What is the cause of chalking in epoxy coating

UV or radiation exposure

What is polymerization cured coating?

Two parts mixed together just prior to use

Examples of non-convertible coatings

1. Chlorinated rubber 2. Vinyl 3. Acrylic 4. Bituminous

Non-convertible curing def.

No chemical change during cure cycle

Convertible curing def.

Some chemical change during cure cycle

What info should be included when sending samples to

a lab?
1. Identity of materials 2. Properly packed/labeled
samples 3. Chain of custody form 4. Type of analysis that
is expected and the concentrations of interest

Specialized tests or equipment coating inspectors may

encounter
1. AA/AE Atomic Absorption/Emission 2. ISP Induction
coupled plasma Spectrometer 3. GLC Gas liquid
chromatographs 4. IR, FTIR, FTIR-ATR INfrared
spectrophotometers 5. DSC Differential scanning
calorimeters

What is a cathodic dis-bondment test?

Procedure to determine how easily a coating loosens
from a substrate or develops holidays as a result of
normal soil potentials

Individuals who perform surveys

1. O-Cat or S-cat tech 2. NACE coating specialist 3. NACE
Level III 4. Coating Inspector w/field experience 5.
Coating manufacturer representative 6. Maintenence
engineer with specific plant knowledge.

Coating survey steps

1. Understand scope 2. Gather team 3. Develop survey
plan 4. Review standards 5. Agree on format 6. Delegate
various tasks 7. Eveluate existing coating 8. Delegate
various tasks 9. Evaluate existing coating 10. Gather
additional info 11. Summarize data 12. Prepare
maintenance plans 13. Prepare reports/input data 14.
Submit final survey reports.

List some of the primary reasons surveys are

performed
1. Plan maintenance. 2. Prioritize work 3. Budgetary
concerns 4. Determine value of assets 5. Legal
compliance

Definition of a coating survey

Gather baseline info needed to plan maintenance
coating procedures

What are faying surfaces and why not galvanize them?

Surfaces that depend on friction to hold galvanizing it
may/will reduce friction if they are galvanized

Common problems seen during the usual inspections

of HD galvanized items
1. Cracking 2. Peeling 3. Bare spots 4. Lumps 5. Blisters
6. Flux inclusions 7. Ash inclusions 8. Dross inclusions

Post galvanizing treatments and why

To Remove Thickness: Roll, Wipe, Centrifuge/Air Blast
To change properties/To alloy: Annealing

Temperature range for galvanizing kettle

820-850 F

Purpose of pickling
Hydrochloric or sulfuric acid bath to remove oxides and
mill scale

Purpose of caustic cleaning

Acid bath or caustic to remove dirt, oil and grease

Stages of hot dip process

1. Surface prep. 2. Galvanizing 3. Post treatment 4.
Inspection

Hot dip galvanizing safety

1. Can stay for some time 2. Molten metal splash 3.
Nascent hydrogen above kettle

Usual layers of galvanized coating consists of:

1. ETA=100% Zn 2. ZETA= 94% Zn 6%Fe 3. DELTA= 90%
Zn 10 Fe 4. GAMMA= 75% Zn 25% Fe

What is hot dip galvanizing?

Coating iron or steel with zinc at temperatures of 820860 F

If a maintenance coating to be applied is incompatible

with the existing coating system__________may occur
Curling

______________ is performed at the work area by

working the edges of the repaired area back to achieve
a fairly smooth transition from the repair area to sound
coating.
Feathering

With regards to maint. coating all parties should agree

on___________?
1. Spot repair requirements 2. Feathering 3. Appearance
of repaired areas

Maint. coating selection process should take the

following into consideration:
1. Compatability with existing system 2. Surface prep. 3.
If abrasi ve blast is permitted and feasible

When determining coating system life cycle the

following should be considered:
1. Maint. costs 2. Length of coating life 3. Initial and
maint. material costs 4. Intial and maint. labor costs

