Inspection and control

What is QA - QC ?

QA = Quality Assurance
(A documented management system)
QC = Quality Control
(Inspection and testing routines)

The tasks of the paint inspector

To ensure that the requirements of
the coating specification are met.
Verify the quality of work
carried out by the contractor/yard.
Prepare written records of the standard
of work
- Approval (Satisfactory ? / Conforming ?)
- Non-conformance

An inspectors work includes:

To be capable of interpreting
the specifications
To understand the objective
of the inspection
To inspect all structures to be painted
To ensure that all specified requirements are met
To document the results from the inspections
In the case of non-conformance: Issue written reports

Daily logs
Steel temperature
Air temperature
% Relative Humidity
Dew point
Object no. and name
Exact specification
Pre-treatment, specified
and actually conducted.

Film thickness (to be

measured also at spot

repair)
Area, m
Product name, place of
production and batch no.
Name of relevant persons
What was discussed
Non conformance report
(remember signatures)
Other comments

An inspector deals with

several parties
Customer / Owner
The Yard
Contractor / Sub-Contractor
Paint Supplier
Suppliers of Equipment
Classification Society

An inspector needs to know

All the paints that will be used
All the relevant inspection
methods and inspection tools
Relevant standards
Relevant TDS and MSDS
Methods involved in cleaning, pre-treatment and
paint application
The equipment used for pre-treatment and
application: Benefits and limitations

What needs to be inspected ?

If relevant, the following stages
of the production need to be inspected
Shopprimingofthesteel
Thesteelwork
(Preblastingpreparation)
Cleaning and surface preparation
priortopaintapplication
Applicationofpaint
The applied paint film and its
curing/dryingconditions.

Inspection tools

Cd-4932-80

Inspection tools.
Mirror and flash light
Visual inspection
Important tools for inspecting areas difficult to access
For inspection in confined spaces: Use Ex - Class
approved equipment

Cd-4932-83

Using Inspection tools.

Mirror and flash light

Visual inspection
Important tools to be
able to inspect areas
difficult to access
Cd-4932-84

Magnifier
Visual inspection
Handy tool when looking for defects, to
verify cleanliness and roughness of the
substrate

Cd-4932-85

Tools for marking

areas with defects
Photo: Chalk for marking areas during inspection
To be used both after pre-treatment and painting
Areas with defects must be marked properly

NOTE:
Chalk might be
considered as
contamination for
some paint
systems: Remove

Cd-4932-90

Inspection at shop priming

Cleanliness (No salt, oil, grease or other
contaminants)
Rust grade A or B acc. to ISO 8501-1
Shot or grit blasted steel, to Sa 2 acc. to
ISO 8501-1
Correct DFT (Usually 15 - 25 microns)
Satisfactory drying
No damages caused by conveyor.

Inspection of steel work

(Pre-blasting preparation)
The following items need to
be inspected during construction
Roundingofsharpedges.
Smoothingofroughweldingseams.
Removal/grindingofweldspatter
andbeads.
Cracksandpittings.
Surfacefaultslikelaminatesetc.
ISO129443,orISO85013

Pre-blasting preparation
Rounding of edges
Removing of weld spatters etc.
0589-6

0589-5
C3

Inspection of cleaning and surface

preparation prior to application
If relevant, the following conditions
must be inspected / verified

Cleanliness(salt,oil,greaseanddust/dirt)
Evaluationofpresentcondition(rustgrade)
Surfacepreparation(e.g.blastcleaning)
Cleanlinessofpreparedsurface
(salts,oil,grease,dustanddirt)
Climaticconditions
(temperature,relativehumidityetc.)

Relevant standards for assessing

surfaces prior to paint application
Standard

Area

ISO 8501

Visual assessments of surface cleanliness.

ISO 8502

Tests for the assessment of surface cleanliness.

ISO 8503

Surface roughness characteristics

of blast-cleaned steel substrates.

ISO 8504

Surface preparation methods.

ISO 8501 - 1

Surface preparation

Visual assessment of surface cleanliness after

blast cleaning, hand or power tool cleaning
or flame cleaning

Rust grades and preparation grades of uncoated steel

Photographic examples of steel when
blast cleaned with different abrasives

Surface preparation

Standard for deciding rust grades

ISO 8501 - 1
Rust grade A, B, C and D

ISO 8501-1
Evaluation of rust grades
Rust grade A

Cd-0631-59

Rust grade C
Cd-0631-57

Rust grade B

Cd-0631-58

Rust grade D
Cd-0631-56

Mill scale on pipes

Corrosion and mill scale, rust grade B
Rust and mill scale must be removed prior to paint
application.
Mill scale can be removed by blast-cleaning

Cd-4930-86

ISO 8501 - 1

Standard for deciding preparation grades

Sa: Blast cleaning (grades Sa 1, 2, 2 and 3)
St.: Hand and power tool cleaning
(grades St 2 and 3)
Fl:

Flame cleaning (one grade)

