Escolar Documentos
Profissional Documentos
Cultura Documentos
&
PAINTING
INSPECTION
QUESTION PAPERS
AND
ANSWERS
NACE
Question Paper 1
5. Identify three abrasives used in blast cleaning and state their use, advantages
and disadvantages
A 1, - Synthetic slags, open blasting systems, A, expendable, cheap, no silicosis
hazards, D, breaks down quickly, fine particles embed into surface profile.
2, - Chilled iron grit, enclosed blast mills, open blasting with recovery systems,
A, cheap, efficient, D, excessive wear, larger quantities of fines need extracting
3, - cast steel shot, enclosed recovery systems, A, surface peening, work
hardening, D, tendency to impress impurities into surface pages 8 & 9
8 What is a Jasons hammer. Where could it be used and what restrictions are
associated with its use.
A A needle gun, used for cleaning difficult surfaces, rivet heads, welds, etc.
Effective for peening, stress relieves surface. Disadvantage of leaving sharp
edged craters and pushing impurities into the surface. page - 16
10 What is millscale
A millscale is an oxide of iron, on the steels surface, produced when the steel is
Manufactured page - 4
14 Describe a test for the detection of millscale residues on a blast cleaned surface
A Copper sulphate spray a fine mist of the solution onto an are of approx 100mm
dia. The steel turns bright copper colour and any millscale particles show as black
spots page - 19
16 How thick is the plastic backing of testex. Give the answer in imperial and metric
A The plastic backing (Mylar) is 50m or 0.002 thick page - 11
21 Name two test methods that are able to determine the presence of hygroscopic
salts on a substrate
A Potassium ferricynaide test,
Merckoquant test page - 18
1 What is a polymer
A Chemical compound made up of elements of low molecular weight, i.e.
hydrogen, oxygen, carbon, nitrogen. A paint binder forms polymers when drying
page - 20
2 What is polymerisation
A The joining together of hundreds or thousands of atoms in the polymer molecule
page - 20
15 What layers are present in a multi-coat paint system. What is the function of each
Coat
A Primer to provide maximum and lasting adhesion to a substrate, provide a key
to the next layer and to retard corrosion by addition of inhibitive pigment
Midcoat provide a barrier to the passage of water, build up film thickness
Finish provide surface finish, colour, gloss, solar protection page 26/27
22 What is a varnish
A Varnish - an undigested paint composed of oil and resin oleoresinous varnishes
page 19/20
4 What is the difference between the density of a paint and the specific gravity of a
Paint
A Density is the weight per unit volume, Specific gravity is the density of any
substance compared to the density of water page - 38/39
13 What is flocculation
A Tendency of the dispersed pigment particles to come together to reform
Aggregates page - 33
18 What is the problem associated with degreasing hot surfaces with trichlorethylene
A Highly toxic and the possibility of phosgene gas being released page -
5 Explain the purpose and use of the pendulum (Koenig Albert) test
A The purpose of the pendulum test is to determine the hardness of the paint film.
The apparatus consists of a pendulum supported by two ball points, which rest on
the painted surface. the pendulum is set in motion and the number of swings
counted. The softer the paint film, the greater the damping action, the lower the
number of swings and vice-versa page - 44
6 Name two tests for determining drying rates for paint films
A Ballotini test, glass balls falling onto a fresh coated slow moving test panel.
Mechanical thumb test, motor driven mechanical thumb is pressed into a painted
Surface page - 44
7 What is opacity
A Opacity is the hiding power that a paint film possesses page - 45
15 What equipment and procedures are used to determine R.H.% and D.P.
A 1, Screen hygrometer and Masons hygrometer static type relying on a natural
airflow over a wet wick
2, Assman and psychrodyne hygrometers work by fan driven air supply over a
wet wick
3, Whirling hygrometer portable and dynamic type, operates by moving a wet
wick through the air page - 50
16 Paint mills fall into two categories, what are they. Give two examples of each
A Direct charge Ball mill, Attritor mill
Pre-mixes or slurries Bead mill, Colloidal mill
20 State typical tip sizes for chlorinated rubber and zinc rich paints
A Chlorinated rubber 13 21 thou
Zinc rich - 17 23 thou page - 52
9 Are sacrificial primers noble or ignoble with reference to the surface being
coated
A Sacrificial primers, notably those containing zinc or aluminium can be stated as
being ignoble when a steel surface is being coated page - 26
18 Why might you suspect that a paint is out of date, how would you check to make
sure and what action would you then take
A Appearance of paint on a fresh opened container may have the following, heavy
skin on top, paint has segregated, pigment binder separation, paint has solidified,
21 What is another name for a sand mill and how does it differ in operation from a
ball mill.
