Surface Preparation

Paint Inspection &

Quality Control Techniques

Surface Coating and Lining:

The essential aim of surface coating and lining is to prevent corrosion
mechanism and eliminate material loss.
This phenomenon directly effects the design stage.
Anti-corrosive elements and pigments inhibits corrosion mechanism
by

Blocking contact to corrosive environment (Oxidizing

matters)

Acting as a Cathode (- pole) and Galvanic effect.

Externally P.E Coated Pipe

Internally Epoxy Lined Pipe

Externally Epoxy Coated Pipe

Surface Preparation

Before application of coatings or linings, surfaces have to be

properly treated and prepared.
This stage directly effects the durability of layer during service
life.
Four critical parameters relates with surface preparation are
Surface Cleaning Degree
Surface Roughness
Salt Contamination
Dust
Contamination
Surface
Cleaning
Degree: Is directly related to amount of
oxidized portion of surface.
Its evaluated as per the standard of ISO 8501-1.
In this standard ;

Surface Rusting Degrees are categorized into 4 groups

according to availability of mill scale and rust, A,B,C and D.

Surface Preparation degrees are categorized into 4 groups

according to cleanness level, 1 2 2,5 3

Surface Preparation Techniques are categorized into 3

groups
Sa, St, Fl
Sa: Represents Blast Cleaned Surface
St: Represents Mechanically Cleaned Surfaces ( By hand via

Interpretation of Surface Cleaning Degree

Surface reference comparative pictures stated in ISO 85011

Surface Roughness
Surface Roughness is a component of surface texture. It is quantified
by the vertical deviations of a real surface from its ideal form. If these
deviations are large, the surface is rough; if they are small, the
surface is smooth.

We are using Ra value for quantification of roughness. It is the mean

value of profile.
Surface roughness is evaluated as per the standard ISO 8503-1.
Ra and Rz values also can be measured by electronic devices.

ISO Surface
Reference
Comparator

Salt Contamination
Since metal strips and coils are generally carried by ship and because
of the manufacturing methods of metals, surfaces are exposed to
salt contamination. This situation adversely effects anti-corrosion
applications.
Water Soluble Salt contamination can be easily measured by using
a Salt Test Kit as per the standard of ISO 8502-6 or ISO 8502-9.
Nominal value of salt contamination should be kept below
25mg/m2 or 25 ppm.

Dust Contamination

urface prepared for coating should be free of dust. Dust contamination degree of
ace is evaluated as per standard of ISO 8502-3.

tandard describes a method for the assessment of dust remaining on

ed steel surfaces prepared for painting. It provides pictorial ratings for the
sment of the average quantity of dust.

Paint Inspection
Painting inspection can be systematically considered into 3 main steps.
Conditions before painting
Conditions during painting
Performance after painting
Conditions before painting:
Before starting painting works some important conditions have to be
satisfied.
Surface profile and cleaning degree should be suitable for paint
spec. Surfaces have to be free of dust, dirt, grease, oil, loose
abrasives and other contaminations. Weld splatter, picking holes,
sharp edges, burr have to be properly grinded.
Atmospheric conditions should be properly evaluated.
Environmental temperature, Surface temperature, Relative
humidity and Dew point have to be evaluated.
Inspector! Painting works must begin with your permission. Keep in mind!
Conditions during painting:
Atmospheric conditions, painting machinery and auxiliary
equipment (especially nozzles and airless piston/cylinder) should be
inspected. If any improper situation exists the work should be
stopped.
For multi component paints, curing agents & paint combination

Paint Performance

lity of paint is such an important issue that directly effects the overall service li
systems or subsystems. Improper coating applications are disposed to peeling.
portions are quickly corroded and coating remains may cause obstruction in filt
ng and/or coating performance can be evaluate by considering following facts.
Visual inspection, Smoothness, Continuity .
Wet & Nominal Dry Film Thickness.
Pinhole & Holiday
Adhesion
Impact Resistance
Indentation Hardness
Flexibility

Paint Performance
Visual inspection, Smoothness, Continuity

Before starting visual inspection, inspector has to be sure that lighting

intensity is over
200 Lux. If the inspection will be performed in a confined space its
highly recommended
to inspector having a suitable torch.
Painted surface have to be free of overspray, runs, sags, voids,
blistering, peeling,
rusting, mud cracking, inadequate cure, lack of adhesion, holidays,
grids remains and
other impurities.
The surface should be continuously smooth and cosmetically
satisfactory.