ISO 8501 - 1

Standard for deciding preparation grades

Left: Blast standard agreement
Right: Hand tooling of C steel to St 2

4932-76

0631-55

ISO 8501 - 2

Surface preparation

As for ISO 8501-1, but:

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

ISO 8501 - 2
Standard for deciding preparation grades
PSa :

Localised blast cleaning

(grades 2, 2 and 3)

PSt :

Localised hand and power tool cleaning

(grades 2 and 3)

PMa :

Localised machine abrading (one grade)

ISO 8501 - 3

Surface preparation. Design

Visual assessment of surface design
Preparation grades of welds, cut edges and surface
imperfections.
Jan. 2001: Not yet approved

ISO 8502
Assessment of surface cleanliness

(1 of

2)
Part 1

Field test for soluble iron corrosion products

Part 2
Laboratory determination of chloride on cleaned
surfaces.
Part 3
Assessment of dust on steel surfaces prepared
for painting (pressure- sensitive tape method)
Part 4
Guidance on the estimation of the probability of
condensation prior to paint application.
Part 5
Measurement of chloride on steel surfaces
prepared for painting. Ion detector tube method.

ISO 8502
Assessment of surface cleanliness

(2 of

2)
Part 6
Extraction of soluble contaminants for
analysis.
The Bresle method.

*
Part 9
salts

Conductometric measurements of soluble

.

* Part 7, 8 and 10 are not prepared

ISO 8502 Part 1

Merckoquant test for iron
Quantitative test for detection of water soluble
iron-salts
Indicator test strips impregnated with 2,2
bipyridin
Sensitive within the range of 5 mg/l to 250 mg/l
Distilled water
Specified test area 25 x 10 cm
Cotton
Glass/plastic containers

ISO 8502 - 1

Soluble iron salts on blast cleaned surfaces .

Merckoquant test on steel substrate
Steel substrate

Beaker with
test solution

Visual comparison
with the standard

ISO 8502 - 1. Annex 3

Water soluble salts on blast-cleaned
steel.
Potassium Hexacyanoferrate (III) test paper
The filter paper is impregnated with Potassium

Hexacyanoferrate (III)
Water / humidity
In case of the presence of Iron salts the colour will turn
blue
This is a qualitative , not a quantitative test

ISO 8502-1. Annex. 3

Water soluble salts on blast cleaned steel

Filter paper impregnated

with Potassium Hexacyanoferrate

Blue spots

Blast cleaned steel

ISO 8502 - 2

Laboratory test. Determining

chlorides.
Laboratory test method for
determination of Chlorides
on cleaned surfaces

ISO 8502-3
Assessment of dust
Steel Surfaces Prepared for Painting.
Tape

Approved
Not approved

Blast cleaned steel

ISO 8502 - 3
Assessment of dust
Assessment of dust on
steel surface prepared for painting
1. Quantity ratings 1, 2, 3, 4 and 5
corresponding to pictorial references
2.

Dust size classes 0, 1, 2, 3, 4 and 5

ISO 8502 - 3
Assessment of dust
Left: Dust on steel beam
Right: Control of dust according to standard

0866-13

0866-14

ISO 8502 - 3
Assessment of dust
Assessment of dust on steel
surface prepared for painting
1. Quantity ratings 1, 2, 3, 4
and 5 corresponding to
pictorial references
2. Dust size classes:
0, 1, 2, 3, 4 and 5
Inspection / Dust_control1

ISO 8502-4
Estimating probability of condensation
Guidance on estimating probability
of condensation prior to paint application
Psychometer

Thermometer

Wet cotton

ISO 8502 - 4
Humidity
Guidance on the estimation of the probability
of condensation prior to paint application
1.
2.
3.
4.

Air temperature
% Relative humidity
Steel temperature
Dew point

Steel temperature min. 3 oC above the dew point

ISO 8502-4
Measuring the relative humidity
Photo: Sling
psychrometer for
measuring:
- Dry temperature
- Wet temperature
Measure the
temperature in the
vicinity.
Calculate the relative
humidity
Use together with dew
point calculator

Cd-4932-88

Contact thermometer
Electronic instrument for measuring the steel
temperature
Other types of thermometres are also available.
E.g. magnetic thermometers

Cd-4932-87

ISO 8502-4
Dew point calculator
For calculation of dew
point
To be used together with
surface temperature
thermometer and sling
psychrometer.
Use this frequently during
pre-treatment, application
and drying of the paint.
Recommendation: Every 6
hours and when weather
conditions are changing

Cd-4932-89

IX - diagram for determination of

relative humidity (%RH)
Example:
Measured values
Air dry temp.:
14.0 C
Wet bulb temp.: 10.5 C
Read
Relative humidity: 65 %
Dew point:
7 C
Air-water content: 6.3 g/kg

Atmospheric conditions.
Requirement during blasting and painting

Surface temperature of the

structure must be minimum
3 C above the dew point
of the surrounding atmosphere

ISO 8502 - 4

Estimating probability of condensation

Cold liquid inside hull and warm air outside causes
condensation
See how frames inside keeps the cold longer