A A bead mill, also known as the pearl or sand mill, differs by that the ball mill is a
horizontally mounted cylinder which uses steel or porcelain balls which cascade
down onto the ingredients as the cylinder rotates
With a sand mill the paint slurry forced through the cylinder, inside which are
rotating discs and between these are ballotini or similar beads page - 34
22 State two methods used to determine the d.f.t. of M.I.O. paints
A By the use of destructive test gauges, as MIO is ferromagnetic standard gauges to
measure the d.f.t. cannot be used. Also the d.f.t. can be assessed by calculation
providing the v.s.% content of the paint is known.
d.f.t. = v.s. x w.f.t.
100
1 What was the volume solid content of the paint if it was applied with a w.f.t. of
50m and a d.f.t. of 25m was obtained
A v.s.% = d.f.t. / w.f.t. x 100
v.s. = 25 x 100
50
v.s. = 50%
2 What was the v.s.% of a paint with a d.f.t. of 43m, if the paint was originally
applied with a 72m w.f.t.
A v.s.% = d.f.t. / w.f.t. x 100
v.s. = 43 x 100
72
v.s. = 60%
3 What w.f.t. would be applied to leave a d.f.t. of 140m using a paint with 58%
volume solids
A w.f. t. = 100 x d.f.t.
v.s.%
w.f.t. = 100 x 140
58
w.f.t. = 241um
4 What d.f.t. would result if a paint with 39% volume solids had a w.f. t. of 70m
A d.f.t. = v.s. x w.f.t.
100
d.f.t. = 39 x 70
100
d.f.t. = 26um
5 What would be the w.f.t. if 19 litres of paint was used to cover an area of 9m *
9m.
A w.f.t. = volume
Area
w.f.t. = 19lts
9m x 9m
w.f.t = 19 x 1000cm3
900cm x 900cm
w.f.t. = 19 x 10,000 convert to um (10,000um = 1cm)
810
w.f.t. = 235um
6 What d.f.t. would be obtained if a paint with 48% volume solids was applied
140m thick
A d.f.t. = v.s. x w.f.t.
100
d.f.t. = 48 x 140
100
d.f.t. = 67um
7 What was the v.s.% of a paint if it was applied with a w.f.t. of 120m and a d.f.t.
of 72m was obtained.
A v.s.% = d.f.t / w.f.t x 100
v.s. = 72 x 100
120
v.s. = 60%
8 What w.f.t. would be applied to leave a d.f.t. of 65m using a paint with 49%
volume solids.
A w.f.t. = 100 x d.f.t.
v.s%
w.f.t. = 100 x 65
49
w.f.t. = 132um
9 What w.f.t. would be applied to leave a d.f.t. of 138m using a paint with 56%
volume solids
A w.f.t. = 100 x d.f.t.
v.s.%
w.f.t. = 100 x 138
56
w.f.t. = 246um
10 What was the w.f.t. if 24 litres of paint was used to cover a circular area of 5
metre radius
A w.f.t. = volume
Area
w.f.t. = 24
r2
w.f.t. = 24
x 5m2
w.f.t. = 24 x 1000cm cancel out by 1000
500cm x 500cm x
w.f.t. = 24 x 10,000 convert to um (10,000um = cm)
785
w.f.t. = 305um
11 What would be the d.f.t. if 15 litres of paint with a volume solids content of 44%
covered an area of 12m * 7m
A d.f.t. = v.s. x w.f.t.
100
d.f.t. = 44 x ?