Life cycle of a coating system can be affected by:

1. Service environment 2. Maint. intervals 3. Coating
system chosen 4. Surface condition

Maint. coating operations are defined as:

Applying coating over a substrate that has been installed
in its final environment and placed in service

Some service situations where permeation may occur

include:
1. Sour crude storage tanks 2. Cooling towers 3.
Fertilizer plants

Special substrated that have tightly adherent oxide

films include:
1. Stainless steel 2. Tin 3. Nickel 4. Cadmium

Non-Ferrous substrates include:

1. Stainless steel 2. Nickel 3. Copper/Nickel alloys 4.

Aluminum 5. Aluminum bronzes 6. Copper 7. Bronzes 8.
Brass 9. Tin 10. Cadmium 11. Lead 12. Magnesium

Common reasons wood is coated

1. Decoration 2. Protection 3. Sealing 4. Stabilization 5.
Preservation 6. Flame retardence

The following materials can be used to repair fusion

bonded epoxy:
1. Epoxy FBE melt sticks 2. LIquid epoxy 3. Repair
patches

Destructive tests for heat shrink sleeves

include_____________
Peel test

Non destructive tests for heat shrink sleeves include

1. UT 2. Physical inspection 3. Holiday inspection

Pipeline coating field joints include

1. Heat shrink sleeves 2. Insulation 1/2 shells 3. Liquid
epoxies 4. Cold applied tape 5. Hot applied tape 6.
Fusion bonded epoxy 7. Wax tape

Concrete coating characteristics include:

1. Good for wetlands 2. Can be applied in may
thicknesses

General application for CTE includes

1. Prime pipe 2. Apply CTE dope 3. Wrap w/glass fiber
mat 4. Apply 2nd coat of CTE dope 5. Apply 2nd layer of
glass met 6. Apply outer wrap of CTE impregnated glass
fiber felt. 7. Cool

Disadvantages of CTE coatings include:

1. Environmental concerns 2. Subject to corrosion and
damage from soil stress

Advantages of CTE pipeline coatings

1. Ease of application 2. Long life

FBE process includes:

1. Preheat 2. Grit/shot blast to NACE #2 SSPC-SP10 3.
Heat pipe 4. Apply coating 5. Cure coating 6. Quench 7.
Stencil

Common characteristics of FBE include:

1. Typically green or red 2. Single or two layer 3. DFT
from 10-20 mils

Typical plant applied coatings include

1. Two layer poly 2. 3 layer poly 3. FBE 4. Coal tar
enamel 4. Asphalt 5. Concrete 6. Asphalt

The majority of the pipes coated at a facilty or plant

and shipped to site are called:
Plant applied

Construction materials may include:

1. Steel 2. Aluminum 3. Stainless steel 4. Plastic

Proper safe accurate operating procedure for low

voltage holiday detector
Ground equipment and set for coating thickness VS
voltage. Keep probe in contact with work, move slowly
across surface. Don't oversaturate sponge

Standards used for dry film measurement of coatings

over concrete
ASTM-D6132-97 and SSPC-PA9

DFT of coating on concrete can be measured by:

UT thickness guage

Which organization produces comparator plates for

various prepared concrete surfaces?
International concrete repair institute

Disadvantages of plural component airless spray over

single piston:
1. Higher costs 2. Education for mechanic is higher 3.
Heaters require HV electric 4. Applicators job is more
difficult

Advantages of plural component airless over single

piston:
1. Automatic, accurate material mixing 2. Ability to spray
thick materials w/o thinning 3. Ability to spray materials
2/short pot lives.

4 stages powder goes thru when heat is applied?

1. Flow 2. Wetting 3. Gel 4. Curing

Two curing categories of powder coating

1. Thermoplastic: Softens when heated 2. Thermosetting: Hardens when heated

Characteristics of flouropolymer coatings?