B-24/2-4
4847-693

Relative humidity, RH
% R.H.:

% water vapour in the air as percentage of the

total amount water vapour the air can contain
at the same temperature.
Example

Air at 20 oC can contain 17.31 g. water/m3, but

contains 15 g/m3. What is the R.H. ?
R.H. =

= 86.65 %

15 x 100
17.31

Ambient temperature and

steel temperature
Is the temperatures important ? YES !
Ambient temperature will
influence:
shelf life
pot life
viscosity/sprayability
steel temperature
Steel temperature will affect:
speed of cure
degree of cure
recoating interval
service life of the coating

Determination of water soluble salts

The most frequently used methods are:

Conductivity
Titration
Colour-reactions
Other Methods:
SCM 400 Salt Contamination
Meter

ISO 8502 - 5

Chlorides on steel surfaces

Measurement of Chloride on steel
surfaces prepared for painting
(The ion detection method)

ISO 8502 - 6

The Bresle method.

A method for extraction of
soluble contaminants on
steel substrates for analysis:
The Bresle method
This is a quantitative test

ISO 8502-6
Salt test equipment - Bresle test
ISO 8502 - 9
(Conductivity)
Equipment for
measuring content of
water soluble salt on
substrate
Bresle method

Cd-4932-96

ISO 8502-6
Syringe - Bresle test: Sampling
Bresle salt test
Syringe for injecting
distilled water
Shows how to inject
the distilled water
through the frame
and into the pad
The water must be
pumped in and out
several times. Follow
the standard

Cd-4932-97

ISO 8502 - 9
Conductometric measurement of soluble salts.

Field method for measuring soluble salts

by conductivity ( S) of solutions
containing water soluble salts

ISO 8502-9
Conductivity meter
Instrument for
measuring the
conductivity
Salt level is measured
as the conductivity of
the solution
Instrument shows the
conductivity which
have to be recalculated
to give the salt level on
the substrate.
Only water soluble salts
and not salted fish!

Cd-4932-98

Different types of salt have different

affinity to water / humidity
Laboratory test.
Different types of salt are formed on the steel plates
Several month of exposure
At similar levels: Chlorides more severe than Sulphates

CD 4932 no. 99

Sodium
Chloride

Iron
Sulphate

No
salt

How to measure the

salt level on a surface

Water soluble salts will

be removed by water
jetting
Here: The substrate is
cleaned at a pressure of
2000 bar
Salt level is measured by
the Bresle method
Dissolve the salt inside
the frame of the patch
Measure the conductivity
of the water sample

Pre-treatment: Wj_saltlevel1

Calculation of salt level

on the substrate
Formula:

(L2 - L1) x 6

= mg salt per m2

L2 = S after cleaning
L1 = S before cleaning
Water sample, ml.:
Constant in formula:

10 15 20 50
4
6
8

20

Units
1 mg
1 m2
1 mg/m2 =
1g/cm2 =
Na+ + ClMol Weights

= 1000 micro grams (g)

= 10 000 cm2
0,1 micro g/cm2 (g)
10 mg/m2
= NaCl (Sodium Chloride)
= Cl- : 35,5 NaCl : 58,5

1 mg Cl- is corresponding to 58,5/35,5 mg NaCl

= 1,6 mg NaCl

Instruments for measuring

surface roughness

Stylus instruments
Elcometer Mod. 123
Testex Press-O-film
Microscope
Comparator
Rugotest No. 3
ISO 8503 etc.

ISO 8503

Surface roughness of blast-cleaned

steel
Part 1
Part 2

Specifications and definitions for ISO surface

profile comparatives for the assessment of
abrasive blast-cleaned surfaces.
Method for the grading of surface profile of abrasive
blast- cleaned steel - Comparator procedure.

Part 3

Method for the calibration of ISO surface profile

comparators and for the determination of surface
profile- Focusing microscope procedure.

Part 4

Method for the calibration of ISO surface profile

comparators and for the determination of
surface profile - Stylus instrument procedure

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

Cd-4932-86

ISO 8503 - 1

Limits of profile grades

a) Comparators for steel. Blast-cleaned with grit abrasives
Fine (G)
Medium (G)
Coarse (G)

Profiles equal to segment 1 and up to,

but excluding segment 2
Profiles equal to segment 2 and up to,
but excluding segment 3
Profiles equal to segment 3 and up to,
but excluding segment 4

b) Comparators for steel. Blast-cleaned with shot abrasives

Fine (S)
Medium (S)
Coarse (S)

Profiles equal to segment 1 and up to,

but excluding segment 2
Profiles equal to segment 2 and up to,
but excluding segment 3
Profiles equal to segment 3 and up to,
but excluding segment 4

ISO 8503 - 1

Nominal values and tolerances

a) Comparators for steel, blast-cleaned with grit abrasives
Segment
1
2
3
4

Nominal reading
m
25
60
100
150

Tolerance
m
3
10
15
20

b) Comparators for steel, blast-cleaned with shot abrasives

Segment
1
2
3
4

Nominal reading
m
25
40
70
100

Tolerance
m
3
5
10
15

ISO 11124

Content of the standard

Specifications for metallic blast-cleaning abrasives.
The standard consists of 5 parts
Part 1