100
w.f.t. = volume
area
w.f.t. = 15 convert all to cm
12m x 7m
w.f.t = 15 x 1000cm3 cancel out by 1000
1200cm x 700cm
w.f.t. = 15 convert to um (10,000um = 1cm)
840
w.f.t. = 15 x 10,000
840
w.f.t. = 179um
d.f.t = 44 x 179um
100
d.f.t. = 79um
12 What would be the d.f.t. if 14 litres of paint with a volume solids content of 49%
covered an area of 14m * 8m
A w.f.t. = volume
Area
w.f.t = 14 x 1000cm3 convert to cm
1400cm x 800cm
w.f.t = 14
1120
w.f.t. = 125um
13 What volume of paint would be required to cover an area of 290m2 if the volume
solids content is 43% and a minimum d.f.t. of 65m is specified
A
14 What volume of paint would be required to cover an area of 300m2 if the volume
solids content is 49% and a minimum d.f.t. of 70m is specified.
A
15 What would be the d.f.t. if 3 gallons of paint with a volume solids content of
49% covered a circular area 9metres in diameter
A w.f.t. = volume
area
w.f.t. = 3 x 4.55 convert to cm
r2
w.f.t. = 13.65 x 1000cm3
45002 x
w.f.t. = 13650
6361725
w.f.t. = 215um
d.f.t. = 49 x 215
100
d.f.t. = 105um
16 What d.f.t. would be achieved if 4.5 gallons of paint is used to cover a circular
area 14 m in diameter. The volume solid content of the paint is 43%
A w.f.t. = volume
Area
w.f.t. = 4.5 x 4.55 x 1000cm3 convert to cm units
70002 x
w.f.t = 20475
1539380
w.f.t = 133um
d.f.t. = 43 x 133
100
d.f.t. = 57um
17 What d.f.t. would be achieved if 22 litres of paint is used to cover a circular area
23 yards in diameter. The volume solid content of the paint is 56%
A w.f.t. = volume
Area
w.f.t. = 22 x 1000cm3 convert to cm units 23yards = 23 x 0.914
105002 x = 21.m
w.f.t = 22000
346360590
w.f.t. = 64
d.f.t = 56 x 64
100
d.f.t. = 36um
18 How much paint would be required to paint the external surface of a 4metre
diameter circular cylinder standing 7m in height. The flat circular top of the
cylinder must also be coated. The paint to be used is solvent free and the surface
of the cylinder has been wire brushed. The d.f.t. required is 130m
A Area of cylinder = D x H
= 4x7
= 88m2
Area of roof = r2
=x4
= 12.6m2
19 What d.f.t. would be achieved if 5.2 gallons of paint is used to cover a circular
area 27.5 yards in diameter. The volume solid content of the paint is 67%
A
2 What action is taken if a wet paint film gets contaminated with grit
A Reblast and recoat.
3 What paint system is applied for steel surfaces operating at less than 65C
A SPA 1
6 Describe the operations for preparing and painting surfaces for hot duties
between 66-99C.
A SPA 1 Surface preparation to BS 7079 Sa21/2, surface profile of 30 - 75m,
application of high solids solvent based epoxy primer to 75 m followed by
Epoxy MIO coat to 75 m. A High build epoxy undercoat of 75 m and a top
coat of epoxy or polyester acrylic finish of 40 m.
10 State the requirements for preparing and painting steel surfaces attaining
temperatures between 150-340C.
A
12 State the preparation and paint system required for aluminium cladding.
A Paint system I accordance with SPA6. The surfaces shall be thoroughly cleaned
of dust, chemicals, oil & moisture. Lightly abraded to provide an adequate key
2 What is an attritor
A Type of paint mill, of the direct charge type
7 What is cross-linking
A Cross-linking is a term for polymerisation that occurs during the drying or curing
of the paint by oxidation or chemical reaction, these paints are convertible or
non-reversible paints, page - 25
14 What is the difference between the term thinner and the term solvent
A
16 List the main advantages and disadvantages of a water based paint for use on steel
A
17 Describe the methods for detecting oil contamination on the surface of steel
A
18 Why is distilled water or clean rain water used in a whirling hygrometer
A
19 What is an electrolyte
A
23 What are the advantages of using wet blasting instead of dry blasting
A
Corrosion occurs as a result of a reaction between the iron and the environment, whereby
the iron reverts to its natural neutral state of iron oxide. It is a naturally occurring process
and the speed of corrosion is influenced by air, water and temperature. An electrolytic cell
comprising a cathode, an anode and an electrolyte is set up, with the anode corroding and
the cathode being protected.
