inspection grade1
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Paint School1
Inspection and control
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Paint School2
What is QA - QC ?
QA = Quality Assurance
(A documented management system)
QC = Quality Control
(Inspection and testing routines)
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The tasks of the paint inspector
To ensure that the requirements of
the coating specification are met.
Verify the quality of workcarried out by the contractor/yard.
Prepare written records of the standard
of work- Approval (Satisfactory ? / Conforming ?)
- Non-conformance
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An inspectors 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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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)
Area, m
Product name, place ofproduction and batch no.
Name of relevant persons
What was discussed
Non conformance report
(remember signatures)
Other comments
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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
An inspector needs to know
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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.
If relevant, the following stagesof the production need to be inspected
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Inspection tools
Cd-4932-80
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Inspection tools.
Mirror and flash light
Visual inspection
Important tools for inspecting areas difficult to access
For inspection in confined spaces: Use Ex approved
equipment
Cd-4932-83
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Using Inspection tools.
Mirror and flash light
Visual inspection
Important tools to be ableto inspect areas difficult to
access
Cd-4932-84
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Inspection at shop priming
Cleanliness (No salt, oil, grease or other
contaminants)
Rust grade A or B acc. to ISO 8501-1
Shot or grit blasted steel, to Sa 2 acc.to ISO 8501-1
Correct DFT (Usually 15 - 25 microns)
Satisfactory drying
No damages caused by conveyor.
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Inspection of steel work
(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
The following items need to
be inspected during construction
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0589-5
C3
0589-6
Pre-blasting preparation
Rounding of edges
Removing of weld spatters etc.
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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.)
If relevant, the following conditionsmust be inspected / verified
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Relevant standards for assessing
surfaces prior to paint application
Standard Area
ISO 8501 Visual assessments of surface cleanliness.
ISO 8502 Tests for the assessment of surface cleanliness.
ISO 8503 Surface roughness characteristics
of blast-cleaned steel substrates.
ISO 8504 Surface preparation methods.
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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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ISO 8501 - 1
Rust grade A, B, C and D
Surface preparation
Standard for deciding rust grades
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Cd-0631-59Cd-0631-58
Cd-0631-57 Cd-0631-56
ISO 8501-1
Evaluation of rust grades
Rust grade A
Rust grade D
Rust grade B
Rust grade C
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Sa: Blast cleaning (grades 1, 2, 2 and 3)
St.: Hand and power tool cleaning(grades 2 and 3)
Fl: Flame cleaning (one grade)
ISO 8501 - 1
Standard for deciding preparation grades
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ISO 8501 - 2Surface preparation
As for ISO 8501-1, but:
For steel where previous coating has been removed
locally, not completely.
SO
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PSa : Localised blast cleaning
(grades 2, 2 and 3)
PSt : Localised hand and power tool cleaning
(grades 2 and 3)
PMa : Localised machine abrading (one grade)
ISO 8501 - 2Standard for deciding preparation grades
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ISO 8502
Assessment of surface cleanliness(1 of 2)
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.
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ISO 8502
Assessment of surface cleanliness(2 of 2)
Part 6 Extraction of soluble contaminants for analysis.
The Bresle method.
*Part 9 Conductometric measurements of soluble salts
.
* Part 7, 8 and 10 are not prepared
*
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Filter paper impregnated
with Potassium HexacyanoferrateBlast cleaned steel
Blue spots
ISO 8502-1. Annex. 3
Water soluble salts on blast cleaned steel
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ApprovedNot approved
Tape Blast cleaned steel
ISO 8502-3
Assessment of dust
Steel Surfaces Prepared for Painting.
ISO 8502 3
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1. Quantity ratings 1, 2, 3, 4 and 5corresponding to pictorial references
2. Dust size classes 0, 1, 2, 3, 4 and 5
ISO 8502 - 3
Assessment of dust
Assessment of dust onsteel surface prepared for painting
ISO 8502 3
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ISO 8502 - 3
Assessment of dust
Assessment of dust on steel
surface prepared for painting
1. Quantity ratings 1, 2, 3, 4
and 5 corresponding to
pictorial references
2. Dust size classes:
0, 1, 2, 3, 4 and 5
Inspection / Dust_control1
SO
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ISO 8502-4
Estimating probability of condensation
Wet cotton
Psychometer Thermometer
Guidance on estimating probabilityof condensation prior to paint application
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1. Air temperature
2. % Relative humidity
3. Steel temperature
4. Dew point
ISO 8502 - 4
Humidity
Guidance on the estimation of the probabilityof condensation prior to paint application
Steel temperature min. 3 oC above the dew point
ISO 8502 4
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ISO 8502-4
Measuring the relative humidity
Photo: Sling psychrometer
for measuring:
- Dry temperature
- Wet temperature
Measure the temperature in
the vicinity.