1. Non-stick 2. High temperature resistance

Two main types of fireproofing coatings

1. Passive 2. Intumescent

Three main types of anti-fouling coatings

1. Ablative 2. Self smoothing 3. Foul release

What are anti fouling materials and how do they work?

They are materials that make ships hulls distasteful, or
too slick for bio-fouling material to attach

Surface prep for lining installation

White metal blast SA3/NACE1/SSPC 5

Describe wicking
1. Liquid travels along fibers path and can cause
substrate to corrode, blister or delaminate

What does re-enforcing add to a resin?

Strength

Some resins used in re-enforced linings:

1. Polyester 2. Epoxy 3. Vinyl ester

Lining Definition
A coating normally in immersion service

Thermal spray safety practices

1. HP rated hoses 2. Never use compressed air to clean
work area or clothing 3. Don't use plant air for breathing
air

Common hazards associated with specialized

applications
1. Fume/dust inhalation 2. Electrical shock 3. Burns 4.
Falling objects

Disadvantages of water jetting

1. Expensive equipment 2. Water injection danger 3.
Surface needs anchor profile 4. Collection/Disposal of
water

Water jet advantages:

1. Less dangerous 2. Better air quality 3. Less stringent
respiratory requirements 4. Less environmental damage
5. Less clean up

Water jetting safety items include:

1. Barricade work area 2. Protect electrical equipment 3.
Electrical connections dry 4. Make sure hoses and
fittings are not worn excessively and are rated for use

Two condsiderations w/regards to back thrust

1. Operator body weight 2. Alternating operators (fatigue
etc.)

Water jetting is effective for removing:

1. Surface oil or grease 2. Rust 3. Concrete spatter 4.
Existing coatings

Typical water jetting team

1. Nozzle operator 2. Pump operator 3. Additional
operators or workers

Requirements for NACE 5/SSPC-SP12

1. Visual contaminants 2. Non-visual contaminants

Robotic water jetting

1. A cleaning vehicle that attachs itself by vacuum,
cables or magnets and is controlled by a single operator

Inspection concerns during centrifugal blasting

1. monitor dust collector 2. monitor amperage of motors
3. monitor conveyor line 4. monitor line speed 5. inspect
surfaces leaving line for spec. conformance

Well balanced operating mix of abrasives will:

1. provide consistency of finish 2. Ensure uniform
abrasive coverage

Functions of a centrifugal blast machine separator

include:
1. Control size of abrasive mix 2. Remove contaminants
3. Control abrasive consumption

Low amperage reading on centrifugal blast machine

could signify:
1. Abrasive starved wheel 2. Flooded or choked wheel

Efficiency of a centrifugal blast wheels depends on:

1. abrasive operating mix 2. abriasive size 3. quantity
and direction of thrown abrasive 4. condition of feed
parts

Centrifugal blast systems have these elements

1. Centrifugal abrasive blast wheel 2. Blast cabinet 3.
Material handling system 4. Abrasive recycling system 5.
Dust collector 6. Abrasives

Portable centrifugal blast systems can be used on:

1. Ship decks, hull sides and bottoms 2. Storage tanks 3.
Concrete floors 4. Highways and bridge decks

Centrifugal blast conveyor systems are commonly used

for cleaning:
Plate and rolled structural shapes

Basic centrifugal blast set ups include:

1. Tumbling mills 2. Multi table machines 3. Plain table
machines 4. Swing tables 5. Custom designed systems

Transfer methods for environmental test instruments

1. USB transfer cable 2. IR (Infrared) 3. Bluetooth

Electronic hygromenters determine:

1. Relative humidity 2. Air temperature 3. Dew point
temp.

Benefits of de-humidification
1. crews can begin earlier/work later 2. all coating done
in ideal conditions 3. eliminates contamination of
previously applied coating 4. extended overcoating
intervals are avoided. 5. contractor can guarantee
completion time w/accuracy

Two types of de-humidification equipment

1. Refrigeration 2. Desiccants

Two ways to reduce the relative humidity of the

boundary layer
1. Increase surface temp. 2. Reduce moisture content by
de-humidification

At what relative humidity does corrosion virtually

cease?