Where a reaction is set up between two closely attached differing metals, the less noble
one will act as the anode, sacrificing itself to the more noble cathode. I.e. millscale
(cathode) to steel (anode).
b) Millscale
A thin blak flaky layer of oxidised iron, formed during steel manufacture or forming
operations of around 1000C, contact with air causes millscale to form.
Water blasting with or without abrasion injection, operates at pressures from 100psi to
60,000psi and can cut a profile into the steel.
Pressure washing low pressure, typically 100psi applied with or without detergent,
useful for removing salt and chloride contamination.
Name two tests used to determine the presence of hygroscopic salts left on a blast cleaned
surface.
Name four expendable abrasives and state the difference between expendable and
reusable abrasive
Name the three basic constituents of a solvent carrying paint and the functions each
performs in the paint.
1) Binder Binds the particles together, holds them in suspension. Gives the paint its
finish, achieves adhesion to the surface, gives flexibility. Resistance to water,
chemicals and abrasion.
2) Pigment Gives colour to the paint and opacity. Resistance to acids, alkali and light
3) Solvent Forms the evaporative part of the drying process. Thins the paint for ease
of application.
Describe what qualities a laminar pigment gives to a paint and name four laminar pigments.
Laminar pigments have a shape like small leafs that overlap and interweave on drying. Form
a coating that has a low permeability to water and solvents
M.I.O. Mica, Graphite, Glass flake.
Describe what a tie-coat is and give three reasons why we may require one.
An intermediate coat between two incompatible coating systems. Used to prevent problems of
lack of adhesion, bleeding out, solvent stripping.
Describe a typical paint manufacturing process and give two types of paint mill which could
be used.
Process, select and assemble paint components, mill the paint, carry out QC checks, density,
opacity, viscosity etc, tin the paint, warehouse and distribute.
Describe what you know of viscosity and outline one method of testing.
Viscosity the measure of a fluids resistance to flow. Free flowing paint use of a Ford flow
cup No4. Put finger over hole and fill cup with paint, scrape off excess and allow a small time
for bubbles to escape. With stopwatch at hand, release paint, start watch simultaneously. Stop
watch at first noticeable break in paint stream. Time is in seconds. All type of paint measured
at same temperature 20C + - 0.5C
Density is weight per unit volume, calculated by weight over volume with the unit of g/cm3.
Used to test how much solvent has been added or if a two pack paint has been correctly mixed
Give four artificial weather devices and describe what they simulate.
What is the name of any instrument that measures opacity and give two types.
Degrease and roughen test surface, stick down dolly with regular araldite (standardises test),
wait 24hrs at 25C, cut around dolly down to substrate. Apply pulling force until failure.
Record pull-off force in PSI and mode of failure, cohesive or adhesive.
a) Conventional spray set-up comprised either gravity cup, suction cup or pressure
feed, operate at relatively low pressure, only suitable for thin materials. Paint is
atomised at the nozzle with the operator making adjustments.
b) Airless spray system paint from non-pressurised container is sucked in using a
fluid pump. The fluid pump pressurises the paint at up to a rate of 67:1, the pump
operating pressure is about 100psi. high volume and high build paints can be
applied, with little overspray. Manufacturer sets pressure at pump with the paint
atomising only when the gun is operating. Dangerous due to high velocity.
c) Electrostatic spray system a special spray gun applies a charge to the paint
particles. The substrate positively earthed attracts the negatively charges paint
particles. The particles are drawn to the substrate in a wrap around effect,
resulting in a very even coating and very little wastage.
What are the essential differences between a blister and an Osmatic blister
Blister Usually dry, caused by expansion and contraction of the paint film away from the
substrate.
Osmatic blister Caused by the entrapment of water or solvent or by hygroscopic salts, left
on a blast cleaned surface.