Paint Performance
Wet & Nominal Dry Film Thickness ( NDFT)
Protective performance of a paint is directly dependent on NDFT.
But, in order to guarantee required NDFT, wet film thickness should
be checked after application of paint. Wet film thickness can be
measured by WFT Gauges.

Approximation of WFT ( m/m2):

Paint inspector should be capable of approximating WFT by
using tabulated data. Characteristics of paints are stated in PDSs.
Approximate WFT of a coated area can be easily estimated by
dividing total volume (or mass) of paint to referenced unit volume of
paint.
Example: Theoretical spreading rate is given 0.321 L. / m2 ( for
400 m. )
Total package volume= 15 L.
Approximate WFT= 15/0.321= 46.7 m2

Paint Performance
Wet & Nominal Dry Film Thickness ( NDFT)

Paint Performance
Wet & Nominal Dry Film Thickness ( NDFT)
NDFT can be measured by both destructive and Non-destructive
methods. Conventional destructive method for measuring NDFT is using
a P.I.G (Paint Inspection Gauge)

Elcometer 121/2
Universale P.I.G

VIEW FROM ABOVE THROUGH EYEPIECE WITH GRATICULE SCALE. TABLES IN INSTRUCTION BOOK
GIVE CONVERSION FACTORS FOR EACH BLADE, FROM GRATICULE UNITS TO MICRONS.
Advantages: Measurement of not only Nominal thickness but also interlayer thickness .
Disadvantages: Repair work required if applied onto workpiece. Relatively slow.

Paint Performance
Wet & Nominal Dry Film Thickness ( NDFT)

Non destructive methods are more common for NDFT measurement.

Magnetic devices should be verified before each use via calibrated foils.
ATTENTION: These devices should be used after full curing of paint
in order to prevent pinhead indentation loss !
This method is performed as per standard of ASTM D6132 / ISO 2808

Paint Performance
Pinhole & Holiday Control

Paint systems are highly prone to formation of pinholes, holidays or gas

blistering because of the comprised Volatile Organic Compounds (VOC)
inside it.
Especially fast cured paints are strongly prone to that situation.
HV Holiday Test is a simple and reliable method to detect such these
defects.
Recommended value to perform this test
The test is based on discharge of iselectric
8 V/m.current.

This method is performed as per

standard of ASTM D5162 / EN 10289

Paint Performance
Adhesion Measurement

By coating meaning, intermolecular force between steel surface and

paint is called adhesion.
Adhesion force is such an important characteristic of a paint system
that directly effects the anti-corrosive protection performance.
Coating
Layer
Steel Work
piece

Cohesion
Force

Adhesion
Force

Adhesion force between Steel surface and coating can be

measured by both mechanical and non-destructive Techniques.
Conventional methods are; Peel test, Tape Peel Test, Pull Test,
Indentation Debonding Test, Scratch Test, Blister Test, Beam
Bending Test, Self Loading Test, Electromagnetic Test and Dynamic
Modulus Test.
Most common tests are Pull-Off Test, X-Cut Tape Test, Cross-Cut
Test,

Paint Performance
Adhesion Measurement
Pull-Off Test

This test method covers a procedure for evaluating the pull-off of a coating
by determining either the greatest perpendicular force (in tension) that a
surface area can bear before a plug of material is detached, or whether the
surface remains intact at a prescribed force .
Failure will occur along the weakest plane within the system comprised of
the test fixture,
adhesive, coating system, and substrate, and will be exposed by the
fracture surface

Dolly

Paint Performance
Adhesion Measurement
Pull-Off Test
Screw Type / Direct Pull Model

Adhesive
Layer
Coating
Layer
Steel
Substrate
Procedure
Grind the coating surface that you pull off to increase roughness
and adhesion.
Be sure that the surface is dry and free of pain dust.
Apply adhesive bonder onto grinded surface and locate dolly onto
adhesive. If
exist put a weight onto dolly.
Wait curing time of adhesive bonder.
Locate the Tester onto substrate and cover bonded dolly. Make
pre-tightening
and set the scale to 0.
Start to tighten of tester up to fracture force.

Paint Performance
Adhesion Measurement
Pull-Off Test
Hydraulic Model

Dolly
Adhesive
Layer
Coating
Layer
Steel
Substrate

Procedure
Same procedure with direct pull type. Only difference is cleaning
of interior
section of dolly.
This method is also performed as per standard of ASTM D4541 /

Paint Performance
Adhesion Measurement
X-Cut Tape Test

One of the easiest methods to evaluate adhesion is X-Cut Tape Test.