Introduction

Part 2

Chilled iron grit

Part 3

High carbon cast steel shot and grit

Part 4

Low carbon cast steel shot

Part 5

Cut steel wire

ISO 11125

Content of the standard

Methods of test for metallic blast-cleaning abrasives.
The standard consists of 8 parts
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8

Sampling
Determination of particle size distribution
Determination of hardness
Determination of apparent density
Determination of defective particles
and microstructure
Determination of matter
Determination of moisture
Abrasive mechanical properties

ISO 11126

Content of the standard

Specification for non-metallic blast-cleaning abrasive.
The standard consists of 10 parts
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
Part 9
Part 10

Introduction
Silica sand
Copper refinery slag
Coal furnace slag
Nickel refinery slag
Iron furnace slag
Fused aluminium oxide
Olivine sand
Staurolite
Garnet

ISO 11127

Content of the standard

Test methods for non-metallic blast-cleaning abrasives.
The standard consists of 8 parts
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8

Sampling
Determination of particle size distribution
Determination of apparent density
Determination of hardness by a glass slide test
Determination of moisture content
Determination of water soluble
contamination by conductive measurement
Determination of water soluble chlorides
Abrasive mechanical properties

Contamination of abrasives
The abrasives can be contaminated with

Water
Oil and grease
Chlorides
Sulphates

ISO 11127 - 5

Content of humidity of the abrasives

Laboratory test
Requirement: Maximum 0,2
%

ISO 11127 - 6

Content of water soluble

contaminants

Conductivity measurements

A sample of 100 g. of the abrasives

100 ml of water
Shake for 5 minutes and let rest for 1 hour
Shake again for another 5 minutes
Measure the conductivity at a temperature of
10 oC

Requirement: Maximum conductivity of 25 mS/m

How to check the abrasives

According to ASTM D 4940

Mix 300 ml of abrasive and 300 ml water
Stir for 1 min. let stand for 8 min., stir again for 1 min.
Conductivity (AB-1)
Fill the liquid for test
and measure the
conductivity.
Max 25 mS/m

Oil content (AB-1)

No presence of oil,
either on top or as an
emulsion after 30 min.

Is the abrasive free from

oil and grease ?
Put a handful of the abrasives into a
beaker

Pour clean, fresh water into the beaker

Shake the mixture
A film of oil will form on top of the water
if oil or grease are present

This is of particular importance to

check when abrasives are recycled

Is the abrasive free from

oil and grease ?
ASTM D 4940
Put a handful of the
abrasives into a beaker

Pour clean, fresh water

into the beaker

Shake the mixture

A film of oil will form on
top of the water if oil or
grease are present

Shopprimer/ Abrasive_Test1

Inspection during application

The following must be verified, inspected or tested:
Recordnameofcoatingandbatchno.
Ensurepropermixingof2packpaints
Ensureuseofthecorrectthinner
Measuringthewetfilmthickness(WFT)
Numberofcoatsasgiveninthespecification
Cleanlinessbetweencoats(salts,dust,oiletc.)
Dryingtime/recoatingintervals
Controlofequipment:Pressure,nozzleetc.
Climaticconditions(Ventilation,Airandsteel
temperatureandtherelativehumidity)

Information to be found from the

technical data sheet, TDS

Product description
Generic type etc.

Recommended use
Where to use the product

Technical information
Solids by volume, WFT, DFT

Application data
Methods, mixing, potlife

Surface preparation
Different methods given

Conditions during
application
Drying and overcoating
time at different
temperatures
Typical recommended
system
Storage
Handling
Packing control
Health and safety
Details in MSDS

ISO 2808 - 97

Determination of film thickness

(1 of 2)

Method 1: Determination of wet film thickness.

Method 2: Determination of dry-film thickness by
calculation from mass
Method 3: Measurement of dry-film thickness by
mechanically contacting method
Method 4: Measurement of dry-film thickness by
the profilometer method
Method 5: Measurement of dry-film thickness
using microscope method

ISO 2808 - 97

Determination of film thickness:

2)
Method 6: Magnetic method

(2 of

Method 7: Eddy current method

Method 8: Non-contact methods
Method 9: Gravimetric method (dissolving
methods)
Method 10:

Determination of dry-film thickness

on blast-cleaned steel substrates

ISO 2808 - 97 Method No.1

Wet film measuring comb

Microns
250

225 200 175 150 125 100

Steel

Wet paint
75

50

25

ISO 2808
Wet film thickness gauge
Wet film thickness
gauge
To be used on flat,
even surfaces
1-coat: no problem
2-coat: be careful if ;First Coat is not fully
cured/dried
or if
First coat is soft or
resoluble

Cd-4932-81

ISO 2808
Wet film thickness gauge
Measure wet paint film
Here: 25 microns between the teeth

