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Painting & Coating-1

Painting & Coating-1

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Published by: sattanathan07 on May 26, 2012
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11/19/2013

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Question & Answers for Coating Exams
QWhat kind of process is corrosion?ACorrosion is an electrochemical process.QDefine corrosion? Why do uncoated steel structures corrode?ACorrosion is an electrochemical process. In practical terms; iron ore is an oxide of iron in chemical balance with atmosphere, following conversion with iron ore to iron, the chemical balance changesand the resulting iron become active but it always have the tendency to revert to its original statewhen it contact with the natural environment.QWhat factors influence the rate of corrosion?AVariation in oxygen content on the material surface. Chlorides and sulfides, higher nobilitymaterials being in contact with iron, acids, and alkalis.QWhat is a mill scale, and why is it a particular problem with attempting to protect steel?AWhen ferrous metal is forged into flat plates, beams and girders. It is worked at temperature oftenexceeding 1000˚C while the metal is in this white hot state it is in contact with the cool air andrapidly oxidizes, the results in the formation of a thin flaky layer called mill scale. Mill scale must be removed from the surface of the steel before painting take place mill scale is noble to steel therefor in close contact with each other steel will corrode.QWhat particular problems relate to the splash zone?AThe area of the materials, which are neither in water nor in air due to waves, high tide and low tideetc are cold splash zone. There is variation in oxygen level on the surface of the material, due tomedium change. Corrosion rate can be accelerated due to this reason.QWhat is the number of the Swedish standard contained within BS 7079 and list the rust and blastinggrades together with their brief titles?AThe Swedish pictorial standard 05-59-00 is contained with B.S. 7079 Preparation of Steel SubstratesPrior to the application of paint and related products.The Swedish standard gives visual information on the following:Rust Grades:- which depict the condition of steel before preparation.A.Covered in millscale with little or no rust.B.A mixture of millscale and rust.C.Millscale gone, rusted with slight surface pitting.D.Heavily rusted and pitted.Blast Cleaning Grades:SA 1 – Light blast cleaningSA 2 – Thorough Blast cleaningSA 2 ½ - Very thorough blast cleaningSA 3 – Blat cleaning to visually clean steelGrades of Wire brushing:ST 2 – Thorough hand & power tool cleaning (manual)ST 3 – Very thorough hand & power tool cleaning (mechanical)
 
QList blast cleaning surface. Give a comparism of blasting grades to SSPC, BS 7079, BS 4232 and NACE?ASA. 1 – Light Blast cleaningWhen viewed without magnification, the surface shall be free from visible oil, grease, dirt and from poorly adhering millscale.SA 2 – Thorough Blast cleaningWhen viewed without magnification, the surface shall be free from oil, grease, dirt and from most of the millscale, rust, paint coating and foreign matter. Any residual contamination shall be firmlyadhering.SA 2 ½ - Very thorough blast cleaning.When viewed without magnification, the surface shall be free from visible oil, grease, dirt and frommillscale, rust, paint coatings and foreign matters. Any remaining traces of contamination shallshow only as light stains in the form of spots and strips.SA 3 – Blast cleaning to visually clean steel.When viewed without magnification, the surface shall be free from visible oil, grease, dirt and shall be free from millscale, rust, paint coatings and foreign matter. It shall have a uniform metalliccolour.
Comparison of Blasting Grades
SSPCBS 7079BS - 4232NACEWhite metal (SP 5)SA 3Ist QltyGrade 1 Near white metal (SP 10)SA 2 ½2
nd
qltyGrade 2Commercial finishSA 23
rd
qltyGrade 3Light blast & Brush offSA 1N/AGrade 4QWhat factor influence how clean and how rough the surface becomes after blast cleaning?AThe cleanliness of the steel surface and its amplitude are governed by the abrasive characteristicsand human factors as follows:ABRASIVE HUMAN FACTORSSize SpeedShape AngleDensity DistanceHardness TimeQGive the essential requirements for abrasive blasting?AThe equipment required including safety features as follows:Compressor – providing air supply – 100 psiPressurised pot – containing abrasiveLiquid separator i.e. moisture filter Carbon impregnated hoses & external couplingDeadmans handle for direct operator controlBlasting nozzle (ventori shaped)Personnel equipment – Airfilled helmet, ear defender, boots, gloves & leather apron.
 
QSome metals are hard to prepare and paint? Name three and how you might prepare them?ANew Galvanizing: Sweep blasting, hand abrade, etch primer- where above two options areimpractical.Aluminum: Sweep blast, Hand abrade – for thin guage aluminum an etch primer is used prior tointermediate and finish coats. Not to be blast cleaned. Chlorinated hydrocarbon solvent shall not beused. Etch primer – Polyvinyl butyl.Stainless steel: Sweep blast – only aluminum used as blasting mediumQWhat is rough peak? What problem can it cause?ARouge Peaks are peaks, which stand out above the required profile and should be avoided if applying thin coating as they may lead to spot or flash rusting.QHow do you measure surface profile? Explain the method?AThe surface profile may be measured by a number of methods including the use of a surface profileneedle guage, surface replica tape (Testex tape) or a surface comparator.Surface Replica Tape:Testex tape or Press-O-Film is the commonly used surface replica tape. It is used in conjuction witha dial micrometer, has the advantage of providing a permanent record. The procedure for carryingout this text is as follows.Zero the micrometer ensuring the flat, contact points are clean.Remove paper backing and stick testex tape to the surface to be measured.3.Rub the Testex paste in to the thorough using a blunt instrument until peaks can be seen butting up to the transparent plastic.4.Remove the testex tape from the surface and measure the overall thickness with dialmicrometer 5.Deduct 50 mic from the reading to obtain the amplitude. The plastic layer to which thetestex paste is attached is 50 mic thick.QList all Safety Equipment and clothing required for open site blasting?AUse of Carbon impregnated hosed to reduce the chance of static shock. (Reinforced)Use of Deadmans handle for direct operator controlKeep hoses straight as possible to prevent kinks, which may lead to a blow out.Use of external coupling.Liquid separator.Hypodermic needle guage – to control the nozzle pressure.Operator should wear protective clothing, including air fed helmet, boots, gloves, ear defender andleather apron.Warning signs at the area, barrier tapeKeep the compressor pressure below 100 PSIQGive the three basic ingredients within a solvent carrying paint and list the job each has to do?AA traditional solvent carrying paint consists of three basic ingredients, these areBinder- It binds the particles together and holds them in suspension, gives the paint its finish, makesthe coating adhere to the surface, gives flexibility to the paint film, converts the coating to a soliddry film, give resistance to water, chemical and abrasion.Pigment – Gives colour to the paint, gives opacity to the paint, gives resistance to acids, alkalis andlight.Solvent – Forms the evaporative part of the drying process, thins the paint so it can be appliedeasily, washes out brushes and equipments, acts as a degreasing agent if approved.

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