Calculate the relative
humidity
Use together with dew
point calculator
Cd-4932-88
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Contact thermometer
Electronic instrument for measuring the steel temperature
Other types of thermometres are also available. E.g.
magnetic thermometers
Cd-4932-87
ISO 8502 4
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ISO 8502-4
Dew point calculator
For calculation of dew point
To be used together with
surface temperature
thermometer and sling
psychrometer. Use this frequently during pre-
treatment, application and
drying of the paint.
Recommendation: Every 6
hours and when weatherconditions are changing
Cd-4932-89
At h i diti
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Surface temperature of the
structure must be minimum
3 C above the dew point
of the surrounding atmosphere
Atmospheric conditions.
Requirement during blasting and painting
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B-24/2-4
4847-693
ISO 8502 - 4
Estimating probability of condensation
Cold liquid inside hull and warm air outside
causes condensation
See how frames inside keeps the cold longer
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Relative humidity, RH
% R.H.:
% water vapour in the air as percentage of the total amount
water vapour the air can contain at the same temperature.
Example
Air at 20 oC can contain 17.31 g. water/m3, but contains 15
g/m3. What is the R.H. ?
R.H. = = 86.65 %15 x 100
17.31
A bi t t t d
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Ambient temperature will influence:
shelf life
pot life
viscosity/sprayability
steel temperature
Steel temperature will affect:
speed of curedegree of cure
recoating interval
service life of the coating
Ambient temperature and
steel temperature
Is the temperatures important ? YES !
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Determination of water soluble salts
Conductivity
Titration
Colour-reactions
Other Methods:
SCM 400 Salt Contamination Meter
The most frequently used methods are:
ISO 8502 6
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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
ISO 8502 6
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ISO 8502-6
Salt test equipment - Bresle test
ISO 8502 - 9
(Conductivity)
Equipment for measuring
content of water solublesalt on substrate
Bresle methodCd-4932-96
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ISO 8502 - 9
Conductometric measurement of soluble salts.
Field method for measuring soluble salts
by conductivity ( S) of solutionscontaining water soluble salts
How to measure the
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How to measure the
salt level on a surface
Water soluble salts will beremoved by water jetting
Here: The substrate is
cleaned at a pressure of
2000 bar Salt level is measured by
the Bresle method
Dissolve the salt inside the
frame of the patch Measure the conductivity
of the water samplePre-treatment: Wj_saltlevel1
Calculation of salt level
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Calculation of salt level
on the substrate
(L2 - L1) x 6 = mg salt per m2
L2 = S after cleaning
L1 = S before cleaning
Water sample, ml.: 10 15 20 50
Constant in formula: 4 6 8 20
Formula:
Instruments for measuring
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Instruments for measuring
surface roughness
Stylus instruments
Elcometer Mod. 123
Testex Press-O-film
Microscope
Comparator
Rugotest No. 3
ISO 8503 etc.
ISO 8503
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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
manufacturers
recommendation
Cd-4932-86
ISO 8503 - 1
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ISO 8503 1
Limits of profile grades
a) Comparators for steel. Blast-cleaned with grit abrasivesFine (G)
Profiles equal to segment 1 and up to,
but excluding segment 2
Profiles equal to segment 2 and up to,
but excluding segment 3
Profiles equal to segment 3 and up to,but excluding segment 4
Medium (G)
Coarse (G)
b) Comparators for steel. Blast-cleaned with shot abrasives
Fine (S)
Medium (S)
Coarse (S)
Profiles equal to segment 1 and up to,
but excluding segment 2Profiles equal to segment 2 and up to,
but excluding segment 3
Profiles equal to segment 3 and up to,
but excluding segment 4
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Contamination of abrasives
Water
Oil and grease
Chlorides
Sulphates
The abrasives can be contaminated with
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According to ASTM D 4940
Mix 300 ml of abrasive and 300 ml water
Stir for 1 min. let stand for 8 min., stir again for 1 min.
Oil content (AB-1)
No presence of oil,
either on top or as anemulsion after 30 min.
How to check the abrasives
Conductivity (AB-1)
Fill the liquid for test
and measure theconductivity.