0459-21

4932-81

Calculation of
paint consumption

Calculations : Paint
Abbreviations
WFT
DFT
% VS
LF
DV

=
=
=
=

Wet Film Thickness

Dry Film Thickness
=
Percent Volume Solids
Loss Factor
Dead Volume

Formula for determining the DFT

Formula: DFT

WFT x % VS
100

Example:
WFT=

250 m

% VS

DFT =

50 %

250 x 50=

125 m

Formula for determining the WFT

Formula : WFT

DFT x (100 % +THR)

Example:
DFT

% VS
WFT

% VS
100 m
=

65 %
100 x 100
= % 154 m

Formula for determining the WFT

after thinning (Method 1)
= DFT x (100 % + % thinner)

Formula: WFT

Example:
% VS
DFT
= 100 m
% VS
= 65 %
Added thinner
= 20 %
WFT

100 x (100 % + 20
%) m
=185

65 %

Formula for determining the WFT

after thinning (Method 2).
DFT
=
% VS
=
Added thinner
Volume of paint
54 %
Volume of thinner
New volume
WFT

100 microns
65 %
=
20 %
=
1 litre
=
=

65
1,2

New % VS:

0,2 litre
1,2 litre

100 % x 100 microns

54 % = 185 m

Theoretical spreading rate

% VS x 10
DFT

Formula:

DFT
% VS
10

=
=

100 microns
=
65
Factor
= 6,5m2/litre

Spreading rate:

65 x 10
100

m2/litre

Consumption of paint, no loss

(1 of 2)

To be painted: Tank, area of 500 m2

Paint
DFT
Epoxy mastic
200 microns
Polyurethane topcoat
50

Consumption

% VS
85 %
50 %
=

litre

Area (m2) x DFT

10 x % VS

Consumption of paint, no loss

(1 of 2)

To be painted: Tank, area of 500 m2

Formula:
Epoxy mastic

Area, m2 x DFT
10 x % VS
500 x=200 117,7 litre
10 x 85

Polyurethane topcoat

500 x 50
10 x 50

50,0 litre

Consumption of Paint with loss

To be painted: Tank, area of 500 m2 , 40 % loss
40 % loss implies that only 60 % will remain on the surface.
The correction factor, Loss factor, will be 0.6
Formula:
Epoxy mastic

Area, m2 x DFT
10 x % VS x loss factor
500 x 200
= 196 litre
10 x 85 x 0,6

Polyurethane topcoat

500 x 50
10 x 50 x 0,6

83 litre

Consumption of paint with loss

including Dead Volume (1 of 2)
A certain roughness will give a certain dead volume
Roughness, microns
30
45
60
75
90
105

Dead volume, l/ m2
0.02
0.03
0.04
0.05
0.06
0.07

Total Dead volume, litre =

Area (m2) x DV x 100

% VS x LF

Dead volume increases the

volume of paint required
Smooth (polished) steel surface
Even film thickness

Steel
Specified thickness
Uneven steel surface
Paint will fill the valleys

Steel

Dead volume

Consumption of paint with loss

including Dead Volume (2 of 2)
Tank area 500 m2, 40 % loss, surface roughness 60 microns
DFT
Epoxy mastic
Polyurethane topcoat

% VS
200

85
50

50

Litre dead volume =

500 x 0,04 x 100

85 x 0,6

Epoxy mastic (EM)

500 x 200
=
10 x 85 x 0,6

196 litre (EM)

Polyurethane topcoat 500 x 50

10 x 50 x 0,6

39 litre (EM)

83 litre (EM)

How much paint should we order ?

calculation of paint consumption with
loss
A loss of 40 % means that only 60 %
will be applied on the surface

Example: 100 litre is needed, loss is 40 %

We have to order

100 x 100
60

=
167 litre
100
0,6 (loss factor)

Not 100 litre + 40 % extra = 140 litre

Inspection after application

After application
the following must be checked
Climaticconditions(Ventilation,
Temperatureandhumidity)
Curing/dryingofthefilm
Dryfilmthickness(DFT)
Adhesion
Holidaydetection(ifrequired)

Using PIG Universal on a ships hull

PIG = Paint
Inspection Gauge
Destructive test
method
Possible to verify the
number of coats
applied
Possible to measure
the thickness of each
individual coat

Cd-4932-100

PIG
Paint Inspection Gauge
Mainly for laboratory use

4932-100

ISO 2808 - 97

Determination of film thickness

Method No. 6: Magnetic method

Magnetic induction principle (Method 6 A)

Permanent magnetic principle (Method 6 B)
Instruments for magnetic, metallic substrates
Calibration must be done in accordance
with instructions from the manufacturer

Before testing the paint system

must be properly cured.

