protection of steel structures by protective

paints systems.
 Part 1 General introduction.
 Part 2 Classification of environments.
 Part 3 Design considerations.
 Part 4 Types of surface and surface preparation.
 Part 5 Protective paint systems.
 Part 6 Laboratory performance test methods.
 Part 7 Execution and supervision of paint work.
 Part 8 Development of specifications for new work and maintenance.

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 PROTECTIVE COATING

Inspection and Control :

Measuring WFT
 Measuring WFT:
 Place the gauge perpendicular to the
surface immediately after paint
application so as to have the two edge
legs touch the hard substrate beneath
the paint film
 Do not drag the gauge
 Withdraw the gauge and observe the
coated teeth between the edge legs
 The highest notch coated is the wet
film thickness
 If all the notches are coated choose the
next side of the WFT which will have
higher readings
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 PROTECTIVE COATING

Inspection and Control :

Measuring DFT
 Dry film thickness (DFT) can be
measured using two methods:
destructive thickness measurement,
where the coating is cut to the
substrate using a cutter; and non-
destructive coating thickness
measurement, using techniques which
do not damage the coating or the
substrate such as magnetic, magnetic
induction and eddy current thickness
measurement methods.

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 PROTECTIVE COATING

Inspection and Control :

Measuring DFT
 The non-destructive coating thickness
measurements can be taken on either
magnetic steel surfaces or non-
magnetic metal surfaces such as
stainless steel or aluminium. Digital
coating thickness gauges are ideal to
measure coating thickness on metallic
substrates. Electromagnetic induction
is used for non-magnetic coatings on
ferrous substrates such as steel, whilst
the eddy current principle is used for
non-conductive coatings on non-
ferrous metal substrates.

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 PROTECTIVE COATING

Inspection and Control :

Low Voltage wet sponge Holiday detector
 Wet Sponge Holiday Detectors are used
for the detection of discontinuities
(holidays) in thin film coatings (0-20mils)
of paint, epoxy, or any non-conductive
material applied to a conductive material.
This type of detector uses 671 ⁄2 volts DC
for a test voltage, which is applied to the
test surface via a wet sponge. The fluid
media (usually water) in the wet sponge
fills the voids in the surface to be tested
and allows low current (micro-amps) to
flow into any holidays in the test area.
The current moves through the holiday
and into the conductive substrate which
activates a horn, light or output to indicate
the presence of the holiday.
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 PROTECTIVE COATING

Inspection and Control :

Low Voltage wet sponge Holiday detector
 Completing A Circuit :
 The circuit is completed by
connecting the ground of the holiday
detector to the conductive substrate of
the test piece. Which thereby allows
the circuit to complete directly from
detector through the holiday into the
substrate back into the detector. This
method is most often used when
testing with a portable unit.

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 PROTECTIVE COATING

Inspection and Control :

Paint adhesion testing
 paint adhesion testing is often used to determine if the paint or coating will
adhere properly to the substrate to which they are applied.
 There are three different tests to measure the resistance of paints and
coatings from substrates:

 cross-cut test,
 scrape adhesion, and 
 Pull-off test

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 PROTECTIVE COATING

Inspection and Control :

Paint adhesion testing
 Cross-cut Test:
 The cross-cut test is a method for determining
the resistance of paints and coatings to
separation from substrates by utilizing a tool to
cut a right angle lattice pattern into the coating,
penetrating all the way to the substrate.
 There are two methods described in the ASTM
Specification
 Test Method A
 An X-cut is made through the film with a
carbide tip tool to the substrate. Pressure-
sensitive tape is applied over the cut. Tape is
smoothed into place by using a pencil eraser
over the area of the incisions. Tape is removed
by pulling it off rapidly back over itself as
close to an angle of 180°. Adhesion is assessed
on a 0 to 5 scale.
 [0- Greater than 65% area removed & 5 is 0% 51
area removed]
 PROTECTIVE COATING

Inspection and Control :

Paint adhesion testing
 Test Method B
 A crosshatch pattern is made through the film to
the substrate. Detached flakes of coating are
removed by brushing with a soft brush. Pressure-
sensitive tape is applied over the crosshatch cut.
Tape is smoothed into place by using a pencil
eraser over the area of the incisions. Tape is
removed by pulling it off rapidly back over itself
as close to an angle of 180°. Adhesion is assessed
on a 0 to 5 scale.
 [Method B is not considered to be suitable for
coatings thicker than 5 mils]

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 PROTECTIVE COATING

Inspection and Control :

Paint adhesion testing
 Pull-off test :
 The adhesion of a coating or several coated
sample of any paint product is measured by
assessing the minimum tensile stress needed
to detach or rupture the coating perpendicular
to the substrate. Unlike the other methods, this
method maximizes the tensile stress, therefore
results may not be comparable to the others.
The test is done by securing loading fixtures
(dollies) perpendicular to the surface of a
coating with an adhesive. Then the testing
apparatus is attached to the loading fixture and
is then aligned to apply tension perpendicular
to the test surface. The force that is applied
gradually increases and is monitored until a
plug of coating is detached, or a previously
specified value is reached
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 PROTECTIVE COATING

Inspection and Control :

Paint adhesion testing
scrape adhesion : This method is least used.

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