Max 25 mS/m
Is the abrasive free from
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Is the abrasive free from
oil and grease ?
ASTM D 4940
Put a handful of the
abrasives into a beaker
Pour clean, fresh water intothe beaker
Shake the mixture
A film of oil will form ontop of the water if oil or
grease are presentShopprimer/ Abrasive_Test1
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Inspection during application
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)
The following must be verified, inspected or tested:
Information to be found from the
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Information to be found from the
technical data sheet, TDS
Product descriptionGeneric 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 duringapplication
Drying and overcoating time
at different temperatures
Typical recommendedsystem
Storage
Handling
Packing control
Health and safety
Details in MSDS
ISO 2808 - 97 Method No 1
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Wet paint
Steel
ISO 2808 - 97 Method No.1
Wet film measuring comb
Microns250 225 200 175 150 125 100 75 50 25
ISO 2808
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4932-81
0459-21
ISO 2808
Wet film thickness gauge
Measure wet paint film
Here: 25 microns between the teeth
Calculation of
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Calculation of
paint consumption
Calculations : Paint
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Calculations : Paint
Abbreviations
WFT = Wet Film Thickness
DFT = Dry Film Thickness
% VS = Percent Volume SolidsLF = Loss Factor
DV = Dead Volume
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Example:
WFT = 250 m
% VS = 50 %
DFT = = 125 m
WFT x % VS
100
250 x 50
100
Formula for determining the DFT
Formula: DFT =
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Formula for determining the WFT
Example:
DFT = 100 m
% VS = 65 %
WFT = = 154 m
DFT x 100 %
% VS
100 x 100 %
65 %
Formula : WFT =
Formula for determining the
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Example:
DFT = 100 m
% VS = 65 %
Added thinner = 20 %
WFT = =185 m
DFT x (100 % + % thinner)
% VS
100 x (100 % + 20 %)
65 %
Formula for determining the
WFT after thinning (Method 1)
Formula: WFT =
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Theoretical spreading rate
DFT = 100 microns% VS = 65
10 = Factor
= 6,5m2/litre
% VS x 10
DFT
65 x 10
100
= m2/litreFormula:
Spreading rate:
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Consumption of Paint with loss
Epoxy mastic = 196 litre
Polyurethane topcoat = 83 litre
500 x 200
10 x 85 x 0,6
500 x 50
10 x 50 x 0,6
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
Formula: Area, m2 x DFT10 x % VS x loss factor
Dead volume increases the
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Dead volume increases the
volume of paint required
Steel
Smooth (polished) steel surfaceEven film thickness
Steel
Uneven steel surface
Paint will fill the valleys
Specified thickness
Dead volume
How much paint should we order ?l l i f i i i h
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calculation of paint consumption with
loss
Example: 100 litre is needed, loss is 40 %
We have to order
= = 167 litre
Not 100 litre + 40 % extra = 140 litre
100 x 100
60
100
0,6 (loss factor)
A loss of 40 % means that only 60 %will be applied on the surface
I ti ft li ti
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Inspection after application
Climatic conditions (Ventilation,
Temperature and humidity)
Curing / drying of the film
Dry film thickness (DFT)
Adhesion Holiday detection (if required)
After applicationthe following must be checked
ISO 2808 - 97
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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
Determination of film thickness
Method No. 10 - On blast cleaned steel substrates
ISO 2808 - Magnetic and electromagnetic
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ISO 2808 - Magnetic and electromagnetic
Dry film thickness gauges
Dry film thickness gauge Calibrate on smooth
surface to zero and to
thickness similar to be
measured Check with your
calibration foil frequently
Plastic material foils wear
easily. Replace frequently. No internal memory in
gaugeInspection \ Dryfilmthickness1
ASTM D 4752-87
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Glove RagMEK
Rubbing 50 x
No Zinc on the Rag:
Cured
Approved
ASTM D 4752 87
Curing test of Zinc - ethylsilicate with MEK.
A lot of Zinc on Rag:
Not cured
Further curing / Reblasting
ASTM D 4752-87
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Glove
Rag
MEK
ASTM D 4752 87
Curing test of Zinc - ethylsilicate with MEK.