ISO 2808 - 97

Determination of film thickness

Method No. 7 - Eddy current method
High frequency electromagnetic instrument
For non-magnetic substrates
Calibration in accordance with the
manufacturers instruction

ISO 2808 - 97

Determination of film thickness

Method No. 10 - On blast cleaned steel substrates
Electromagnetic instruments
Calibration on a smooth steel surface min.
1,2 mm thick
For DFT measurement, not less than 25 and
preferably above 50 microns
Number of readings, as a guide:
1 reference area: At least 3 readings evenly
2 reference areas for every square meter for flat
plates
4 reference areas for every length for a web
2 reference areas every metre length for a flange
2 reference areas every metre length for a pipe

ISO 2808 - Magnetic and

electromagnetic
Dry film thickness gauges
Dry film thickness
gauge
Calibrate on smooth
surface to zero and to
thickness similar to be
measured
Check with your
calibration foil
frequently
Plastic material foils
wear easily. Replace
frequently.
No internal memory in
gauge

Cd-4932-82

ISO 2808 - Magnetic and

electromagnetic
Dry film thickness gauges
Dry film thickness
gauge
Calibrate on smooth
surface to zero and to
thickness similar to be
measured
Check with your
calibration foil
frequently
Plastic material foils
wear easily. Replace
frequently.
No internal memory in
gauge

Inspection \ Dryfilmthickness1

SSPC - PA 2

Measuring DFT on small areas

Procedure
1.

Area of 10 m2: 5 spot measurements

2. Each spot measurement: The average of 3

individual readings made on one small area
3. The average of 5 spot measurements must
be within specified range of film thickness
4. Single spot measurements may be as low as
80% of specified minimum film thickness
5. Individual readings included in the spot
measurements may be less than 80% of
minimum thickness

SSPC - PA 2

Number of film thickness

measurements
Case

Area

Selection of Measurements

1.

10 m2

5 spots (on each spot: 3 measurements)

2.

30 m2

As for case 1 for each 10 m2

3.

Up to100 m2

Select 3 areas, each of 10 m2

4.

Above 100 m2 The first 100 m2 as for case 3

For each following 100 m2 select
randomly one area of 10 m2

Note: If measurements outside the specification for any 10 m 2 in

case 3 or 4 above are found, then each 10 m 2 shall be measured

ASTM D 4752-87

Curing test of Zinc - ethylsilicate with MEK.

Glove

MEK

Rag

Rubbing 50 x

No Zinc on the Rag:

Cured
Approved

A lot of Zinc on Rag:

Not cured
Further curing / Reblasting

ASTM D 4752-87
MEK curing test of zinc ethyl silicate
Left: One cured and uncured test plate
Right: Uncured zinc over coated. Result:
Delamination
0807-2
A-4

ASTM D 4752-87

Curing test of Zinc - ethylsilicate with MEK.

Glove

MEK

Rag

Inspection / Zincsilicate_curing1

ASTM D 3359-87
Adhesion testing by knife and adhesive
tape
There are two test methods
The method to select depends on the DFT
Method A: DFT above 125 microns
Method B: DFT below 125 microns
(Above 125 if wider cuts are used)
Method A: X - cut. Tape test
Method B: Cross - cut. Tape test

ASTM 3359-87. Method B

Adhesion testing

< 50 microns = 1 mm apart (11 cuts)

50 - 125 microns = 2 mm apart (6 cuts)
> 125 microns = Method A or 3 mm between cuts

1.
2.
3.
4.
5.
6.
7.

Cuts: 20 mm long
Brush with a soft brush
Examine
Cuts: 20 mm long at 90o on the original cuts
Brush with...
Tape 75 mm
Within 90 + 30 sec. remove tape

Classification of adhesion test results.

Method B. (Example for six parallel cuts).
5B
4B

None

3B
2B
1B
0B Greater than 65%

5B
The edges of the cuts are completely
smooth; none of the lattice is detached
4B
Small flakes of the coating is detached
at intersections: 5% of the area is affected
3B
Small flakes of the coating are
detached along edges and at intersections
of cuts. The area affected is 5 to 15% of
the lattice.
2B
The coating has flaked along the
edges and on parts of the squares. The
area affected is 15 to 35% of the lattice.
1B
The coating has flaked along the
edges of cuts in large ribbons and whole
squares have detached. The area affected
is 35 to 65 % of the lattice.
0B
Flaking and detachment worse than
Grade 1B.

ISO 2409

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

ISO 2409

Cross-cut test
Procedure:
Make 6 parallel cuts with defined space in
the coating.
Repeat operation, crossing original cuts at
90o so that a grid pattern is formed.
Brush with soft brush.
Apply adhesive tape and pull off.
Classify results in accordance with table 1.

ISO 2409
Cross cut adhesion test
Cross cut adhesion
test
Cut vertical and
horizontal lines to
form a grid
Apply a strong tape
Pull off the tape
Evaluate according
to the standard

Cd-4932-91

ISO 2409
Cross-cut adhesion test
Left: A good type of cross-cut tool
Right: Evaluation of performed test

0002-002

0002-001

ISO 2409
Classification of Cross-cut test

Classification

Description

Appearance of surface
Six parallel cuts

0
1

Completely smooth: none of the squares detached

Small flakes at the Intersections. Area affected 5 %

Flaked along the edges and/or at the

Intersections. Area affected: 5-15%

Flaked along the edges, wholly in large ribbons,

and/or partly or wholly on different parts of
the squares. Area affected: 15-35%

Flaked along the edges in large ribbons and/or

some squares have detached partly or wholly.
Area affected: 35-65%

Any degree of flaking that cannot even be classified by 4.

