Inspection and control

Paint School
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 What is QA - QC ?

QA = Quality Assurance
(A documented management system)

QC = Quality Control
(Inspection and testing routines)

Paint School
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 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

Paint School
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 An inspector’s work includes:

• Be capable of interpreting
the specifications
• Understand the objective
of the inspection
• Inspect all structures to be painted
• Ensure that all specified requirements are met
• Document the results from the inspections
• In case of non-conformance: Issue written reports

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 Daily logs

• Steel temperature • Film thickness (to be

• Air temperature measured also at spot repair)
• % Relative Humidity • Area, m²
• Dew point • Product name, place of
production and batch no.
• Object no. and name
• Exact specification • Name of relevant persons
• Pre-treatment, specified and • What was discussed
actually conducted. • Non conformance report
(remember signatures)
• Other comments

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 An inspector deals with
several parties
• Customer / owner
• The Yard
• Contractor / sub-contractor
• Paint supplier
• Suppliers of equipment
• Classification society

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 An inspector needs to know

• All paints that will be used

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

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 What needs to be inspected ?

If relevant, the following stages

of the production need to be inspected

• Shop-priming of the steel

• The steel work
(Pre-blasting preparation)
• Cleaning and surface preparation
prior to paint application
• Application of paint
• The applied paint film and its
curing/drying conditions.
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 Inspection tools

Cd-4932-80

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

Cd-4932-83

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 Using Inspection tools.
Mirror and flash light

• Visual inspection
• Important tools to be able
to inspect areas difficult to
access

Cd-4932-84

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

Cd-4932-85

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 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
Cd-4932-90
considered as
contamination for
some paint
systems: Remove

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 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 ½ acc.
to ISO 8501-1
• Correct DFT (Usually 15 - 25 microns)
• Satisfactory drying
• No damages caused by conveyor.

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 Inspection of steel work
(Pre-blasting preparation)
The following items need to
be inspected during construction
 Rounding of sharp edges.
 Smoothing of rough welding seams.
 Removal / grinding of weld spatter
and beads.
 Cracks and pittings.
 Surface faults like laminates etc.
 ISO 12944 - 3 , or ISO 8501 - 3

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 Pre-blasting preparation

• Rounding of edges
• Removing of weld spatters etc.
0589-6

0589-5

C3

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 Inspection of cleaning and surface
preparation prior to application
If relevant, the following conditions
must be inspected / verified

 Cleanliness (salt, oil, grease and dust/dirt)

 Evaluation of present condition (rust grade)
 Surface preparation (e.g. blast cleaning)
 Cleanliness of prepared surface
(salts, oil, grease, dust and dirt)
 Climatic conditions
(temperature, relative humidity etc.)

Paint School
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 Relevant standards for assessing
surfaces prior to paint application

Standard Area
ISO 8501 Visual assessments of surface cleanliness.

ISO 8502 Tests for the assessment of surface cleanliness.

ISO 8503 Surface roughness characteristics
of blast-cleaned steel substrates.
ISO 8504 Surface preparation methods.

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 ISO 8501 - 1
Surface preparation

• Visual assessment of surface cleanliness after

blast cleaning, hand or power tool cleaning
or flame cleaning
• Rust grades and preparation grades of uncoated steel
• Photographic examples of steel when
blast cleaned with different abrasives

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 Surface preparation
Standard for deciding rust grades

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

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 ISO 8501-1
Evaluation of rust grades
Rust grade A Rust grade B

Cd-0631-59
Cd-0631-58

Rust grade C Rust grade D

Cd-0631-57 Cd-0631-56

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 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

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 ISO 8501 - 1
Standard for deciding preparation grades

Sa: Blast cleaning (grades 1, 2, 2 ½ and 3)

St.: Hand and power tool cleaning

(grades 2 and 3)

Fl: Flame cleaning (one grade)

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 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

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 ISO 8501 - 2
Surface preparation

As for ISO 8501-1, but:

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

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 ISO 8501 - 2
Standard for deciding preparation grades

PSa : Localised blast cleaning

(grades 2, 2 ½ and 3)

PSt : Localised hand and power tool cleaning

(grades 2 and 3)

PMa : Localised machine abrading (one grade)

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 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

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 ISO 8502
Assessment of surface cleanliness (1 of 2)
Part 1 Field test for soluble iron corrosion products

Part 2 Laboratory determination of chloride on cleaned

surfaces.

