Train the Inspector: Protective Coatings Application

Quality Control

© Copyright 2016 Fitz-Coatings Ltd

 Environmental Conditions Inspection Equipment

Objective:
The objective of this training unit is to gain an understanding that environmental conditions are very important
for surface preparation and coating application, including drying and cure.

The protective coatings applicator does not generally have to use inspection equipment, however the
basic environmental Inspection equipment should be available and methods of use understood.

Protective Coatings Applicator

The protective coatings applicator is not a coatings Inspector but

should have a basic understanding of coating instruments that are
used on a daily basis for environmental monitoring and are
fundamental to correct surface preparation and coatings
application.

This unit will review basic Inspection equipment for assessing

environmental conditions.

There is a lot more coating inspection equipment available but this

should only be used by a qualified coatings Inspector or
Supervisor.

Protective Coatings Applicator

There are many jobs that the protective coatings applicator may
apply coatings without full time coating inspection.

It may be simply uneconomical to have a full time coating

inspector for say two or three painters.

The foreman or supervisor (or lead hand) may have to monitor the
environmental conditions while conducting surface preparation and
coating application.

Coating Failures
There are many coating failures caused by coating application
under the wrong environmental conditions.

The coating may look fine during the application, and can even
cure and look fine initially, however if there was moisture on the
surface or between coats, adhesion problems such as flaking,
blistering or delamination (as illustrated) are a real possibility at a
later date.

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 Environmental Conditions
The environmental conditions can change from one area to
another:

If a substrate is hot on one side and cold on another,

condensation can occur ie a tank or vessel.
If you have a hot day and the sun goes down there is a high
possibility of condensation on the substrate.
As the sun moves some substrates can be heated and
cooled (east to west), again condensation is possible.
Some steel structures warm up during the day, however
some parts of the structure such as the underside of flange
beams on bridges for example may not warm as fast and will
have condensation.

The coatings applicator should be aware of the condensation

risks.

Condensation
Another example of condensation.

If you took a cold can of pop or beer from a fridge into a warm
environment you will get virtually instant condensation.

The dew point has been reached ie the temperature at which

condensation occurs.

Coating Specification
Always check the coating specification before you start the
works.

The coating specification should specify the type of coating and

environmental constraints during coating application.

Not all jobs have a coating specification so you then revert to the
product data sheets which generally advises on the application
conditions and limitations for the specific product.

Manufacturers Data Sheets

The protective coatings applicator should have the product data

sheets available at all time. These product data sheets will
generally detail the environmental conditions that the coating can
or can not be applied at.

As a general rule the relative humidity should not be more that

90% and the steel temperature should be 3°C (5°F) above the
dew point - although certain coatings will differ.

The product data sheets will also detail the overcoating times etc.

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 Inspection Equipment for Environmental
Conditions
To assess the environmental conditions for surface preparation or
coatings you only need some simple equipment such as a whirling
hygrometer and steel temperature gauge.

The readings taking from the instruments can be checked against

a hygrometric table or calculator to establish the relative humidity
and dew point.

Whirling Hygrometer

Wet and dry bulb Hygrometer or sometimes referred to as

"Whirling Psychrometer" is used to determine the relative humidity
in the air.

This instrument has a wet and dry bulb and is whirled in the air by
the handle for a specific length of time.

Hygrometric tables are then used to assess the relative humidity.

Check the painting specification or product data sheets for

recommendation on the minimum and maximum levels of relative
humidity.

Use of a Whirling Hygrometer

This video demonstrates the use of a whirling hygrometer by a
qualified painting inspector.

The equipment is not complex and training can be conducted with

the coatings applicator.

There are particular ways to use the whirling hygrometer such as

the number of revolutions per minute etc.

Ensure the readings are not taken in one particular location as you
can get micro climates especially on large structures.

Magnetic Steel Temperature Gauge

A limpet Gauge is a a low cost method of assessing the steel

surface temperature.

This magnetic gauge is attached to the steel surface to give a

temperature reading.

The gauge must be left in place for about 10-15 minutes to obtain
a stabilised temperature.

The gauges are available in centigrade and fahrenheit types.

This picture is an example of steel temperature gauges.

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 Digital Steel Temperature Gauge

A digital thermometer is used for assessing the surface

temperature.

This process is quick and an accurate reading is displayed when

the probe is attached to the steel surface.

The instrument is a relatively small and sensitive instrument and

has to be handled it with care.

Do not drag the probe over the surface as you could damage the
probe or instrument.

You will have to ensure the gauge is calibrated correctly prior to

use.

Digital Vs Magnetic Temperature Gauge

This animation gives a comparison in the time taken to record the

temperatures with a digital and magnetic thermometer.

Although the digital thermometer gives almost instant results it

may not be possible to use in all working environments due to the
use of a battery.

Certain locations such as offshore structures do not allow the use

of battery operated equipment.

Other than these locations, the digital is by far the best gauge to
use compared to the magnetic type which is considerably slower.

Digital Steel Temperature Gauge

This video demonstrates the simple use of a digital thermometer.

The gauge is a simply operated by an on and off switch.

The digital steel temperature gauge will give instant reading

making it very easy to use.

Ensure you do not drag the probe over the surface as the probe is
sensitive and could give false readings.

Dewpoint Calculator
A dewpoint calculator is a simple low cost table wheel that
provides accurate values of relative humidity & dewpoint from wet
& dry bulb temperatures of a whiling or sling hygrometer.

The instruction on the use are written on the from of the

calculator.

The calculator is generally available in Fahrenheit and Centigrade.

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 Relative Humidity Table
A relative humidity table can also be used to assess the relative
humidity.

The difference between the dry bulb (air temperature) and the wet
bulb can simply be calculated on the table to assess the relative
humidity.

Other tables also indicate the dew point.

Electronic Instruments -Environmental Monitoring

Equipment is now available that will record the relative humidity,

dew point and surface temperature.

The equipment is fast and reliable and does all the calculations on
the screen.

The probe is sensitive so ensure that the equipment is used

correctly and stored after every use.

The equipment must be within calibration which is generally

assessed annually.

Check for wear, tear and damage before every use and change
batteries as recommended by the supplier.

Equipment Maintenance
Which ever type of equipment is used, always check for wear,
tear and damage before use.

Ensure the correct type of water, wicks and bulbs are used on the
whirling hygrometer and any electronic equipment such as the
digital thermometers are working correctly and verified on a daily
basis.

Specialist Coatings
Specialist coatings do exist that allow the coating to be applied to
damp surfaces. These coatings are best applied by brush as they
'sweep' the moisture away.

The technology is very good and the materials are expensive.

Client approval would be required to use such products.

However be aware that some products do say 'surface tolerant' on

the data sheets. This generally refers to the surface preparation
and not coating application onto damp surfaces.

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 Documentation
It is extremely important that the person using the equipment to
assess the environmental conditions records the findings.

Generally you assess the environmental conditions about four

times a day, however this can increase as the the humidity
increases or there is a sudden change in weather etc.

This documentation should be stored with the contract files as the

end of the job for reference later, if necessary.

Summary
This training unit reviewed the use of basic inspection equipment
for assessing the environmental conditions.

We reviewed the different types of equipment for steel

temperature and relative humidity.

We also reviewed maintenance of equipment and documentation.

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 BS, EN, ISO, SSPC, NACE etc.

Objective:
The objective of this training unit is to appreciate that within the coatings industry, a number of standards and
codes of practice exist and are specified for work that is carried out by the Protective Coatings Applicator.

The Protective coatings applicator does not need to fully understand all standards but should be aware of
them.
The standards are usually specified in the painting specification or contract.
There are a wide range of standards for surface preparation and coating treatments.
Contractors, applicators and inspectors should have access to all relevant Standards.

Coating Specifications
Most painting and coating contracts will have a specification
which is usually developed by a protective coatings specialist.

The coating specification will refer to standards specific to the

coatings industry.

The standards are generally globally recognized and cover all

aspects of surface preparation and coating application as well as
paint testing and paint performance criteria.