Inspection / Zincsilicate_curing1
ISO 2409
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ISO 2409
Cross-cut testCutting 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
ISO 2409
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Cross cut adhesion test
Cross cut adhesion test
Cut vertical and
horizontal lines to
form a grid
Apply a strong tape
Pull off the tape
Evaluate according to
the standard
Inspection / Adhesion_crosscut1
ISO 2409
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Classification of Cross-cut testClassi-
fication Description Appearance of surfaceSix parallel cuts0 Completely smooth: none of the squares detached1 Small flakes at the Intersections. Area affected 5 %
2Flaked along the edges and/or at the
Intersections. Area affected: 5-15%
3Flaked along the edges, wholly in large ribbons,
and/or partly or wholly on different parts of
the squares. Area affected: 15-35%
4Flaked along the edges in large ribbons and/or
some squares have detached partly or wholly.
Area affected: 35-65%
5 Any degree of flaking that cannot even be classified by 4.
ISO 4624
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Instruments:
Elcometer Adhesion Tester
Saeberg Adhesion Tester (pneumatic) Hate Adhesion Tester (hydraulic)
PAT
Pull-off test for adhesion
Failure:Adhesion failure: Between coats or between or substrate and 1st coat
Cohesion failure: Inside a coat
ISO 4624
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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 1. coat
Cohesion failure - fracture within a coat
ISO 4624
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Pull-off dollies glued to the structure
Pull off adhesion test
Dollies are glued to the
structure with a strong
glue
Prior to pull-off:
Cut around the dolly,
through the paint film
and down to the
substrate material
Cd-4932-102
ISO 4624
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Pull-off testing of paint on a structure
Pull off adhesion test.
Destructive test method
Here, connecting of the
device for pulling off the
dollies
Read and note the value
Several types of
instruments are available
Cd-4932-101
ISO 4624
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Area after pull-off testing
Pull off adhesion test
The adhesive failure -
fracture between coats - or
between coating and
substrate must be evaluated Note adhesion failure, %
The cohesive failure -
fracture within the coating-
must be evaluated.
Note cohesion failure, %
Also: Note glue failure, %
Cd-4932-103
ISO 4624
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Pull-off dollies glued to the structure
Pull off adhesion test
Dollies are glued to the
structure with a strong
glue
Prior to pull-off:
Cut around the dolly,
through the paint film and
down to the substrate
material
Record the pull-off value
Evaluate the failure
Inspection / Adhesion_pulloff1
ASTM G 62 - 85 Method A
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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.
ASTM G-62-85, method A
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Low voltage pinhole detector
Detecting pinholes, voidsor metal particles in paint
film up to 250 microns
Non destructive test
method Will only detect defects
down to bare metal
The sponge must be wetted
Do not use excessive water
Inspection / Pore_detection1
ASTM G 62 Method B
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Holiday detection. High voltage.
High voltage: 900 - 20.000 V
Used to detect pinholes, voids andareas with thin paint films
This is a destructive test.
ASTM G 62 Method B
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Holiday detection. High voltage.
Inspection / Holiday_detection1
High voltage: 900 -20.000 V
Used to detect pinholes,
voids and
areas with thin paint
films
This is a destructive
test.
ISO 12944
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General standard for corrosion protection:
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.
Paints and varnishes - Corrosion protectionof steel structures by protective paints systems.
ISO 8504
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Surface preparation methods:
Part 1: General principles.
Part 2: Abrasive blast-cleaning.
Part 3: Hand- and power-tool cleaning.
Using solvents to determine
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Use a rag soaked
with solvent
No reaction:
Chemically curing
Paint dissolves:
Physically drying
generic type of paint
Lifting/Wrinkling:
Oxidatively curingInspection / Determine_generic1
Using solvents to determine
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Paint School83
Steel
Rag soaked
with solvent
No reaction:Chemically curing
Paint dissolves:Physically drying
generic type of paint
2 coat paint
Lifting/Wrinkling:
Oxidatively curing
Abrasion resistance
-
7/18/2019 Inspection Grade1
84/86
Paint School84
Abrasion resistance
Testing paints \ Abrasion resistance1
Weigh the painted
sample
Install it in the apparatusand run 1000 cycles
Measure the weight loss
Flexibility test
-
7/18/2019 Inspection Grade1
85/86
Paint School85
Flexibility test
Testing paints \ Flexibility_test1
Use a thin test panel
Measure the paint film
thickness
Carry out the impact test
on the rear side of the
test panel
Determine the highest
level of impact load
before any crack ordefect in the paint film
occurs
Impact test
-
7/18/2019 Inspection Grade1
86/86
Impact test
Testing paints \ Impact_test1
Use a thick test panel
Measure the paint film
thickness
Carry out the impact test
on the painted side of
the test panel
Determine the highest
level of impact load
before any crack ordefect in the paint film
occurs
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