What shall painting equipment comply with when being used on a BGAS site.
a) Bleeding Colour coming through from the underlying coating, staining the new
coating
b) Blooming Loss of gloss, milky like in appearance, caused by a wet paint film
coming into contact with moisture, cold damp air.
c) Chalking The disintegration of the binder caused by UV light.
d) Cissing Failure of the paint to form a complete film due to the presence of oil
& grease
e) Grinning The showing through of the underlying coat due to poor opacity of
the new coating
f) Flocculation Separation of the paint in the tin and its refusal to mix back together
g) Lifting up applying a coat of paint before the previous one has cured, causing
part of it to be lifted up into the new coating
h) Ropiness Heavy lines in a brush painted surface
i) Solvent stripping The absorption of the solvent of a new coat into the existing coat,
causing the removal of the existing coat
j) Oxidation the curing reaction of a one pack paint, between the binder and
oxygen to bring about the drying process
k) Chemical curing The curing reaction of a 2 pack epoxy paint and catalyst during the
curing period
l) Overspray Loss of paint onto other surfaces and into the atmosphere.
What is Millscale and why is it a particular problem when attempting to protect steel P2
Millscale is oxidised iron, formed on the steel during manufacture or forming operations,
(steel temp, typical 1000C). Millscale is more noble than steel, when the underlying steel is
exposed, the steel will corrode in preference to the millscale. Over painting of loosely
adhering will cause an early failure of the paint system, by bringing the paint away due to
lack of adhesion to the substrate steel.
What is the number of the Swedish standard contained within BS7079 and list the rust and
blasting grades with their relevant brief titles. P9
Name 3 tests for locating hygroscopic salts and millscale on a blast cleaned surface P10
What factors influence how clean and how rough the surface becomes after blast cleaning P6
Regarding hand and power tool cleaning, state what always precludes this process and to what
standards. P8/9
1) Binder
2) Pigment
3) Solvent
What are the functions of each of these three in a solvent carrying paint P15
Binder Binds the particles together and holds them in suspension, gives the paint its
finish, coating adherence, flexibility, resistance to chemicals, water, abrasion.
Pigment Gives colour, opacity, resistance to acids, alkalis and light (UV)
Solvent Forms the evaporative part of the drying process, thins the paint for easy
application, primers and mid-coats only, washing out of equipment, brushes.
Name five items that can be included in a paint to improve its performance or suitability P16
a) Epoxy Acetone
b) Chlorinated Rubber Xylene
c) Alkyd resin White spirit
d) Emulsion Water
Name six opaque pigments, together with their respective colours. P18
Laminar pigment are composed of small flakes, leaf like in appearance, they overlap and
inter-weave on drying, forming a highly resistant, low permeability film, resistant to water,
and solvent. M.I.O., Mica, Graphite, are examples.
Convertible coatings undergo a chemical change on drying and cannot be harmed or softened
by contact with own solvent.
Non-convertible dry by solvent evaporation only, no chemical change, therefore can be
softened by contact with own solvent.
The length of time a two pack paint has to stand before application. Time to let the air bubbles
escape and any chemical reactions to take place. Time is stated by the manufacturer.
The length of time following the induction period, where the paint remains in an applicable
state, according to the manufacturers instructions.
Where a substrate is isolated from the environment by using a low permeability coating,
highly resistant to moisture and air. The coating may comprise of 4 coats one usually an
M.I.O. coat.
Define the term Tie-coat and give an example of its use P23
An intermediate coating that can tie together two normally incompatible systems, i.e. Alkyd
and chlorinated rubber. Tie coating would prevent the problems of adhesion, solvent
stripping, bleeding, etc.
Name two types of paint mill and give two examples of each P24
Pigment particle size, to assess the degree of grinding of the pigment, the smaller the particle
size the finer the pigment and the higher degree of gloss.
What is a Flashpoint and in what apparatus is it determined.
The lowest temperature at which a liquid will ignite when introduced to a source of ignition.
It is determined by the use of an Abel Cup.
What is viscosity and what equipment is used to measure the viscosity of A) a free flowing
paint, B) a Thixotropic paint P29
A small cup made of aircraft alloy, usually holding 100cc. It is used to measure the density of
a paint by calculating weight over volume. It can show how much solvent has been added.