General Agreement
Technical Committees prepare, National, European, International
and Industry Standards for:

Methods of surface preparation.

Coating Materials and types.

Coating Application.

Coating Testing and Failure.

These standards are made up of committee members in various

countries and can take years to develop, get agreement and
finally print.

Organisations Bodies Include

British Standards Institution (BSI)

European Committee for Standardisation (CEN)

Norwegian Offshore Sector (NORSOK)

International Standards Organisation (ISO)

National Association of Corrosion Engineers (NACE

INTERNATIONAL)

SSPC. The Society for Protective Coatings

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 American Society for Testing and Material (ASTM
INTERNATIONAL)

Army and Navy Standards

SSPC The Society for Protective Coatings

The SSPC has many standards and guides relating to the
protective coatings industry.

There are standards and guides for;

Surface preparation
Abrasives
Painting and Coating systems
Qualification procedures
Technology guides

Some of the SSPC standards and guides are universal with

regards to being specified such as;

SSPC-PA2

PROCEDURE FOR DETERMINING CONFORMANCE TO DRY

COATING THICKNESS REQUIREMENTS.

NACE International
NACE International - The Corrosion Society

Develops various standards for the corrosion industry.

Some standards are jointly written with SSPS The Society for
Protective Coatings.

An example of a NACE standard globally specified is;

SP0188-2006 (formerly RP0188), Discontinuity (Holiday) Testing

of New Protective Coatings on Conductive Substrates.

ISO Standards
There are various standards produced by ISO specifically related
to the protective coatings industry.

The most recognizable standards include;

ISO 8501 to 8504 which have various sections.

ISO 8501-1 is the "Preparation of steel substrates before

application of paints and related products - Visual assessment of
surface cleanliness - Part 1: Rust grades and preparation grades
of uncoated substrates after overall removal of previous coatings"

This standard is widely used in the protective coatings industry.

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 ASTM Standards
ASTM International, known until 2001 as the American Society for
Testing and Materials (ASTM), is an international standards
organization that develops and publishes voluntary consensus
technical standards for a wide range of materials, products,
systems, and services.

The organization produces many paint testing standards.

Well recognized standards include;

ASTM D3359 which is the test method for measuring adhesion by

tape test.

The test methods cover procedures for assessing the adhesion of

coating films to metallic substrates by applying and removing
pressure-sensitive tape over cuts made in the film. (cross cut and
cross hatch tests)

NORSOK Standards
NORSOK refers the Norwegian Standards.

NORSOK develop many standards relating to the the oil and gas
industry.

One particular standard that is globally recognized is the

NORSOK M-501;

Surface preparation and protective coating, which gives the

requirements for the selection of coating materials, surface
preparation, application procedures and inspection for protective
coatings to be applied during the construction and installation of
offshore installations and associated facilities.

This standard specifies generic coatings and testing performance

for coatings relating to the offshore oil and gas industry.

Examples of Standards Used

Visual Standards: (or guides for SSPC/NACE)

Mechanical Preparation.

Abrasive Blast Cleaning.

Flame Cleaning.

High Pressure Water Washing-waterjetting.

Text Standards:

Dry Film Thickness.

Holiday Detection.

Types of Coating Failure.

Specialised Testing.

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 Surface Preparation Standards
An ISO Standard regularly specified for surface preparation is the
ISO 8501-1 (BS 7079 Part A1)

This Standard is widely used in Europe.

This standard has both visual and text.

The Standard has various sections.

SSPC has various visual standards for surface preparation such

as SSPC-VIS 1 and 3. These standards also contain text and
photographs of different levels of surface preparation.

SSPC-NACE Visual Standards (Guides)

There are a number of visual standards or guides used in the
protective coatings industry.

These standards or guides can be visually used against a

specified surface preparation standard.

The visual standards or guides should be used in conjunction with

a written standard and the written standard takes precedence.

SSPC-VIS 1

Guide to Reference Photographs for Steel Surfaces Prepared

by Dry Abrasive Blast Cleaning

SSPC-VIS 3
This guide describes the use of reference photographs depicting
the appearance of unpainted, painted, rusted, and welded hot-
rolled carbon steel prior to and after power and hand tool cleaning.

Guide to Reference Photograhs for Steel Surfaces Prepared

by Power-and Hand-Tool Cleaning

SSPC-VIS 4/NACE VIS 7

This guide describes the use of Reference Photographs depicting
the appearance of unpainted rusted carbon steel and painted
carbon steel, with or without rust, prior to and after cleaning by
waterjetting(WJ).

Guide to Reference Photographs for Steel Surfaces Prepared

by Waterjetting

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 SSPC-VIS 5
This guide describes the use of Reference Photographs depicting
the appearance of unpainted, rusted carbon steel prior to and after
cleaning by wet abrasive blast cleaning (WAB)(slurry blasting).

Guide and Reference Photographs for Steel Surfaces

Prepared by Wet Abrasive Blast Cleaning

Recommendations
There are also standards which give recommendations to the
corrosion protection industry.

An example is EN ISO 12944. Paints and Varnishes – Corrosion

Protection of Steel Structures by Protective Paint Systems Parts
1-8.

Part 3 gives recommendations of design which relates to

steelwork.

Coating Specification
The coating specification will detail the relevant standards that are
to be used on a contract.

The contractor should have these standards available, or have

access too, during the contract.

Some coating specifications include reference to the relevant

standards while others list a complete library.

Summary
This training unit reviewed the International bodies such as ISO,
ASTM, NORSOK, NACE International, SSPC The Society for
Protective Coatings etc.

We discussed the above briefly and gave examples of their

standards in the protective coatings industry.

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 Visual Standards (Introduction)

Objective:
The objective of this training unit is to understand that within the protective coatings industry, a number of
visual standards exist, for preparation and coating activities. The protective coating applicator must be
familiar with such standards.

Coating performance is primarily dependent upon proper surface preparation.

A number of visual standards have been developed to check the quality of surface preparation.
Visual standards or guides produced by industry bodies and coating suppliers along with ISO, SSPC etc.
The protective coatings applicator should understand the requirements of visual standards and guides.

Visual Standards and Guides used for Surface Preparation

Visual standards and guides exist for a number of surface

preparation methods including;

Abrasive Blast Cleaning - wet and dry methods.

Mechanical Cleaning - wire brushing, disking, grinding etc.

Flame Cleaning.

High Pressure Water jetting - hydrojetting.

These standards and guides have been developed by ISO, SSPC

and NACE etc.

Note: The visual standard should be held close to the surface to

be assessed.

Surface Preparation Standards

The main standard now used in Europe is ISO 8501-1 (BS 7079)
Part A1.

This standard also gives visual standard for assessing rust

grades of steel substrates before surface cleaning.

These grades are; A, B, C and D

SSPC also has four rust grades A, B, C and D within the SSPC-
VIS 1 "Guide and Reference Photographs for Steel Surfaces
Prepared by Dry Abrasive Blast Cleaning".

Rust Grades

There are 4 rust grades (A, B, C and D) illustrated in ISO 8501-1

(BS 7079) and SSPC-Vis 1.

Part A1 Grade 'A' has tight mill scale with grade 'D' having rusting
and pitting.

Rust grade 'A' is not that common as most grades generally fall
between 'B' to 'D'.

You will not generally see a rust grade 'A' as corrosion generally
begins as the steel is stored, shipped etc.

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 SSPC-VIS 1
Illustration of the Initial steel conditions from SSPC-VIS 1 (dry
abrasive blast cleaning)

Condition A - 100% mill scale

Condition B - Mill scale and rust

Condition C- 100% rust

Condition D-100% rust with pits

If you are abrasive blast cleaning steel using the ISO 8501-1 or
SSPC-VIS 1 you will be able to choose one of the four initial
conditions.

Initial Steel Condition

As previously discussed there are four initial rust grades. (A, B,

C, D ).