Part 3 Assessment of dust on steel surfaces prepared for

painting (pressure- sensitive tape method)

Part 4 Guidance on the estimation of the probability of

condensation prior to paint application.

Part 5 Measurement of chloride on steel surfaces

prepared for painting. Ion detector tube method.

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 ISO 8502
Assessment of surface cleanliness (2 of 2)
Part 6 Extraction of soluble contaminants for analysis.
The Bresle method.

*
Part 9 Conductometric measurements of soluble salts
.
*
* Part 7, 8 and 10 are not prepared

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 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

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 ISO 8502 - 1
Soluble iron salts on blast cleaned surfaces.
Merckoquant test on steel substrate
Steel substrate

Beaker with Visual comparison

test solution with the standard

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 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

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 ISO 8502-1. Annex. 3
Water soluble salts on blast cleaned steel

Filter paper impregnated Blast cleaned steel

with Potassium Hexacyanoferrate

Blue spots

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 ISO 8502 - 2
Laboratory test. Determining chlorides.

Laboratory test method for

determination of Chlorides
on cleaned surfaces

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

Approved
Not approved

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 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

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

0866-14
0866-13

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 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

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

Psychometer Thermometer

Wet cotton

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

1. Air temperature
2. % Relative humidity
3. Steel temperature
4. Dew point

Steel temperature min. 3 oC above the dew point

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 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 Cd-4932-88
humidity
• Use together with dew
point calculator

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 Contact thermometer

• Electronic instrument for measuring the steel temperature

• Other types of thermometres are also available. E.g.
magnetic thermometers

Cd-4932-87

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 ISO 8502-4
Dew point calculator

• For calculation of dew point

• To be used together with
surface temperature
thermometer and sling
psychrometer.
• Use this frequently during
pre-treatment, application and
drying of the paint. Cd-4932-89
• Recommendation: Every 6
hours and when weather
conditions are changing

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 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

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 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

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 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

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 Relative humidity, RH

% R.H.:
% water vapour in the air as percentage of the total amount
water vapour the air can contain at the same temperature.

Example
Air at 20 oC can contain 17.31 g. water/m3, but contains 15
g/m3. What is the R.H. ?

R.H. = 15 x 100 = 86.65 %

17.31

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 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
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 Determination of water soluble salts

The most frequently used methods are:

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

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 ISO 8502 - 5
Chlorides on steel surfaces

Measurement of Chloride on steel surfaces

prepared for painting
(The ion detection method)

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 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

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 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

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 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 Cd-4932-97
• The water must be
pumped in and out
several times. Follow the
standard

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 ISO 8502 - 9
Conductometric measurement of soluble salts.

Field method for measuring soluble salts

by conductivity ( S) of solutions
containing water soluble salts

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 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 Cd-4932-98
to be recalculated to give
the salt level on the
substrate.
• Only water soluble salts !

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

CD 4932 no. 99

Sodium Iron No
Paint School Chloride Sulphate salt
56
 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

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 Calculation of salt level
on the substrate

Formula: (L2 - L1) x 6 = mg salt per m2

L2 = µS after cleaning

L1 = µS before cleaning

Water sample, ml.: 10 15 20 50

Constant in formula: 4 6 8 20

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 Units
1 mg = 1000 micro grams (µg)
1 m2 = 10 000 cm2
1 mg/m2 = 0,1 micro g/cm2 (µg)
1µg/cm2 = 10 mg/m2
Na+ + Cl- = NaCl (Sodium Chloride)
Mol Weights = Cl- : 35,5 NaCl : 58,5

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

= 1,6 mg NaCl

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 Instruments for measuring
surface roughness
• Stylus instruments
• Elcometer Mod. 123
• Testex Press-O-film
• Microscope
• Comparator
–Rugotest No. 3
–ISO 8503 etc.