ISO 2409
Cross cut adhesion test
Cross cut adhesion
test
Cut vertical and
horizontal lines to
form a grid
Apply a strong tape
Pull off the tape
Evaluate according
to the standard
Inspection / Adhesion_crosscut1

ISO 4624

Pull-off test for adhesion

Instruments:
Elcometer Adhesion Tester
Saeberg Adhesion Tester (pneumatic)
Hate Adhesion Tester (hydraulic)
PAT

Failure:
Adhesion failure: Between coats or between or substrate and 1st coat
Cohesion failure: Inside a coat

ISO 4624

Pull-off test for adhesion

Procedure:

Test dollies glued onto the coating

Adhesive: Cyano-acrylate or solvent free epoxy
Remove adhesive and coating around the dollies
Pull off test-dollies vertical to the surface
Read adhesion value and report the type of fracture
Fractures:

Adhesion failure - fracture between coats or substrate

and 1. coat
Cohesion failure - fracture within a coat

ISO 4624
Pull-off dollies glued to the structure
Pull off adhesion test
Dollies are glued to
the structure with a
strong glue
Prior to pull-off:
Cut around the dolly,
through the paint
film and down to the
substrate material

Cd-4932-102

ISO 4624
Pull-off testing of paint on a structure
Pull off adhesion test.
Destructive test
method
Here, connecting of
the device for pulling
off the dollies
Read and note the
value
Several types of
instruments are
available

Cd-4932-101

ISO 4624
Area after pull-off testing
Pull off adhesion test
The adhesive failure fracture between coats or between coating and
substrate must be
evaluated
Note adhesion failure, %
The cohesive failure fracture within the
coating- must be
evaluated.
Note cohesion failure, %
Also: Note glue failure, %

Cd-4932-103

ISO 4624
Pull-off dollies glued to the structure
Pull off adhesion test
Dollies are glued to the
structure with a strong
glue
Prior to pull-off:
Cut around the dolly,
through the paint film
and down to the
substrate material
Record the pull-off
value
Evaluate the failure

Inspection / Adhesion_pulloff1

ASTM G 62 - 85 Method A

Pinhole detection. Low voltage.

Low voltage: < 75 V DC
To detect pinholes, voids or metal particles to be in the
range of 25-250 microns.
Effective for paint films up to a DFT of 500 microns if a
wetting agent is used in the water.
This is a non-destructive test.

ASTM G-62-85, method A

Low voltage holiday detector
Photo: Low voltage
pinhole detector
Detecting pinholes, voids
or metal particles in paint
film up to 250 microns
Non destructive test
method
Will only detect defects
down to bare metal
The sponge must be
wetted
Do not use excessive
water

Cd-4932-92

ASTM G-62-85, method A

Low voltage pinhole detector

Photo: Low voltage

pinhole detector
Detecting pinholes, voids
or metal particles in paint
film up to 250 microns
Non destructive test
method
Will only detect defects
down to bare metal
The sponge must be
wetted
Do not use excessive
water

0002-004

ASTM G-62-85, method A

Low voltage pinhole detector
Detecting pinholes,
voids or metal particles
in paint film up to 250
microns
Non destructive test
method
Will only detect defects
down to bare metal
The sponge must be
wetted
Do not use excessive
water

Inspection / Pore_detection1

ASTM G 62 Method B

Holiday detection. High voltage.

High voltage: 900 - 20.000 V
Used to detect pinholes, voids and
areas with thin paint films
This is a destructive test.

ASTM G-62-85, method B

High voltage holiday detector
Destructive test
method for detecting
pinholes, voids and thin
spots in paint film
Adjust voltage
according to the film
thickness or the paint
manufacturers
recommendation
Gives a light or signal
when pinhole or weak
point is detected

Cd-4932-93

ASTM G-62-85, method B

High voltage holiday detector

Destructive test method for

detecting pinholes, voids and
thin spots in paint film
Adjust voltage according to
the film thickness or the
paint manufacturers
recommendation
Gives a light or signal when
pinhole or weak point is
detected

0002-005

ASTM G 62 Method B

Holiday detection. High voltage.

High voltage: 900 20.000 V
Used to detect
pinholes, voids and
areas with thin paint
films
This is a
destructive test.

Inspection / Holiday_detection1

ISO 12944

General standard for corrosion

protection:

Paints and varnishes - Corrosion protection

of steel structures by protective paints systems.

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

ISO 8504 - 1

General principles
Selection of methods

ISO 8504

Surface preparation methods:

Part 1: General principles.
Part 2: Abrasive blast-cleaning.
Part 3: Hand- and power-tool cleaning.