Check the specified standard before work commences. Sa1 to

Sa3 or SP 7 to SP SP 5

These standards should correspond with the initial steel condition

if it was not previously coated ie 'B' Sa 2 or C Sa 3.

SSPC-Vis 1 uses the same process ie 'B' SP-10 and 'B' SP-5

Note: for steel condition 'A' there is no Sa1 or Sa2. Similarly

SSPC-Vis 1 has no SP 6 or SP 7 for steel condition 'A'

Surface Preparation Standards

There are 4 abrasive blast cleaning grades within ISO 8501-1 (BS
7079) Part A1:

Sa 1 - light blast cleaning.

Sa 2 - thorough blast cleaning.
Sa 2½- very thorough blast cleaning.
Sa 3 - blast cleaning to visually clean steel.

SSPC and NACE International Joint Standards

SP 5/NACE No1. White Metal Blast Cleaning.

SP 6/NACE No3. Commercial Blast Cleaning.
SP 7/NACE No4, Brush-Off Blast Cleaning.
SP 10/NACE No2. Near-White Blast Cleaning.
SP 14/NACE No8. Industrial Blast Cleaning.

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 Visual Standards

Visual standards for hand and mechanical preparation are

contained in ISO 8501-1

St 2 - Thorough hand and power tool cleaning.

St 3 - Very thorough hand and power tool cleaning.

SSPC has its own visual guides in SSPC-VIS 3 Power and Hand
Tool Cleaning.

SP 2 - Hand tool cleaning.

SP 3 - Power tool cleaning.

SP 11 - Power tool cleaning to bare steel.

SP 15 - Commercial grade power tool cleaning.

Surface Preparation - Wire Brushing

Illustration of a wire brushed surface.

Visual standards for hand and mechanical preparation are

contained in ISO 8501-1.

St 2 - Thorough hand and power tool cleaning.

St 3 - Very thorough hand and power tool cleaning.

SSPC uses visual guide SSPC-VIS 3 -Power and Hand Tool

Cleaning.

SP 2 - Hand Tool Cleaning by hand wire brush.

SP 3 - Power Tool Cleaning by power wire brush.
SP 11 - Power Tool Cleaning to Bare Metal.
SS 15 - Commercial Grade Power Tool Cleaning.

SSPC VIS 1 Initial Condition

While the ISO 8501-1 gives the initial steel conditions as A,B,C
and D (all bare steel) the SSPC VIS 1 also includes:

E - Light coloured paint applied over blast cleaned steel

F - Zinc rich paint applied over blast cleaned steel

G - Painting system applied over mill scale

A weld seam is also illustrated in SSPC VIS 1 with the exception

of initial condition 'E' and 'G'

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 Flame Cleaning Standards

Flame cleaning standards exist for preparation of rust grades A,

B, C and D within the ISO 8501-1

Flame cleaning has the advantages of giving a clean warm

surface, however it has a major disadvantages in that a naked
flame is used.

Due to the safety concerns this process would not be allowed on

many sites.

The process is rarely seen.

Visual Standards for High Pressure Water Jetting

A number of coating suppliers have previously developed their

own high pressure water jetting standards and they have been
used for a number of years.

However an ISO standards now exist for high-pressure water

jetting.

ISO 8501-4 is a visual assessment of surface cleanliness.

Specialist Organisations such as SSPC and NACE have their own

visual guide which is SSPC-VIS 4. This is a Joint standard
between the two organisations.

Water Jetting Standards - Blast Primer

This is an example of a high pressure water jetting standard to a

red iron oxide shop primer.

Within the standard you will find iron oxide epoxy prefabrication
shop primer and zinc silicate prefabrication shop primer that have
degraded in ISO 8501-1.

DP I - Iron oxide primer standard.

DP Z - Zinc silicate primer standard.

SSPC visual guide SSPC-VIS 4 has light coloured paints, zinc

rich paints and non-brittle and brittle paints as previously coated
substrates.

Visual Standards

Visual standards have been developed to compare against a

prepared substrate.

In practice, this does not happen if a qualified coating inspector is

assessing the surface preparation standard.

The standards must be available on site at all times during the

surface preparation.

The standards will be necessary if a dispute arises about the

surface preparation standard.

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 Comparison of ISO, NACE and SSPC Guides for
Surface preparation
The table shows a comparison of the designations and
standards/guides used for the various methods of surface
preparation by ISO, NACE and SSPC.

Not all organisations produce a standard for each method of

surface preparation or standard of preparation.

The Standards or guides should be referenced for further details

Summary
We have looked at visual standards used in the protective
coatings industry.

The main visual standards consist of standards produced by:

SSPC (The Society for Protective Coatings)

SSPC/NACE Joint Standards
ISO Standards

Standards exist for surface preparation by hand and power tool

cleaning and abrasive blast cleaning.

There are differences between standards and it is important to

ensure the chosen standards are written within the coating
specification and that the standards are available during the
contract.

Note; The pictorial document used by ISO are referred to as

standards while the SSPC/NACE pictorial documents are guides.
Written standards are available to accompany the guides.

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 Standards, Specifications and Codes of Practice

Objective:
The objective of this training unit is to understand the basic principles of a painting and coating specification.

A painting specification is usually included in every contract.

Some painting specifications can be simple one sheet documents or very thorough complex documents.
The painting specification usually forms part of a contract.
The painting specification is usually held by the Supervisor, Foreman or Inspector.

Relevance and Importance of Documents

Generally within a tender document for surface preparation and
application of protective coatings there will be a coating
specification.

The coating specification will detail how the works are completed
and refer to Industry Codes of Practice and Industry Standard.

These documents are very important and must be read and

understood by contractors at tender stage as they will be used
throughout the contract.

The coating specification will form part of the contract and

therefore a legal document which will be used in the event of a
dispute.

Revision Status
It is extremely important to check the revision status of the
coating specification.

The coating specification should be continuously reviewed by the

owner or operator and changes highlighted.

Changes are made for Legal reasons, changes in coatings and

suppliers and lessons learned from continual improvement.

It is possible that a revision can be made during a contract and

this may have contractual implications on the works.

Roles and Responsibilities

The roles and responsibilities are usually clearly defined within the
coating specification.

It is important to fully understand the roles of representatives of

the companies and personnel, especially if there are a number of
organizations involved.

There may be, for example, the coating contractor, the fabricator,
the customers representative etc.

The definitions should be understood also in respect of:

"the contractor shall"

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 "the contractor must"

"the contractor may"

The definitions will usually be defined within the coating

specification.

Definitions
Examples

1. "the contractor shall" take every precaution to ensure no

dust or debris is released from the tempoary containment
2. "the contractor must" ensure no dust or debris is released
from the temporary containment
3. "the contractor may" propose alternative methods of
containment to ensure no dust or debris is released from the
containment

It is important to understand the exact meaning of the

specification.

Quality Assurance and Quality Control

QA is an abbreviation for Quality assurance.

QC is an abbreviation for Quality control.

The terms QA and QC are commonly referred to in coating

specifications.

While there is a distinct difference, the exact definition and roles

for the duties are often missing from the coating specification.

All too often the lines between QA and QC can become blurred.

Quality Assurance (QA)

Quality assurance is defined as;

"the process to verify that the Quality of work performed is

actually what was reported by Quality control".

Quality assurance is typically performed by the owner/ client or a

third party on behalf of the owner/client.

Quality assurance is more of an audit function, used to verify that

t h e Quality control is being performed but may include
conducting actual testing on a spot or periodic basis.

In simple terms, quality assurance is used to verify that the

quality control meets the requirements of the specification.

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 Quality Control (QC)
Quality control is performing necessary;

observations, testing and documentation that verifies if

the work performed meets or exceeds some minimum
standards as required by the project or contract
specifications.

Quality control is the responsibility of the contractor or applicator

organisation.

Quality control involves the;

'routine and systematic inspection and test that are

conducted to verify that each phase of the work is in
compliance with the specification'.

Coating Inspector
The coating inspectors role may be specific depending upon who
actually employs or hires that person.