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 ISO 8503
Surface roughness of blast-cleaned steel
Specifications and definitions for ISO surface
Part 1 profile comparatives for the assessment of
abrasive blast-cleaned surfaces.
Method for the grading of surface profile of abrasive
Part 2
blast- cleaned steel - Comparator procedure.
Method for the calibration of ISO surface profile
Part 3 comparators and for the determination of surface
profile- Focusing microscope procedure.
Method for the calibration of ISO surface profile
Part 4 comparators and for the determination of
surface profile - Stylus instrument procedure

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 ISO 8503
Surface roughness
• Example of a reference
comparator
• Surface profile comparator
comprising four segments.
• Grit (G)
• Shot (S)
Cd-4932-86
• Check if the profile is
according to specification
and the paint
manufacturer’s
recommendation

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 ISO 8503 - 1
Limits of profile grades
a) Comparators for steel. Blast-cleaned with grit abrasives
Profiles equal to segment 1 and up to,
Fine (G)
but excluding segment 2
Profiles equal to segment 2 and up to,
Medium (G)
but excluding segment 3
Coarse (G) Profiles equal to segment 3 and up to,
but excluding segment 4

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

Fine (S) Profiles equal to segment 1 and up to,
but excluding segment 2
Medium (S) Profiles equal to segment 2 and up to,
but excluding segment 3
Profiles equal to segment 3 and up to,
Coarse (S)
but excluding segment 4
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 ISO 8503 - 1
Nominal values and tolerances
a) Comparators for steel, blast-cleaned with grit abrasives
Segment Nominal reading Tolerance
µm µm
1 25 3
2 60 10
3 100 15
4 150 20

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

Segment Nominal reading Tolerance
µm µm
1 25 3
2 40 5
3 70 10
4 100 15

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 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

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 ISO 11125
Content of the standard
Methods of test for metallic blast-cleaning abrasives.
The standard consists of 8 parts
Part 1 Sampling
Part 2 Determination of particle size distribution
Part 3 Determination of hardness
Part 4 Determination of apparent density
Part 5 Determination of defective particles
and microstructure
Part 6 Determination of matter
Part 7 Determination of moisture
Part 8 Abrasive mechanical properties

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 ISO 11126
Content of the standard
Specification for non-metallic blast-cleaning abrasive.
The standard consists of 10 parts

Part 1 Introduction
Part 2 Silica sand
Part 3 Copper refinery slag
Part 4 Coal furnace slag
Part 5 Nickel refinery slag
Part 6 Iron furnace slag
Part 7 Fused aluminium oxide
Part 8 Olivine sand
Part 9 Staurolite
Part 10 Garnet
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 ISO 11127
Content of the standard
Test methods for non-metallic blast-cleaning abrasives.
The standard consists of 8 parts

Part 1 Sampling
Part 2 Determination of particle size distribution
Part 3 Determination of apparent density
Part 4 Determination of hardness by a glass slide test
Part 5 Determination of moisture content
Part 6 Determination of water soluble
contamination by conductive measurement
Part 7 Determination of water soluble chlorides
Part 8 Abrasive mechanical properties

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 Contamination of abrasives

The abrasives can be contaminated with

• Water
• Oil and grease
• Chlorides
• Sulphates

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 ISO 11127 - 5
Content of humidity of the abrasives

• Laboratory test

• Requirement: Maximum 0,2 %

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 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

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 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) Oil content (AB-1)

Fill the liquid for test No presence of oil,
and measure the either on top or as an
conductivity. emulsion after 30 min.
Max 25 mS/m

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 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

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 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 Shopprimer/ Abrasive_Test1
grease are present

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 Inspection during application

The following must be verified, inspected or tested:

 Record name of coating and batch no.
 Ensure proper mixing of 2-pack paints
 Ensure use of the correct thinner
 Measuring the wet film thickness (WFT)
 Number of coats as given in the specification
 Cleanliness between coats (salts, dust, oil etc.)
 Drying time / recoating intervals
 Control of equipment: Pressure, nozzle etc.
 Climatic conditions (Ventilation, Air and steel
temperature and the relative humidity)

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 Information to be found from the
technical data sheet, TDS
• Product description • Conditions during
– Generic type etc. application
• Recommended use • Drying and overcoating time
at different temperatures
– Where to use the product
• Technical information • Typical recommended
system
– Solids by volume, WFT,
DFT • Storage
• Application data • Handling
– Methods, mixing, potlife • Packing control
• Surface preparation • Health and safety
– Different methods given – Details in MSDS
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 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