ISO 8504 - 2

Abrasive blast-cleaning
Methods
Effectiveness
Fields of application

ISO 8504 - 3

Hand and Power-tool Cleaning

Methods
Equipment to be used
Procedure to be followed

Using solvents to determine

generic type of paint
Rag soaked
with solvent

Paint dissolves:
Physically drying

No reaction:
Chemically curing

Steel
2 coat paint

Lifting/Wrinkling:
Oxidatively curing

Using solvents to determine

generic type of paint
Use a rag soaked
with solvent
No reaction:
Chemically curing
Paint dissolves:
Physically drying
Lifting/Wrinkling:
Oxidatively curing

Inspection / Determine_generic1

Standards for testing of

corrosion protective properties
Property / Environment
Humidity chamber
Condensation

Salt spray
Natural weather exposure
Weather-o-meter
Cathodic disbonding
Cathodic protection

Standard / Test method

o
ISO 6270 (Condensation, water at 40 C)
DIN 50017
ASTM D 2247 (Condensation, water at 38 o C)
ASTM D 1735 (Humidity chamber)
ISO 7253, ASTM B 117, BS 3900 - F12,
DIN 53167, DIN 50021
ASTM G 85 (Prohesion test)
ISO 2810
BS 3900 F 6
ASTM G 53
o
ASTM G 8 (1500 mV/Ag-AgCl at 20 C
o
ASTM G 42 (1500 mV/Ag-AgCl at 60 C
BS 3900 F 11

Standards for evaluation

of coated surfaces
Property

Standard / Test method

Paint film thickness

ISO 2808 (Wet and dry)

SSPC - PA 2

Holiday detection

ASTM G 62
(Low and high voltage)

Degradation of coatings

ISO 4628

Standards relating to
mechanical properties
Property
Adhesion (Cross cut)
Adhesion (Pull-off)
Adhesion
(Shear strength)
Hardness
Hardness
Hardness
Elasticiy
Flexibility
Impact resistance

Standard / Test method

ISO 2409, DIN 53251, BS 3900-E6, ASTM 3359
ISO 4624, ASTM 4541, BS 3900 - E10
ASTM D 1002 (Specified for Chartek)
ISO 2815 (Buchholz - methode)
ISO 1522 (Knig - pendel)
Barchol
ISO 1520 (Cupping test)
ISO 6860 ASTM D 522
BS 3900 - E11 (Conical mandrel)
ISO/TR 6272 - 79E
DIN 55669

ASTM D 2794 - 84
BS 3900 - E3

Standards relating to
physical properties
Property
Solids, % by weight
Solids by % volume
Drying time
Flash point
Milling grade
Viscosity
Paint film thickness
Density
Gloss
Covering capacity
Recoatability
Curing of Zn-silicate

Standard
ISO 1515 (105 C - 3 hours)
ASTM D 2697 (1 hour - 110C - dip)
ISO 1517 (Surface dry)
ISO 1523 (Closed cup)
ISO 3679 (Zeta flash)
ISO 1524
ISO 2431 (Flow cup)
ISO 2808
ISO 2811 (Psykrometer)
ISO 2813 (60 C commonly used)
ISO 2814
ASTM D 1640
ASTM D 4752 - 87

Testing and evaluation.

marine atmosphere (1 of 2)
Test method

Standards

Comments

ISO 2409
ISO 4624
ISO 1510
ISO 1520
ISO 2815
ISO 6272
ISO 2813
ASTM D 4060

Before and after exposure

Before and after exposure
Before and after exposure
Before and after exposure

Physical testing
Adhesion
Adhesion
Flexibility
Elasticity
Hardness
Impact resistance
Gloss
Abrasion resistance

Exposure conditions:
Saltspray
Prohesion test
UV-cabinet
Condensation chamber
Humidity chamber
Weathering
Resistance to liquids

ISO 7253 or ASTM B 117

ASTM G 53
ISO 6270
BS 3900
ISO 2810
ISO 2812

Oil, petroleum , etc.

Testing and evaluation.

marine atmosphere (2 of 2)
Test method

Standards

Comments

Evaluation of paint films

Blistering
Rust
Cracking
Flaking
Chalking
Scribe

ISO 4628/2
ISO 4628/3
ISO 4628/4
ISO 4628/5
ISO 4628/6
ASTM D 1654

Evaluation of the liquid paint

Appearance in tin

ISO 2431

Viscosity

ISO 2884

Application properties

Flow time

Abrasion resistance

Weigh the painted

sample
Install it in the
apparatus and run
1000 cycles
Measure the weight
loss

Testing paints \ Abrasion resistance1

Flexibility test
Use a thin test panel
Measure the paint
film thickness
Carry out the impact
test on the rear side
of the test panel
Determine the
highest level of
impact load before
any crack or defect
in the paint film
occurs

Testing paints \ Flexibility_test1

Impact test
Use a thick test panel
Measure the paint
film thickness
Carry out the impact
test on the painted
side of the test panel
Determine the
highest level of
impact load before
any crack or defect in
the paint film occurs

Testing paints \ Impact_test1