Calculate the volume solids of a paint if the WFT was 186m and the DFT was 93m
Calculate the WFT of a paint of the VS% was 66% and the DFT was 88m
Calculate the DFT of a paint if the VS% was 44% and the WFT was 234m
Calculate the density of a two pack material of part A (paint) was 1.5g/cm3 and part B
(catalyst) was 0.5g/cm3 (assume a mix ratio of 1 : 1)
a) Banana gauge
b) P.I.G. Paint Inspection Gauge
Name four artificial weathering devices and say what they are designed to simulate
Tropical box Humidity, Salt Spray Marine, Water soak Permeability, Temperature
Cycling Flexibility.
Name two drying / curing tests and stated how they are operated P32
What does a Cryptometer measure and give two examples of cryptometer P31
The degree to which the pigment content of the paint is ground down in the paint mills. The
finer/smoother the pigment is ground the higher degree of gloss achieved. Gloss finish can be
influenced by the type and amount of binder, method of application and skill of operator.
Name three adhesion tests and describe how one of them is carried out. P36
State the conditions under which B Gas allow painting to take place P37
1) The air and metal temperature is at least 3C above the Dew Point temperature
2) The Relative Humidity is less than 90%
3) The temperatures for application are within the manufacturers given limits
Name three methods of applying paint and compare the advantages and disadvantages of each
in terms of quality and cost effectiveness.
1) Brush Achieve a high quality finish, very slow application (strip coat ok)
cannot be used to apply High Build coatings
2) Roller fast application, 3 times faster than with brush, poor finish, orange peel
effect, uneven coating thickness
3) Airless spray Fast application, 30 times quicker than by brush, can apply high
build coatings, expensive equipment, parts and maintenance.
What does BS 2015 Glossary of Paint Terms refer to and give 3 examples P27
Used for specifying standardised colours for the construction industry. It is a range of 100
colours taken from the 237 colours identified in BS 5252.
New Galvanising A galvanised steel surface, less than 3 months old, upon
which a cohesive layer has yet to form (bright and shiny)
Weathered galvanising A galvanised steel surface upon which a cohesive oxide layer
has formed by natural weathering (dull, no sheen)
What is the procedure for removing oil and grease from a surface before preparation
commences P12
Oil and grease shall be removed with an approved solvent, low pressure detergent may be
used on large areas, followed by rinsing with clean water and thorough drying.
What is the procedure for removing oil and grease from a surface, if found after preparation
has taken place. P12
Swab down with an approved solvent, a 2% detergent wash, wash down with clean water,
thorough drying and re-blast.
What is the procedure for removing algae and mould growth from pipework
Treat with a biocidal agent, leave for 24hrs at least to kill all spores. Use a stiff bristled brush,
scrub with water, or use a high pressure water wash.
Under what conditions must paint be stored
In a dry lockable well ventilated building at a minimum of 5C below the materials flashpoint,
away from any source of heat. Legal requirements and manufacturers recommendations to be
met.
What is T-Wash, what is it used for, what colour is it, how do we check for a correct
reaction when using it.
T-Wash is an etch primer, that provides a key on new galvanised surfaces and its colour os
blue, after application it should turn black on drying.
A distance of 75mm
What is the maximum allowed time for priming to take place, following preparation and by
what method is primer applied.
4hrs, except SPA 4 where it must be immediately after washing. Primer applied by brush or
spray as appropriate.
What must all pneumatically and electrically operated power tool equipment be.
Earthed to ground
What type of sheeting may and may not be used for protection against spillage and spotting.
What must not be used to clean out paint kettles or to dispose of rubbish
Fire or flames
Some metals are difficult to prepare, name three and describe how you might prepare them.
Aluminium sheeting - etch and degrease Emery cloth and white spirit. Etch primer, Zinc
chromate
Zinc sprayed Denib with emery cloth and degrease, Etch primer followed by zinc chromate
Sheradised - Denib with emery cloth and degrease, Etch primer followed by zinc chromate
Copper Emery cloth and white spirit, etch primer.
What additional information would you record when maintenance painting a pipeline, without
removing the previous coats P20
Establish existing system for surface preparation type, (may contain toxic coating).
Compatible to new system - adhesion. amount an type of contamination, extent of paint
breakdown, extent of corrosion.