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 ISO 2808 - 97
Determination of film thickness: (2 of 2)

Method 6: Magnetic method

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

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 ISO 2808 - 97 Method No.1
Wet film measuring comb

Microns Wet paint

250 225 200 175 150 125 100 75 50 25

Steel

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 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
Cd-4932-81
cured/dried
or if
First coat is soft or
resoluble

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

0459-21

4932-81

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 Calculation of
paint consumption

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 Calculations : Paint
Abbreviations

WFT = Wet Film Thickness

DFT = Dry Film Thickness
% VS = Percent Volume Solids
LF = Loss Factor
DV = Dead Volume

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 Formula for determining the DFT

Formula: DFT = WFT x % VS

100

Example:

WFT = 250 m

% VS = 50 %

DFT = 250 x 50 = 125 m

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 Formula for determining the WFT

DFT x 100 %
Formula : WFT =

Example:

DFT = 100 m
%
% VS = 65 %
VS

WFT = 100 x 100 % = 154 m

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 Formula for determining the
WFT after thinning (Method 1)

Formula: WFT = DFT x (100 % + % thinner)

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

100 x (100 % + 20 %)
WFT = =185
m

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86
 Formula for determining the
WFT after thinning (Method 2).
DFT = 100 microns
% VS = 65 %
Added thinner = 20 %
Volume of paint = 1 litre New % VS:
65 = 54 %
Volume of thinner = 0,2 litre
1,2
New volume = 1,2 litre

WFT = 100 % x 100 microns = 185

m 54 %

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 Theoretical spreading rate

% VS x 10
Formula: = m2/litre
DFT

DFT = 100 microns

% VS = 65
10 = Factor

Spreading rate: 65 x 10 = 6,5m2/litre

100

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 Consumption of paint, no loss (1 of 2)

To be painted: Tank, area of 500 m2

Paint DFT % VS
Epoxy mastic 200 microns 85 %
Polyurethane topcoat 50 “ 50 %

Area (m2) x DFT

Consumption = = litre
10 x % VS

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 Consumption of paint, no loss (1 of 2)

To be painted: Tank, area of 500 m2

Formula: Area, m2 x DFT

10 x % VS

Epoxy mastic 500 x 200 = 117,7 litre

10 x 85

Polyurethane topcoat 500 x 50 = 50,0 litre

10 x 50

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 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: Area, m2 x DFT

10 x % VS x loss factor

Epoxy mastic 500 x 200 = 196 litre

10 x 85 x 0,6

Polyurethane topcoat 500 x 50 = 83 litre

10 x 50 x 0,6

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 Consumption of paint with loss
including Dead Volume (1 of 2)
A certain roughness will give a certain dead volume

Roughness, microns Dead volume, l/ m2

30 0.02
45 0.03
60 0.04
75 0.05
90 0.06
105 0.07

Total Dead volume, litre = Area (m2) x DV x 100

% VS x LF

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 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 Dead volume

Steel

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 Consumption of paint with loss
including Dead Volume (2 of 2)
Tank area 500 m2, 40 % loss, surface roughness 60 microns
DFT % VS
Epoxy mastic 200 85
Polyurethane topcoat 50 50

500 x 0,04 x 100

Litre dead volume = = 39 litre (EM)
85 x 0,6

500 x 200
Epoxy mastic (EM) = 196 litre (EM)
10 x 85 x 0,6

Polyurethane topcoat 500 x 50 = 83 litre (EM)

10 x 50 x 0,6

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 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 100 100

=0,6 (loss factor) = 167 litre
60

Not 100 litre + 40 % extra = 140 litre

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 Inspection after application

After application
the following must be checked
 Climatic conditions (Ventilation,
Temperature and humidity)
 Curing / drying of the film
 Dry film thickness (DFT)
 Adhesion
 Holiday detection (if required)

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 Using “PIG” Universal on a ship’s hull

• PIG = Paint Inspection

Gauge
• Destructive test method
• Possible to verify the
number of coats applied
• Possible to measure the
thickness of each Cd-4932-100
individual coat

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 PIG
Paint Inspection Gauge
Mainly for laboratory use

4932-100

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 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.
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 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

