Inspection Grade1

7/18/2019 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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Paint School3

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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Paint School4

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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Paint School5

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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Paint School6

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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Paint School7

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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Paint School8

Inspection tools

Cd-4932-80


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Paint School9

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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Paint School10

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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Paint School11

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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Paint School12

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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Paint School13

0589-5

C3

0589-6

Pre-blasting preparation

Rounding of edges

Removing of weld spatters etc.


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Paint School14

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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Paint School15

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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Paint School17

ISO 8501 - 1

Rust grade A, B, C and D

Surface preparation

Standard for deciding rust grades


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Paint School18

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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Paint School19

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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Paint School21

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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Paint School23

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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Paint School27

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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Paint School30

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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Paint School31

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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Paint School36

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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Paint School37

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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Paint School38

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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Paint School39

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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Paint School42

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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Paint School43

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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Paint School44

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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Paint School45

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 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)


but excluding segment 2Profiles equal to segment 2 and up to,





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Paint School46

Contamination of abrasives

Water

Oil and grease

Chlorides

Sulphates

The abrasives can be contaminated with


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Paint School47

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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Paint School48

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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Paint School49

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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Paint School50

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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Paint School51

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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Paint School56

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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Paint School57

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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Paint School58

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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Paint School59

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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Paint School60

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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Paint School65

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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Paint School68

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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Paint School70

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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Paint School71

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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Paint School73

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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Paint School74

Area after pull-off testing


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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Paint School75

Pull-off dollies glued to the structure


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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Paint School76

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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Paint School81

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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Paint School82

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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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


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Abrasion resistance

Testing paints \ Abrasion resistance1

Weigh the painted

sample

Install it in the apparatusand run 1000 cycles

Measure the weight loss

Flexibility test


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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


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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

Documents

Inspection Grade1