1. The coating inspector can be hired in by the coating

contractor through a third party organization
2. The coating inspector may be employed directly by the
coating contractor
3. The coating inspector may be hired or employed by the owner
or client (clients representative)

Note; The coating inspector rules should be Observe, Assess,

Document and Report (OADR)

Coating Inspector - Hired

The coating inspector can represent a variety of entities and can
serve different roles in the contractual relationship.

The coating inspector can perform quality control for the painting
contractor, when hired through an inspection or third party
organisation.

Within this role the coating inspector may not have the authority
to direct the coating contractor's employees, however may report
non conformities to the appropriate personnel for action.

Coating Inspection Employee

The coating inspector can perform quality control for the painting
contractor as a member of the contractors staff.

The painting contractor will define the level of authority to the

coating inspector.

The coating inspector can perform quality assurance for the main
contractor or client who is sub contracting the painting work to one
or more painting contractors.

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 Coating Inspector -Client's Representative

The coating inspector can perform independent, third party quality

assurance for the owner or client.

The coating inspector can perform independent, third party quality

assurance for the coating supplier which may be based on a
general inspection role or a requirement for warranty work.

You will see from the above that the coating inspector may be
used in both QA and QC roles at various levels in the contractual
chain.

It is therefore important to know the roles and responsibilities of

personnel at the start of a contract.

Inspection Test Plan

The coating Specification details the requirements for the quality
control on the works.

The works Inspection test plans or procedures should cross

reference the coating specification to detail:

why an inspection is being conducted

how to perform the process
where and how it is to be documented.

Authority Roles
The distinction between owner QA and third party QA is critical.

When the owner performs his own QA with his own staff, he has a
contractual relationship with the contractor and therefore can exert
control through the contract when the operations are out of
compliance.

However, when an owner sub-contracts third party QA, the third

party does not have a contractual relationship with the contractor,
and can only advise and document any non conformances.

Authority Roles
Both the owner and the third party QA representatives must be
careful not to unduly interrupt coating operations as claims for
delays and disruption could be presented by the contractor.

Both QA and QC are necessary components to verify

specification compliance.

Most specifications and contract law make it clear that the owner
or 3rd party performing QA on a project;

'does not relieve the contractor of the responsibility of

undertaking QC and ensuring that the contract requirements
are achieved'.

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 Painting Specification

Typical contents of a painting specification:

Project name and details of the contract.(scope of work)

Customer or client name and revision status.

General definitions e.g. contractor, manufacturer, principle

etc.

Specific definitions e.g. wet and dry film thicknesses,

equipment, abrasive, environmental conditions etc.

Typical contents of a painting specification:

Details of paint manufacturers and specified products,

systems and colours.

Guarantees and warranty periods.

Details of storage, mixing, pot life etc.

Requirements for Health, Safety and Environmental issues.

Details of the painting contractor e.g. training, quality system

etc.

Details of surface cleanliness and roughness.

Typical contents of a painting specification:

Details of method of paint application i.e. brush, roller etc.

Standards e.g. ISO, ASTM, SSPC, NACE etc.

Requirements for method statements, inspection test plans

etc.

Inspection requirements for the contract, qualifications of

inspectors, frequency of inspections and documentation.

Details of test panels, specialist inspection criteria etc.

Typical contents of a painting specification:

The painting specification should be made available during

the contract.
Ensure the latest revision of the painting specification is
utilised.
The painting specification will form part of the contract and
used in the event of a dispute.
The painting specification should not be so onerous that the
conditions specified can not be met.

© Copyright 2016 Fitz-Coatings Ltd Page 21

 Product Data Sheets
If no coating specification exists then use the guidelines found on
the product data sheets.

Always ensure you have the product data sheets for every
contract or task
Always ensure that you have the latest revision of the
product data sheets
Don't be afraid to ask advice from the coating suppliers

Summary
Within this training unit we have reviewed the importance of the
coating specification and the requirements for QA and QC along
with the roles at different levels.

We also reviewed the contents of a typical coating specification.

© Copyright 2016 Fitz-Coatings Ltd Page 22

 Paint Manufacture

Objective:
The objective of this unit is to gain an insight into Paint Formulation and Paint Manufacture.

Coating Manufacturer and the Applicator

The protective coatings applicator does not necessarily have to
know the formulation of every product used.

Coatings are formulated ready for use.

This training unit is a introduction into the basic principals of

coating manufacturer and testing before it is shipped ready for
mixing and application.

Overview
The design of a paint formulation has to take into account the
following:-

Fitness for end use

Fitness for application
Fitness for storage/delivery and importantly
Fitness for manufacture

Constituents
Paint coatings consist of four main components:

1. Binder (sometimes called resin, vehicle or polymer)

2. Pigment and extender
3. Solvent (organic or water)
4. Additives (which can be a number of specific ingredients)

Paint Manufacture

This is a basic animation of paint manufacturer.

The main components are:

Binder
Pigment and Extenders
Additives
Solvents

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 Most paint facilities are fully automated and you may not see the
product until the filling station.

This is a simplistic view of paint manufacture as the final

formulation can be complex and contain many additives etc.

Pigments
Pigments are particulate solids dispersed in the paint to impart the
main characteristics of;

Colour and opacity together with durability, hardness,

mechanical strength and in some cases rust inhibiting or
antifouling properties.

There are two major groups;

Pigments and extenders.

Pigments are either inorganic which constitute the majority, or

organic dyestuffs, the latter being mainly used in cosmetic
finishes where brighter colours are required.

Extenders
They are insoluble in the solvents and binder, do not contribute to
the opacity or colour except sometimes in water based coatings,
but are used to increase viscosity (not today where trend is for
higher solids and lower VOC), modify flow properties, and alter the
mechanical properties, gloss and permeability of the film.

The main purpose is to reduce cost and reinforce the dried/cured

film.

They include Barytes (barium sulphate), China clay (kaolin), Mica,

Talc and Chalk (whiting).

Mica has a laminar structure and reduces water permeability.

Binders
The binder, commonly called the vehicle, is the film-forming
component of paint. It is the only component that must be
present.

The binder impart adhesion and strongly influences properties

such as gloss, durability, flexibility and toughness.

Paints and coatings are often referred to as there binders ie

epoxy, polyester, polyurethane etc.

© Copyright 2016 Fitz-Coatings Ltd Page 24

 Binders
Examples of binder types in principal use are:-

Vinyl resin
Acrylic resin
Alkyd resin
Polyester resins
Epoxy resins
Polyurethane resins
Silicone resins
Silicate resins

Solvents
These volatile organic compounds dissolve the binder and modify
the viscosity to enable the paint to be applied.

The solvent should have an evaporation rate consistent with

achieving the required drying time and formation of a closed film.

Often blends of solvents are used to achieve the desired

application, film forming and drying characteristics.

They can be broadly classified into hydrocarbons, alcohols and

ethers, and esters and ketones.

Curing Agents
Two pack paints consist of the resin as one component and the
curing agent as the second component which when mixed
together chemically react to form a cured film.

The products are both made by the paint manufacturer and

supplied, generally as part 'A' and part 'B'. The tins will be different
sizes depending upon the mixing ratio ie 2:1, 3:1 etc.

Additives
These consist of plasticizers, driers, thixotropes, anti-skinning
agents, diluents, accelerators, fungicides, bactericides, anti-
foaming agents, dispersing agents, catalysts, flow and levelling
agents, stabilisers and surfactants.

Their use varies considerably, depending on the type of binder

and the end use of the coating.

© Copyright 2016 Fitz-Coatings Ltd Page 25

 Raw Materials
Pigments, Extenders and other Powders
The pigments, extenders and others in powder form arrive in pack
sizes from 10 -1000 kg and are usually pre-inspected by the
supplier based on the provision of full certification.

Random sampling of material supplements this system and a

comprehensive traceability procedure is activated prior to any
material being used in production.