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 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
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 ISO 2808 - Magnetic and electromagnetic
Dry film thickness gauges
• Dry film thickness gauge
• Calibrate on smooth
surface to zero and to
thickness similar to be
measured
• Check with your
calibration foil frequently Cd-4932-82
• Plastic material foils wear
easily. Replace frequently.
• No internal memory in
gauge

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 ISO 2808 - Magnetic and electromagnetic
Dry film thickness gauges
• Dry film thickness gauge
• Calibrate on smooth
surface to zero and to
thickness similar to be
measured
• Check with your
calibration foil frequently
• Plastic material foils wear
easily. Replace frequently.
• No internal memory in Inspection \ Dryfilmthickness1
gauge

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 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

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 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 m2 in case 3 or 4 above are
found, then each 10 m2 shall be measured

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 ASTM D 4752-87
Curing test of Zinc - ethylsilicate with MEK.

Glove MEK Rag

Rubbing 50 x

No Zinc on the Rag: A lot of Zinc on Rag:

Cured Not cured
Approved Further curing / Reblasting

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 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

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 ASTM D 4752-87
Curing test of Zinc - ethylsilicate with MEK.

Glove

MEK

Inspection / Zincsilicate_curing1
Rag

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 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

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 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. Cuts: 20 mm long
2. Brush with a soft brush
3. Examine
4. Cuts: 20 mm long at 90o on the original cuts
5. Brush with...
6. Tape 75 mm
7. Within 90 + 30 sec. remove tape
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 Classification of adhesion test results.
Method B. (Example for six parallel cuts).

5B None 5B The edges of the cuts are completely smooth;

none of the lattice is detached
4B
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
3B 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
2B parts of the squares. The area affected is 15 to
35% of the lattice.
1B The coating has flaked along the edges of cuts
1B in large ribbons and whole squares have
detached. The area affected is 35 to 65 % of the
lattice.
0B Greater than 65% 0B Flaking and detachment worse than Grade 1B.

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 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
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 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.

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 ISO 2409
Cross cut adhesion test

• Cross cut adhesion test

• Cut vertical and
horizontal lines to
form a grid
• Apply a strong tape
Cd-4932-91
• Pull off the tape
• Evaluate according to
the standard

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

0002-002

0002-001

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 ISO 2409
Classification of Cross-cut test
Classi- Description Appearance of surface
fication Six parallel cuts
0 Completely smooth: none of the squares detached
1 Small flakes at the Intersections. Area affected 5 %

Flaked along the edges and/or at the

2 Intersections. Area affected: 5-15%

Flaked along the edges, wholly in large ribbons,

3 and/or partly or wholly on different parts of
the squares. Area affected: 15-35%
Flaked along the edges in large ribbons and/or
4 some squares have detached partly or wholly.
Area affected: 35-65%
5 Any degree of flaking that cannot even be classified by 4.

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 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

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 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

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 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

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 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 Cd-4932-102
and down to the
substrate material

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 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
Cd-4932-101
• Several types of
instruments are available

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 ISO 4624
Area after pull-off testing
• Pull off adhesion test
• The adhesive failure -
fracture between coats - or
between coating and Cd-4932-103
substrate must be evaluated
• Note adhesion failure, %
• The cohesive failure -
fracture within the coating-
must be evaluated.
• Note cohesion failure, %
• Also: Note glue failure, %

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 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 Inspection / Adhesion_pulloff1

• Evaluate the failure

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 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.

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 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 Cd-4932-92
• Will only detect defects
down to bare metal
• The sponge must be wetted
• Do not use excessive water

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 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
0002-004
• The sponge must be wetted
• Do not use excessive water

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 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

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 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.

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 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 Cd-4932-93
recommendation
• Gives a light or signal when
pinhole or weak point is
detected

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 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 • 0002-005
recommendation
• Gives a light or signal when
pinhole or weak point is
detected

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 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
Inspection / Holiday_detection1
test.

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 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.

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 ISO 8504 - 1
General principles

Selection of methods

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 ISO 8504
Surface preparation methods:

Part 1: General principles.