These test methods cover procedures for assessing the adhesion of
coating films to metallic substrates by applying and removing
pressure-sensitive tape over cuts made in the film.
Procedure
Select an area free of blemishes and minor surface imperfections. For tests
in the field,
ensure that the surface is clean and dry.
Make two cuts in the film each about 40 mm long that intersect near their
middle
with a smaller angle of between 30 and 45.
Remove two complete laps of the pressure-sensitive tape from the roll and
discard. Remove
an additional length at a steady rate and cut a piece about 75 mm. Long.
Place the center of the tape at the intersection of the cuts with the tape
running in the same
direction as the smaller angles. Smooth the tape into place by finger in
the area of the
incisions and then rub firmly with the eraser on the end of a pencil.

Paint Performance
Adhesion Measurement
X-Cut Tape Test

Coated
Area

Evaluation of Results

This method is performed and

evaluated as per standard of ASTM
D3359
This method is proper for coatings
over 250 m.
Test Tape should have a 10 N 1N
adhesion strength for 25 mm.
Width.

Paint Performance
Adhesion Measurement
Cross Cut Tape Test
This method is suitable for coatings which
NDFT below 250 m. thick.

Procedure
Select an area free of blemishes and minor surface imperfections. For tests
in the field,
ensure that the surface is clean and dry. Make parallel cuts as below.
For coatings having a dry film thickness up to and including 50 m. space
the cuts 1 mm apart
and make eleven cuts.
For coatings having a dry film thickness between 50 m. and 125 m,
space the cuts 2 mm
apart and make six cuts. Make all cuts about 20 mm. long.
Brush the area as before and inspect the incisions for reflection of light
from the substrate. If
the metal has not been reached make another grid in a different location.

Paint Performance
Adhesion Measurement
Cross Cut Tape Test
Evaluation of Results

Paint Performance
Impact Resistance
Drop Weight Test

Impact resistance is one of the important mechanical property of

coating system. This test method covers the determination of the
energy required to rupture coatings applied to pipe under specified
conditions of impact from a falling weight.
Procedure
Check the surface condition
with holiday tester. Surface
should be free of defect.
Apply regular impacts onto
the specimen. Measure the
impact energy by means of
joule.
Apply holiday test between
trials.
Try to find maximum impact
energy that will cause a defect
on the substrate.
Document the data.
This test is performed as

Paint Performance
Indentation Hardness

Hardness of a coating system is such an important property that

represents the performance against wear. A coating system should
hard enough to resist adverse effects of friction and wear and should
be flexible enough to deform without crack formed at surface.
Durometer hardness test is widely used technique for evaluation of
hardness.
This test is performed as per the standard of ISO 868.

Paint Performance
Flexibility

Flexibility of a coating system is such an important property that

represents the durability against deformation. A coating system
should be flexible enough to preserve its original shape without
cracking or adhesion loss.
Flexibility of a paint system is evaluated by mandrel bend test.
This test method covers the determination of the resistance to
cracking (flexibility) of attached coatings on substrates of sheet metal
or rubber-type materials.
This test is performed as per standard of ASTM D522

100
mm.

0.8
mm.
150 mm.

Paint Defects
Pinholes & Boiling
Pinhole formation happens due to rapid curing. If paint system includes
excessive VOC or solvent and if these volatiles could not removed within
the liquid paint that causes to pinholes
at the surface of the cured paint.

Paint Defects
Orange Peel
Orange Peel forms on the substrate due to inadequate spreading of paint
film layer.

Paint Defects
Blushing

hite cloudy haze that generally appears on lacquer but may occasionally affect
fast drying finish. This defect generally forms when painting apply at cold weath
high humidity.

Paint Defects
Mud Cracking

defect forms generally at excessively thick coated layers. If this layer subjected
ir stream or a crack form under the top coat and if it propagated mud cracks ma
erved on the surface.

Paint Defects
Runs, Sags, Curtains, Voids
, Wrinkles

e type of defects generally formed by applying excessively thick layer and

inadequate thinner.

Paint Defects
Blistering

type of defects generally formed at rapid cured paint systems. If air bubbles
ed within the liquid paint and cured in this manner, nodular shaped discontinuitie
ved on the surface.

Paint Defects
Chalking

nt splashes to the surface as a chalked form this type of defect may observed.
ed paints may prone to loss of adhesion.

Paint Defects
Peeling

grease or other impurities which may cause adhesion loss on the surface of subs
ormed, that may cause local peeling on the coated part.