Raw Materials
Synthetic Resins
The majority of synthetic resins are delivered by road tanker and
are usually supplied at elevated temperature to assist unloading
and on site distribution.

Resins are then pumped directly into the manufacturing vessels

via a computer controlled system or into storage tanks.

Solid resins are delivered in bags to be stored before use.

Raw Materials
Solvents
Solvents are delivered by tanker and stored on-site in dedicated
tanks prior to use.

The solvents are generally supplied by chemical organizations

direct to the paint supplier.

The solvents tanks should be away from any of the main building
of the paint manufacturer.

There maybe a number of solvents along with solvent blends to

suit the particular coating.

Overview
Pigments, extenders, resin, solvents and additives are mixed
together to form a paste.

The paint mixture is milled to break up aggregates of particles and

disperse them homogeneously throughout the mixture.

The introduction of micronised pigments and extenders decreased

the necessity for grinding and attrition and high speed dispersers
predominated. This resulted in larger batch sizes and faster
production rates although bead mills and sand mills are still in use
for certain products.

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 Dispersion
The stages involved in dispersion are wetting of the
pigment/extender surface by the binder, breakdown of the
pigment/extender agglomerates into individual particles and
keeping the separated particles in a stable condition in a
homogeneous mixture.

Pigment dispersing agents are often used to assist the process.

The dispersing action depends on the mill used as follows:

Ball, Bead and Sand Mills-Impact and shear.

Roller Mills-Shear.
High Speed Dispersers-High shear friction forces at the
periphery of the toothed disc.

Mills and High speed Dispersers

The apparatus includes:

Ball Mill - Horizontally rotated cylinder containing steel or ceramic

balls (not often used nowadays).

Bead Mill - Horizontal or vertical attritor with internal agitator and

glass or ceramic beads

Sand Mill - Vertical mill with agitator and quartz sand.

Roller Mill – Single roll against a bar or 2 or 3 rollers often

rotating at different speeds and in close contact with each other
(not used nowadays).

High Speed Disperser - Vertical cylindrical unit with a disc

impeller (various designs) on the end of a high speed rotating
shaft.

Filling
After manufacture and after quality control checks the products
are filled into containers. These can vary in size from 2.5 litres to
20 litres although where decorative paints are concerned the pack
sizes can be much smaller.

Re-usable containers holding up to 1,000 litres of product are

often supplied to high volume users and to accommodate
environmental concerns.

On many production lines the filling procedure is automatic and

computer controlled.

© Copyright 2016 Fitz-Coatings Ltd Page 27

 Finished Product
When the paint is filled into the paint tin or can it should be ready
to use.

The applicator should have nothing to do but mix the paint in

accordance with the supplier's recommendations.

Solvents may however be added depending upon the type of

application and temperatures etc.

Sealing and Labelling

The containers are then sealed and labelled which in many cases
takes place on an automatic line after which they are stacked and
palletized.

The labelling has to identify the product with reference numbers

and batch numbers for traceability and to provide health and
safety information and transport codes.

Quality Control
The majority of raw materials are now supplied with a certificate of
analysis or conformity to an agreed standard. Certification is
reviewed prior to supply saving both time and cost and only once
the data has been reviewed and approved is the order
despatched.

On receipt, raw materials are sampled at regular intervals to

ensure conformity.

This procedure supplements the data provided by the

manufacturer and ensures that quality standards are maintained.

Quality Control
Defined quality control and quality assurance procedures are
present throughout the manufacturing process.

After initial raw material tests they cover in-process testing at

various stages of manufacture including, for example, viscosity to
determine if adjustments are required prior to filling.

The tests will vary depending on products and may include,

fineness of grind, colour, and specific gravity.

Small retained samples of each batch are kept for future reference
together with batch cards that record the quantities of each raw
material and other parameters of the manufacturing process thus
ensuring traceability.

© Copyright 2016 Fitz-Coatings Ltd Page 28

 Paint Testing
The manufacturer will do a series of tests during and after the
paint manufacture on the coatings as per their quality procedures.

Examples include:

Drying and curing

Volume solids
Opacity
Sag test
Adhesion
Colour
Hardness
Finess of grind
Flash point etc

Quality Control
Quality control checks are also made of labelling and packaging
and transport.

The checks made are documented and available to demonstrate

compliance with the quality standards in the event of complaints
and for the purpose of both in-house and third party audits.

Long Term Testing

A lot of coatings will be subject to long term external exposure.

Painted panels are placed on racks at 65 degrees and spend

many months (or years) assessing the performance in normal
sunlight.

A lot of fast track testing is set up in sunny climates.

Some of the panels maybe even subject to salt spray etc to

simulate marine environments.

Marine paints maybe testes on panels and subject to immersion

in certain environments.

Product Labels
The paint supplier has to supply every paint can/pot with a
product label in accordance with the legislation of the particular
country.

The legislation will change from country to country.

Do not accept any product that has no product label or has labels
that can not be read due to transit damage etc

© Copyright 2016 Fitz-Coatings Ltd Page 29

 Health and Safety Data Sheets
The paint supplier will have to supply the health and safety data
sheets with the product.

The health and safety data sheets will allow the user to assess
the risk to the user, operator etc

It is essential that the health and safety data sheets are reviewed
prior to product use.

Technical Support
Paint materials can be highly complex products. The application
data sheets will give a number of recommendations such as
environmental conditions, wet and dry film thickness, overcoating
times etc. There will be many instances where the paint supplier
will have to give technical support.

When technical support is given always ensure this is in writing

and filed with the contract files.

Summary
This training unit has reviewed the process of paint
manufacturing.

We reviewed the basics of paint formulation and paint

manufacturing.

© Copyright 2016 Fitz-Coatings Ltd Page 30

 Inspection and Test Equipment

Objective:
The objective of this unit is to gain an insight into the inspection and testing equipment used in the protective
coatings industry.

There are various manufacturers of inspection and testing equipment across the globe.
There are also various national and international standards available for the calibration, use and recording
of the instruments.

The Protective Coatings Applicator

The protective coatings applicator is not a coatings inspector.

This unit has been developed to give an overview of coating

inspection and test equipment used in the protective coatings
industry.

The protective coatings applicator has to ensure that the surface

preparation and coatings application are in accordance with the
coating specification and product data sheets.

Inspection and Testing Equipment

Dry Film Thickness

There are numerous types of dry film thickness gauges available

around the globe.

It is essential that the correct gauge or instrument is chosen to

suit the requirements of the task or contract.

It is always advisable to check the painting specification and the

manufacturers instructions.

Magnetic Dry Film Thickness Gauge (Pull off Gauge)

Available in a number of dry film thickness ranges.

Intrinsically safe.(no batteries)
Robust and hard wearing.
Easy to use.
Reliable.
Track record.

Meets the requirements of SSPC-PA2 Type 1 gauge

Verification of calibration for a Type 1 Gauge

Starting at zero move the dial forward slowly with your thumb until
magnet attaches to the coating thickness standard (You will hear

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 a “clunk”) and the white indicator pops down.

Continue moving the dial forward until the reading is greater than
the 50 micron (2 mil) standard.

Move the dial slowly backwards with thumb until magnet detaches
from standard (You will hear a “clunk”) and the white indicator
pops up.

The reading on the dial is the coating thickness in microns.

Repeat the procedure using 2 other standards e.g 150 microns (6

mil) and 250 microns (10 Mil).

Electronic Dry Film Thickness Gauges (Constant Probe Type)

There are a number of electronic (digital and analogue) gauges

available to suit the task.

Electronic gauges are accurate and easy to use.

They can be a simple measure and read or sophisticated gauges.

Capable of storing a great number of dry film thickness readings.

Various ranges available from zero to 1000 microns ( 40 mil ) and

some up to 20 millimetres or more.

Meets the requirement of SSPC-PA2 Type 2 gauge

Eddy Current Dry Film Thickness Gauge

Eddy current techniques are used to nondestructively measure
the thickness of nonconductive coatings on nonferrous metal
substrates.