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

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 ISO 8504 - 2
Abrasive blast-cleaning

• Methods
• Effectiveness
• Fields of application

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 ISO 8504 - 3
Hand and Power-tool Cleaning

• Methods
• Equipment to be used
• Procedure to be followed

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 Using solvents to determine
generic type of paint
Paint dissolves:
Rag soaked
Physically drying
with solvent

No reaction:
Chemically curing

Steel

Lifting/Wrinkling:
2 coat paint Oxidatively curing

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 Using solvents to determine
generic type of paint
Use a rag soaked
with solvent

No reaction:
Chemically curing

Paint dissolves:
Physically drying

Lifting/Wrinkling: Inspection / Determine_generic1

Oxidatively curing

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 Standards for testing of
corrosion protective properties
Property / Environment Standard / Test method
o
ISO 6270 (Condensation, water at 40 C)
Humidity chamber
DIN 50017
Condensation
ASTM D 2247 (Condensation, water at 38 o C)
ASTM D 1735 (Humidity chamber)
ISO 7253, ASTM B 117, BS 3900 - F12,
Salt spray DIN 53167, DIN 50021
ASTM G 85 (Prohesion test)
Natural weather exposure ISO 2810
BS 3900 F 6
Weather-o-meter ASTM G 53
o
ASTM G 8 (1500 mV/Ag-AgCl at 20 C
Cathodic disbonding o
ASTM G 42 (1500 mV/Ag-AgCl at 60 C
Cathodic protection BS 3900 F 11

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 Standards for evaluation
of coated surfaces
Property Standard / Test method
ISO 2808 (Wet and dry)
Paint film thickness
SSPC - PA 2

Holiday detection ASTM G 62

(Low and high voltage)

Degradation of coatings ISO 4628

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 Standards relating to
mechanical properties
Property Standard / Test method
Adhesion (Cross cut) ISO 2409, DIN 53251, BS 3900-E6, ASTM 3359
Adhesion (Pull-off) ISO 4624, ASTM 4541, BS 3900 - E10
Adhesion ASTM D 1002 (Specified for Chartek)
(Shear strength)
Hardness ISO 2815 (Buchholz - methode)
Hardness ISO 1522 (Kønig - pendel)
Hardness Barchol
Elasticiy ISO 1520 (Cupping test)
Flexibility ISO 6860 ASTM D 522
BS 3900 - E11 (Conical mandrel)
Impact resistance ISO/TR 6272 - 79E ASTM D 2794 - 84
DIN 55669 BS 3900 - E3

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 Standards relating to
physical properties
Property Standard
Solids, % by weight ISO 1515 (105 °C - 3 hours)
Solids by % volume ASTM D 2697 (1 hour - 110°C - dip)
Drying time ISO 1517 (Surface dry)
Flash point ISO 1523 (Closed cup)
ISO 3679 (Zeta flash)
Milling grade ISO 1524
Viscosity ISO 2431 (Flow cup)
Paint film thickness ISO 2808
Density ISO 2811 (Psykrometer)
Gloss ISO 2813 (60 °C commonly used)
Covering capacity ISO 2814
Recoatability ASTM D 1640
Curing of Zn-silicate ASTM D 4752 - 87

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 Testing and evaluation.
marine atmosphere (1 of 2)
Test method Standards Comments
Physical testing
Adhesion ISO 2409 Before and after exposure
Adhesion ISO 4624 Before and after exposure
Flexibility ISO 1510 Before and after exposure
Elasticity ISO 1520 Before and after exposure
Hardness ISO 2815
Impact resistance ISO 6272
Gloss ISO 2813
Abrasion resistance ASTM D 4060
Exposure conditions:
Saltspray ISO 7253 or ASTM B 117
Prohesion test
UV-cabinet ASTM G 53
Condensation chamber ISO 6270
Humidity chamber BS 3900
Weathering ISO 2810
Resistance to liquids ISO 2812 Oil, petroleum , etc.

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 Testing and evaluation.
marine atmosphere (2 of 2)
Test method Standards Comments

Evaluation of paint films

Blistering ISO 4628/2
Rust ISO 4628/3
Cracking ISO 4628/4
Flaking ISO 4628/5
Chalking ISO 4628/6
Scribe ASTM D 1654

Evaluation of the liquid paint

Appearance in tin ISO 2431 “Flow time”
Viscosity ISO 2884
Application properties

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 Abrasion resistance

• Weigh the painted

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

Testing paints \ Abrasion resistance1

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 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 Testing paints \ Flexibility_test1
occurs

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 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 Testing paints \ Impact_test1
occurs

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