Emulsion coalesence
F.B.E. heat cured
Alkyd solvent evaporation, followed by oxidation
2 pack epoxy solvent evaporation, followed by polymerisation
Chlorinated rubber solvent evaporation only
Carbon black
What is a holiday and pinhole detector. What does it detect and how does it work.
If you worked on a contract where frequent stoppages occurred for poor weather, what
additional information would you record.
What is important about selecting a paint system suitable for a particular environment.
What information does B Gas require on a paint tin and what B Gas document deals with the
properties and performance of paints
B Gas PA 9
Tin identification, name, description of product, colour code, special storage requirements,
expiry date, application grade spraying or brushing, batch code, details of current
legislation.
What is unusual about the preparation and paint surfaces which are dealt with under SP 4
State the principles of being able to use a Banana gauge for taking DFT readings.
To use a Banana gauge you must have a substrate that is ferrous and a coating that is non-
ferrous.
Give one advantage of using a Testex tape and disposable WFT combs
What do H.A.S.W.A and C.O.S.H.H. stand for and describe briefly what these deal with.
1) High build epoxy aluminium 75m min, Epoxy M.I.O. 75m min, High build
epoxy u/coat 75m min, Epoxy or Polyester acrylic finish 40m. total system
thickness 265m min DFT.
2) Primer 50m min, M.I.O. 75m min, U/coat 50m min, finish coat 50m min.
total system thickness 225m min DFT. Or 250m DFT min, where primer and
1ST mid coat applied at works.
Primer in all cases to be applied to welds and edges prior to application in order to
achieve final DFT at those areas.
SPA 3 Painting of metal surfaces for hot duties
Surface temperature ranges a) 100 - 149C, b) 150 - 340C, c) above 340C.
Sequence of operations,
Mask out, Remove contamination, oil, grease, with an appropriate solvent. Blast clean to
SA21/2 for Heat Resistant Aluminium pigment epoxy or Urethane primer. SA3 for TSA or
IZS or Polysiloxane system. Clean areas immediately prior to painting.
a) 100C - 149C. H.R. Aluminium pigmented epoxy and Urethane primer,
paint shall be applied within 4hrs of preparation. Following manufacturers
times on overcoating, further coats shall be applied to achieve a minimum
DFT of 100m for Urethane and 250m for epoxy.
b) 150- 340C. Thermally Sprayed Aluminium TSA, preferred system, can
only be applied at works, due to fire hazard. Alternate systems of Inorganic
Zinc Silicate or Polysiloxane coatings applied in accordance with
manufacturers instructions. Care to be taken with IZS as over-thickness can
lead to mud cracking.
c) Above 340C. TSA is the preferred choice. But at site where not practical,
IZS or Polysiloxane primer can be used. With TSA or IZS, a high
temperature sealer should be applied, with heat to cure. Systems are applied
and cured to manufacturers recommendations. The high temperature sealer is
applied because TSA and IZS are porous coatings.
Sequence of operations
Remove surface contamination, swab with grease removing solvents, wash with a 2%
detergent solution. Blast clean to SA21/2, wash down with clean water to remove grit and dust.
Remove standing water by mopping or with squeegee. Two types of materials known to be
damp tolerant. Moisture curing polyurethanes and high solids multi-component epoxy paint.
Both must be applied in accordance with manufacturers instructions, by brush. The painting
shall be in a sequential continuous operation, (single application) Some rust blooming may be
allowed.
Surface preparation
New Galvanising, sweep blast or hand abrade. T-Wash shall be used where these other
options are not practical. Paint system can be Water Borne Acrylic MIO 65m min DFT.
Pigmented high build epoxy 65m min. Alkyd or modified alkyd 40m min DFT primer
thicknesses.
Weathered galvanising
Stiff bristle brush or wire brush, weathering provides its own surface. patch primer with zinc
rich epoxy optional. Paint systems as with new galvanising.
Stainless Steel
Sweep blast with aluminium oxide or garnet. Paint system Water borne Acrylic 65m min
DFT. Zinc rich paints must not be used
Coating systems shall normally be terminated with a full gloss finish of the same generic
type.
For all above, full system when applied must be at least 120m min DFT and include an
M.I.O coat.