A coil of fine wire conducting a high-frequency alternating current

is used to set up an alternating magnetic field at the surface of
the instrument's probe.

When the probe is brought near a conductive surface, the

alternating magnetic field will set up eddy currents on the surface.

Reference document; SSPC PA 9 Measurement of dry coating

thickness using the ultrasonic gauges.

Dry Film Thickness Gauge

This animation demonstrates the use of a digital dry film

thickness gauge.

The gauge works on the principle of 'electromagnetic induction'.

The gauges are generally available in ferrous and non ferrous.

Simple to operate in trained hands.

Always read the operating instructions prior to use.

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 Calibration Foils/Shims

Calibration of the dry film thickness gauge is essential prior to

every use.

Calibration shims are required to calibrate the gauge.

The shims are available in different colours which relate to

different thicknesses.

Use a shim with a thickness close to that of the film thickness

you intend to measure.

Change the shim when worn or damaged.

Although the term calibrate is used the only party that can perform
a calibration is the manufacturer or an approved laboratory.

The user verifies the accuracy of the gauge prior to and after each
period of use.

Calibration and Verification

Any calibration or verification must be conducted in accordance
with the coating specification and the manufacturer's
recommendations.

Depending upon the type of gauge, the calibration maybe done on

a flat plate or a blast cleaned surface as illustrated.

The shim should be checked for wear and tear and match (as
close as possible) the specified dry film thickness.

Calibration and Verification

Animation of a type 2 electronic dry film thickness gauge.

The user m u s t check the exact requirements within the

specification or standard before setting the gauge up for use.

The gauge should be checked regularly, certainly every time it is

switched off or used after extended periods of time.

Remember shims do wear and get worn out giving misleading

results.

Wet Film Thickness Gauge

It is essential that the coating applicator can conduct wet film

thickness following coating application.

Applying too much paint will not only waste paint, but could lead
to premature coating defects.

Apply too little paint and there is a risk of under protection.

Use of wet film combs is 'value for money'

Document reference; ASTM D 4414 Standard Practice for

Measurement of Wet Film Thickness by Notch Gauges.

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 Wet Film Thickness Gauge

Easy to use and economical

All applicators should have a wet comb
All applicators should use a wet comb
They are available in metal or plastic

The wet comb should be used immediately after application of the

coating.

Always keep the comb clean and free from dried paint and debris.

Wet Film Thickness Gauge - Combs

A range of combs are available to suit the thickness of the

coating.

The wet film combs are generally available in aluminium, steel or

plastic.

The plastic type wet film combs are designed to be used once
while the aluminium and steel combs can be cleaned and re-used.

Plastic combs are generally 'use once' only as the paint/solvent

can melt the plastic.

Wet Film Thickness Comb

The applicator may well use a plastic wet film thickness comb as
illustrated. These combs are economical but do have a limited life
and can be softened by solvents and paints.

The applicator should be trained in the use of wet film thickness

combs but should also be aware of the limitations with plastic wet
film thickness combs.

Wet Film Thickness Gauge - Wheel

Another type of wet film gauge is the wet film thickness wheel.

This instrument is, however, used for specialist processes such

as coil coating.

Most industrial type contracts use the traditional combs which are
more economical.

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 Relative Humidity

Relative humidity is extremely important to coating application

and cure.

Relative humidity must be checked on a regular basis.

There are a number of instruments for checking the relative

humidity, the most popular being the whirling hygrometer.

This instrument is manually used by trained personnel.

Environmental Conditions
Record all the environmental conditions as close as possible to
the work place as.

Environmental conditions can change around a single structure,

this is known as 'micro climate'.

While assessing the relative humidity with a whirling hygrometer,

the steel temperature should be taken with a magnetic or
electronic steel temperature gauge.

Ambient Conditions

Once the whirling hygrometer has been used, the user must then
calculate the relative humidity and dew point from tables or a
specialist calculator.

Both the tables and calculator methods are accurate and simple
to use.

The results of the tables or calculator must be recorded for

permanent evidence.

Ambient Conditions

It is also possible to utilise a electronic instrument which

measures the air temperature, relative humidity, surface
temperature and dew point.

This instrument is simple to operate and will give instant readings.

Calibration must be conducted on a regular basis with this type of

gauge.

© Copyright 2016 Fitz-Coatings Ltd Page 35

 Steel Temperature

The steel or substrate temperature is also an essential part of the

environmental conditions for paint application, especially when
assessing the dew point.

There are two basic methods of recording the steel or substrate

temperature, these include the magnetic thermometer and digital
thermometer as illustrated.

The electronic or digital version will give instant and accurate

readings.

Magnetic Surface Temperature Gauges.

These type gauges require 15-20 minutes to stabilise and give
accurate results.

They are safe to use as no batteries are necessary to operate the

equipment.

Dont forget to remove them before applying the coating system!

Animation of Digital Vs Magnetic Temperature Gauge

This animation gives a comparison in the time taken to record the

temperatures with a digital and magnetic thermometer.

Although the digital thermometer gives almost instant results it

may not be possible to use in all working environments due to the
potential hazards with use of battery operated equipment.

Surface Profile

The surface profile is important when abrasive blast cleaning.

There are various methods of testing or checking the surface

profile.

One of the oldest forms of checking the surface profile is with a

surface profile needle gauge.

This gauge measures the peak-to-valley height of a blast cleaned

surface.

Reference documents; SSPC PA 17 Procedure for Determining

Conformance to Steel Profile/Surface Roughness/Peak Count
Requirements

and

ASTM 4417 Standard Test Methods for Field Measurement of

Surface Profile of Blast Cleaned Steel

Animation of a Needle Gauge

The needle gauge is placed onto the steel surface where the

© Copyright 2016 Fitz-Coatings Ltd Page 36

 needle falls into the surface profile.

The profile measurement can be read directly from the gauge.

The needle is quite delicate and care must be taken when using,
cleaning and putting away after use.

A number of readings is necessary to achieve an average surface

profile.

Surface Profile - Digital Type

A digital surface profile gauge is also available.

This gauge is battery operated compared to the analogue type

which does not require any power.

As with all electrical equipment there may be areas where this

gauge can not be used.

The gauge is quick and easy to use.

Surface Profile - Replica Tape

A replica tape is a method of checking the surface profile while

keeping a permanent record.

The type consists of foam with a non-compressible backing.

The foam side is rubbed into the surface providing the permanent
mould of the surface profile.

Various size tapes are available to match the requirement of the

specified surface profile.

The tapes currently being manufactured and used in the industry

are Coarse, Extra Course, and Extra Course Plus.

Surface Profile Testing - Replica Tape

The tape is pressed onto the surface profile and rubbed with a
round head spatula.

The surface profile is copied onto the tape, which is then

measured with a micrometer.

The tape can be kept as a permanent record of the surface profile.

© Copyright 2016 Fitz-Coatings Ltd Page 37

 Surface Profile - Replica Tape
Replica tape demonstrated on an abrasive blast cleaned surface.

Three surface profile ranges are available.

Example demonstrates X course 1.5-4.5 mil or 40 (38)-115

microns

The tapes currently being manufactured and used in the industry

are Coarse, Extra Course, and Extra Course Plus.

Surface Profile - Tape Measurement

A thickness gauge is required to measure the peak to valley

height of the surface profile which is formed on the tape.

The gauges are usually available in imperial and metric versions.

Surface profile - Comparator Gauge

Surface profile can also be assessed with the use of a surface

comparator.

The comparator is available in both grit and shot versions.

Limits of profile grades are fine, medium and coarse.

limits:

Fine: Profiles equal to segment 1 and up to but excluding

segment 2

Medium: Profiles equal to segment 2 and up to but excluding

segment 3

Coarse: Profile equal to segment 3 and up to but excluding

segment 4

Use of a comparator in operation.

The surface comparator is available in grit and shot versions
ISO 8503-2: 1988 outlines three limits of profile grades:

1. Fine
2. Medium
3. Coarse

© Copyright 2016 Fitz-Coatings Ltd Page 38

 Surface Comparator
This video simply demonstrates the use of a surface comparator
on a abrasive blast cleaned steel surface.