50%

Describe air turns:

Air turnover or exchanges to eliminate air stratification

Min. requirements when planning enclosures

1. Large enough to contain work area 2. within capability
of de-humidification equipment 3. Sturdy enough 4.
Minimal leakage

Describe de-humidification:
Removal of moisture from air to lower it dew point

Describe cathodic dis-bondment

Seperation of coating from surface due to potential
increase and hydrogen formation or hydroxyl formation

impressed current power sources include:

1. Generators 2. Fuel cells 3. Wind powered cells 4.
Thermoelectric cells

Two primary types of cathodic protection

1. Galvanic 2. Impressed current

Describe cathodic protection

Reducing or eliminating corrosion by turning the
protected structure into a cathode by an impressed
current or attachment to a galvanic anode

Describe galvanic corrosion

Electrochemical reaction of two dissimilar metals in
contact with the presence of an electrolyte, and an
electron conductive path. Reactive metal will corodoe to
protect the noble metal

Two broad categories of corrosion?

1. General 2. Localized

How do pollutants and gases affect corrosion?

They directly chemically attack the substrate and reduce
the electrical resistance of the electrolyte

How does humidity affect corrosion?

A more humid environment will accelerate corrosion

How do chemical salts affect corrosion?

They increase the rate of corrosion by increasing the

electrolyte efficiency

How does temperature affect corrosion?

1. Corrosion reaction increases with temp. increase 2.
Corrosion reactions are electrochemical in nature

How does oxygen affect corrosion?

Increases corrosion rates as oxygen contact areas are
cathodic

Describe passivation
The production of a tightly adhered layer formed from
the corrosion product

Standard of Engineering Society description of a

standard
A document that applies to codes, specs or practices,
classifications, test methods and guides which have
been prepared and published in accordance with
established procedures

Properties of concrete
1. Inorganic 2. Hard 3. Good compressive strength 4.
Improve with age

Three NACE standards and classifications. Name and

define them.
Standard practice: Details of construction, methods of
treating required to reduce corrosion. Test methods:
Ascertain characteristics of material design and
operation. Materials requirement: State necessary
characteristics when corrosion is a factor in the selection
application or maintenance of a material.

NSB
National Standards Body

SDO
Standards Development Organization

Difference in sacking and stoning

Sacking uses a cement sack or rubber sponge for
application and stoning uses a carborendum brick or
abrasive block

Advantages of watersetting and wet abrasive blasting

1. Quickly cuts surface 2. Washes dust away 3. Reduces

abrasive and concrete particles in air

What is the joint NACE #6/SSPC-SP 13 blast standard

for surface prep of concrete?
Requirements for surface prep by mechanical, chemical
or thermal means

Surface prep is generally performed by:

1. Abrasive blast 2. Hand or Power tool 3. HP water jet 4.
Acid Etch 5. Stone 6. Centrifugal 7. Scarify

Laitance:
Weak surface layer of water, rich cement mixture caused
by upward movement of water

Efflorescence:
Condition caused by water passing thru concrete and
salts reacting with CO2 to create a fluffy, crystalline
surface deposit

Reasons to coat concrete:

1. Waterproofing 2. Freeze protection 3. Chem.
resistance 4. Decontamination 5. Abrasion protection 6.
Color coding 7. Contents protection 8. Improved cleaning
9. Skid resistance 10. Steel Re-enforcement

Explain Gunniting:
Process of sprayiny or slinging concrete onto a surface
as a coating

How do ambient conditions and vibration affect poured

concrete?
1. Hot weather will accelerate cure and cause voids and
low strength surface 2. Vibration can cause heavy
aggregate to sink resulting in a weak, sandy surface
known a laitance

What is the process concrete cures by?

Hydration