The correct type of comparator (grit or shot) is placed on the blast

cleaned surface and viewed to determine the surface profile
range. A hand held magnification not exceeding x7 can be used.

You may also use your nail as a tactile indicator.

Record the fine, medium or coarse. (segment 2, 3 or 4) or if

segment 1 then it is 'finer than fine'. Above segment 4 is 'coarser
than coarse'

Surface Comparator with Magnifier.

Kean-Tator Gauge

The comparator segments are designed to be used with

magnification.

Three versions available: sand, shot and grit.

This instrument finds more use in North America than the rest of
the globe.

Rugotest No.3:
The Rugotest is a surface profile comparator which is rectangular
shaped and has blast cleaned specimens which are grouped
vertically according to the shape of the abrasive used for the blast
cleaning.

One side shows shot blasted plates while the other shows grit
blasted plates.

Each side is divided into six roughness areas from N6 (lowest)

roughness to N11 (highest) roughness.

The popularity of this gauge has decreased since the introduction

of the ISO comparator.

Pinhole and Porosity Detection.

Referred to as spark tester, porosity or holiday detectors and
pinhole testers.

This Instrument is used on cured coatings to establish any breaks

in continuity in a coating along with coating defects.

Various accessories are avaialble with this type of gauge and can
be used on flat and round surfaces such as pipelines etc.

Most high build coatings which are immersion or buried should be

tested for breaks in continuity.

© Copyright 2016 Fitz-Coatings Ltd Page 39

 Pinhole and Porosity Testing

Pinhole and porosity detection is frequently specified for coating

and lining systems where a full continuous coating is essential.

Examples include ballast, cargo and specialist linings.

There are various suppliers of this type of equipment.

The coating manufacturer will advise on the voltages that are to

be set on the gauge.

The Voltage may also be specified in the coating specification.

Two methods of testing.

Wet sponge low voltage technique and the high voltage technique.

The low voltage instrument is suitable for measuring coatings on

metal with less than 500 microns of coatings applied.

The high voltage instrument is suitable for measuring coatings on

conductive substrates above 500 microns up to around 7
millimetres.

Low Voltage Holiday Detector.

Suitable for coatings with less than 500 microns or 20 mils on
conductive substrates. Always check the specification for the
exact maximum dry film thickness as some specifications may
say less than 500 microns (20 mil).

The sponge is dampened with wetting agent.

During use, the liquid penetrate flaws and highlights breaks in
continuity to the user.

Inspection of the coatings.

This animation demonstrates the use of a low voltage holiday
detector on a coated surface.

The instrument is earthed to a bare section of the coated structure

and operator moves the instrument all over the coating looking
and listening for defects and detected defects or misses in the
coating.

The sponge should be dampened and checked regularly for

damage and dirt that may be picked up.

Inspection of the coatings

This video demonstrates the use of a low voltage holiday detector
to a coated section of pipework.

The instrument is earthed to a bare section of the coated pipe and

© Copyright 2016 Fitz-Coatings Ltd Page 40

 operator moves the instrument all over the coating looking and
listening for defects and detected defects or misses in the
coating.

The sponge can fit around most items of coated steelwork

however the process will be relatively slow on large areas.

Always re-check to ensure the instrument is working especially

when no flaws are detected.

High Voltage Holiday Detector

Suitable for coatings above 500 microns or 20 mils up to
approximately 7 millimeters.

A high dc voltage instrument which is suitable for pipelines and

protective linings such as tanks and vessels.

Be aware of the potential health and safety hazards when using a

high voltage instrument.

High Voltage Holiday Detector

This video demonstrates the use of a high voltage holiday
detector being used on a coated piece of steel that has flaws
such as;

pinholes (a very narrow hole running from the coating surface

to the substrate)
holidays (small uncoated areas)
inclusions (objects trapped in the coating, e.g. grit from blast
cleaning)
air bubbles, cracks and thin spots.

The instrument generates a high voltage which is applied to the

surface of the coating via a probe.

When the probe is passed over a coating flaw, the electrical

circuit is completed and current flows from the probe to the
substrate. As a result, the instrument gives audible and visual
alarms and a spark may be produced at the flaw.

Adhesion Testing Equipment

Used to quantify the strength of the bond between substrates and
coating or between different coating layers.

Adhesion testing is generally specified as a test procedure for

newly applied cured coatings.

Should only be used by skilled and experienced coating

inspectors.

Animation of Adhesion Testing

This animation demonstrates the use of an adhesion gauge on a

© Copyright 2016 Fitz-Coatings Ltd Page 41
 painted surface.

A 'dolly' is glued to the surface and the gauge is used to pull the
dolly from the surface.

This is usually a job for an experienced inspector.

The coating supplier will advise on the recommended adhesion

value for their particular coating.

Adhesion Values
The test should only be done by a qualified coating inspector to a
specific standard such as ASTM D4541 which is the test method
for determining the pull-off strength of coatings using a portable
adhesion tester.

Forms of failure include;

Adhesion failure at glue, between base and first coat or

between coats
Cohesive failure is a failure of an individual coating which
splits and you should see the same individual coating on the
dolly and surface.

You regularly get a mixture of all.

Adhesion Test Equipment

Various hydraulic and pneumatic adhesion test gauges are

available.

Potential users must take advice from the suppliers on which

gauge is recommended for which task.

Cross Hatch Adhesion Tester

Simple process for determining the adhesion of a coating.

Suitable for coatings on flat surfaces with a film thickness of less

than 125 microns or 5 mils.

Various size cutting blades are available to suit the task.

© Copyright 2016 Fitz-Coatings Ltd Page 42

 Cross Hatch Cut Test Method
Example of a cross hatch test conducted on a coating applied to
a steel surface.

The exact test method is detailed in ASTM D3359 which is the

test method for measuring adhesion by tape test.

Procedure

Select an area free of blemishes and minor imperfections.

If the test area has been immersed, clean and wipe the surface
with an appropriate solvent and allow to dry –

A lattice pattern with either 6 or 11 cuts is made as follows:

Coatings with thickness up to 50 microns (2 mils).

With a new razor or cutting tool, cut into the coating down to
the substrate with 11 parallel cuts spaced at 1mm between
cuts -
Coating with thickness between 50 microns and 125 microns
(5 mils). With a new razor or cutting tool, cut into the coating
down to the substrate with 6 parallel cuts spaced at 2mm
between cuts –

For coatings with a thickness greater than 125 microns (5 mils)

use Method A the X-cut.

Saberg Drill:
The Saberg drill is a destructive instrument used to assess paint
thickness, number of coats and coating defects such as voids
etc. The portable equipment uses conical drill. A marker is used
on the surface and the instrument drills a hole through the paint
film.

A microscope is used to inspect the coating.

Individual coats can be determined along with the full paint

system.

PIG Gauge Test (Tooke Gauge)

The Paint Inspection Gauge is used by the paint inspector for
either survey work or to check the number of coats applied.

A blade cuts the coating surface at an angle and allows the

operator to look through a magnifying glass to determine and
measure the number and thickness of the coats present.

This test is destructive and should only be conducted on new

works after the agreement of all parties.

The user must be a skilled person such as a qualified Coatings

inspector.

Paint Inspection Gauge (PIG Gauge)

This test is used to assess the number of coatings on a
substrate.

© Copyright 2016 Fitz-Coatings Ltd Page 43

 The animation shows a tool that cuts into the coating on a 45
degree angle. Depending upon the coating thickness, other angles
can be used.

A magnifying light with thickness scales will indicate the individual

coating thickness.

The coating thickness and type of coating such as soft or hard

may have an affect on the use of this test.

Surface Contamination

Surface contamination from soluble salts such as chlorides and

sulphates will lead to blistering of a coating, particularly in
immersed conditions.

These salts are virtually invisible to the human eye and specialist
inspection equipment is required to check the substrate during
cleaning or surface preparation.

Salt Contamination Meter

Measures the conductivity of wet paper which is pressed onto
the surface and placed in the meter.
Calculates soluble salt levels on a surface.
Follow the manufacturers instructions and review the painting
specification for the acceptance criteria.

Reference documents; SSPC Guide 15 Field methods for

extraction and analysis of soluble salts on steel and other
nonporous substrates. (covers all test methods)

Soluble Salt Detection on Blast Cleaned Surfaces

Detects chlorides on the prepared substrate.

Special kits are available to find the specific contaminant such as

soluble chloride salts.

Always observe the suppliers recommendations on the use of the

equipment and the paint specifications for acceptance criteria.

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 Specialist Inspection Equipment

A kit designed to measure chlorides, sulphates and nitrate ions.

All contents are supplied in robust case and ready for instant use.

The coating specification will detail the criteria for the maximum
amount of chlorides, sulphates and nitrates.

Specialist training should be conducted on this type of equipment.

Bresle kit and patches

Conductivity kit.
Used in accordance with ISO 8502-6 standard
This method extracts material for analysis soluble
contaminants from a surface by use of a flexible pad which is
fixed to a surface.

SSPC Technology Guide - 15 Field Methods for Retrieval and

Analysis of Soluble Salts on Steel and Other Non porous
Substrates is a reference source for these and other test
methods.

Pictorial Surface Standards

Numerous standards exist in the protective coatings industry.

Various organisations have developed their own standards.

Examples include the SSPC and NACE.

It is important to have the latest revision of these documents.

Inspection Manual
Various inspection manuals are available which detail inspection
techniques and equipment use.

Inspection manuals are generally available from specialist

organisations such as SSPC the society for protective coatings,
NACE and specific instrument manufacturers.

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 Coating and Application Defects Manual
Visual photographs and text description of coating faults and
defects.

These manuals are extremely useful for identifying basic coating

defects.

A full colour version is however necessary as some manuals are

in black and white.

Test Panels
Some specifications specify that test panels are prepared and
coated by the applicator prior to the commencement of the works.

Surface preparation and full coating application is usually

conducted to ensure the operative is fully conversant with the
process and equipment and is competent in the tasks.

The Coating Supervisor and Inspector will monitor and document

the test panel treatment.

In Process Measuring and Monitoring

An inspection test plan should be developed for the contract.

The inspection test plan will detail all the aspects of the
inspection criteria including the hold and witness points etc.

The inspection test plan should be approved by the customer or

client.

Headings usually contain:

Pre-surface preparation, environmental conditions, surface

preparation standards, coatings application and inspection.

Full Inspection Equipment kit

Contains most use types of equipment.
Can be complemented by specialist equipment.
Available by major instrument suppliers.
Ensure adequate training is conducted before using the
equipment.

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 Summary
This training unit reviewed Coating inspection and test equipment.

We briefly described the instruments used by the coating

inspector including;

Dry film thickness

Wet film thickness
Environmental conditions
Surface profile
Holiday detection
Adhesion test
Surface contamination etc

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 Documentation

Documentation
The objective of this training unit is to review the documentation that may be required on surface preparation
and coating contracts.

The documentation is often completed by the Coating Inspector, Coating Supervisor, Forman or charge hand.

Documentation
The extent of documentation that is required will depend upon the
type of contract, the type and location of work and the
requirements of the coating specification or contract.

It is not expected that the coating applicator completes

documentation as this should be completed by the Coating
Inspector, Coating Manage/Supervisor or foreman (charge hand).

Site Diary
It is important to keep a site diary.

Even the basic information may be useful at a later date such as

weather, number of operatives on site, work locations, deliveries,
meeting notes etc.

A site diary can be used in the event of a dispute as supporting

information.

Coating Specification
The coating specification should be available to all personnel.

The coating specification will detail the documentation to be

produced by the contractor or applicator.

The coating specification should be detailed within the inspection

plan which should be developed by the contractor and used by the
coating supervisor, foreman or coating inspector.

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 Daily Inspection Report
A daily inspection report should be completed for all surface
preparation and coating activities.

This inspection report should detail the ambient conditions,

surface preparation treatment, coating and material details,
including batch number etc.

Details of problems should also be included in the daily inspection

report.

If a problem arises at a later date the inspection reports will be

closely examined.

The daily inspection report should be signed and dated.

Note: The plant and equipment should be logged on a daily basis.

Daily Inspection Report

The daily inspection report should also detail any discrepancies
with the workmanship, material etc.

If re-work is conducted, this should be reported also.

Additional pages (continuation sheets ) can be added to the

report.

Always ensure the additional sheets are identified, numbered etc

in case the sheets are separated.

Documentation
Documentation can be hand written or written directly into the
computer.

Software systems are now available that saves all the

documentation on a specific inspection documentation system
and can be retrieved at any time.

Which every system is used the daily inspection report should be

as comprehensive as possible.

The company or organization should be aware where to find all the

inspection reports at a later date.

Daily Inspection Reports

As a minimum the daily inspection reports should contain the
following;

Contract number
Contract name and title
Date
Location
Name of the Inspector(s)
Environmental conditions
Details of surface preparation such as standards, profile,
cleanliness etc
Details of coating application including wet and dry film

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 thickness, mixing, drying and over coating times etc
Details of the inspection activities and any specific tests etc
Details of the inspection equipment
Details of anomalies or problems
Paint material type and batch number
general overview of the days activities

Any other items relevant to the days work or activities

Plant and Equipment

The plant and equipment should be logged. Information on use,
inspection and maintenance should be documented.

Some equipment may be owned, such as abrasive blast cleaning

equipment, while other items such as de-humidification and
compressors may be hired.

All problems with plant and equipment should be documented

along with break down times, repair times and costs etc.

Inspection Equipment
All the coating Inspection equipment should be documented along
with calibration (verification) dates etc.

Equipment should have a unique ID so the equipment may be

traced back at a later date, if necessary.

Product Data Sheets

The site or office should have the product data sheets for the
products that are being used on the contract.

It is important that the applicator is aware of the product data

sheets as these have all information relating to mixing and
application also over coating times and cure etc.

Copies of any certificates of conformity from suppliers should be

retained on site.

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 Health and Safety Documents
Health and safety documentation (files) must be maintained on
site.

Examples include;

The point of work risk assessments which must be

conducted on every task that is conducted.
Method statements must be available also along with the
health and safety data sheets for all the products that are
going to be used on the job.
Risk assessments.

Labour and Resources

The works should be conducted to a works program, which may or
may not be within the contract.

Planning is essential on coating contracts so an up to date

program should be on site.

The labour and plant should also be recorded against the program
of works.

In the event of a delay etc the details on the program and labour
resources will be extremely important.

General Folders
General folders should be available for most contracts. These
folders should contain a copy of all the purchase orders raised the
delivery notes for paints, abrasives and plant etc.

also:

1. Hire/off hire notes

2. Plant maintenance or suppliers visit

Every document that is sent to the site or workplace should be

copied or maintained with the folders.

Accident Book
An accident book should be available for the works.

Every site should have an accident book.

Every accident should be written into the book and the relevant
health and safety department made aware of accidents.

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 Photographs
It will be very useful to have a number of photographs throughout
the contract.

Maintain a photographic file on the site.

Permission maybe required for certain sites due to security and

other sites will have safety constrains such as petrochemical
sites and offshore structures.

Independent Inspection and Audit Reports

There will be contracts were an independent coating Inspector is
used and may issue a report of the contract.

A close out report may also be needed if there is any anomalies

or non conformances on the preparation or coating.

Internal and External audits may be conducted on certain

contracts and details of the audit should be available for review.

Summary
This training unit reviewed the documentation that should be
completed or retained on coating works.

We discussed the coating specification, inspection reports, daily

log and dairy along with plant and equipment, planning activities
and health and safety.

© Copyright 2016 Fitz-Coatings Ltd Page 52