Professional Documents
Culture Documents
What is QA - QC ?
QA = Quality Assurance
(A documented management system)
QC = Quality Control
(Inspection and testing routines)
Daily logs
Steel temperature
Air temperature
% Relative Humidity
Dew point
Object no. and name
Exact specification
Pre-treatment, specified
and actually conducted.
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
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
NOTE:
Chalk might be
considered as
contamination for
some paint
systems: Remove
Cd-4932-90
Pre-blasting preparation
Rounding of edges
Removing of weld spatters etc.
0589-6
0589-5
C3
Cleanliness(salt,oil,greaseanddust/dirt)
Evaluationofpresentcondition(rustgrade)
Surfacepreparation(e.g.blastcleaning)
Cleanlinessofpreparedsurface
(salts,oil,grease,dustanddirt)
Climaticconditions
(temperature,relativehumidityetc.)
Area
ISO 8501
ISO 8502
ISO 8503
ISO 8504
ISO 8501 - 1
Surface preparation
Surface preparation
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
Cd-4930-86
ISO 8501 - 1
ISO 8501 - 1
4932-76
0631-55
ISO 8501 - 2
Surface preparation
ISO 8501 - 2
Standard for deciding preparation grades
PSa :
PSt :
PMa :
ISO 8501 - 3
ISO 8502
Assessment of surface cleanliness
(1 of
2)
Part 1
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
ISO 8502 - 1
Beaker with
test solution
Visual comparison
with the standard
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
Blue spots
ISO 8502 - 2
ISO 8502-3
Assessment of dust
Steel Surfaces Prepared for Painting.
Tape
Approved
Not approved
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.
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
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
Atmospheric conditions.
Requirement during blasting and painting
ISO 8502 - 4
B-24/2-4
4847-693
Relative humidity, RH
% R.H.:
= 86.65 %
15 x 100
17.31
Conductivity
Titration
Colour-reactions
Other Methods:
SCM 400 Salt Contamination
Meter
ISO 8502 - 5
ISO 8502 - 6
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.
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
CD 4932 no. 99
Sodium
Chloride
Iron
Sulphate
No
salt
Pre-treatment: Wj_saltlevel1
(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
Stylus instruments
Elcometer Mod. 123
Testex Press-O-film
Microscope
Comparator
Rugotest No. 3
ISO 8503 etc.
ISO 8503
Part 3
Part 4
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
ISO 8503 - 1
Nominal reading
m
25
60
100
150
Tolerance
m
3
10
15
20
Nominal reading
m
25
40
70
100
Tolerance
m
3
5
10
15
ISO 11124
Introduction
Part 2
Part 3
Part 4
Part 5
ISO 11125
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
Introduction
Silica sand
Copper refinery slag
Coal furnace slag
Nickel refinery slag
Iron furnace slag
Fused aluminium oxide
Olivine sand
Staurolite
Garnet
ISO 11127
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
Laboratory test
Requirement: Maximum 0,2
%
ISO 11127 - 6
Conductivity measurements
Shopprimer/ Abrasive_Test1
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
(1 of 2)
ISO 2808 - 97
(2 of
Microns
250
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
=
=
=
=
WFT x % VS
100
Example:
WFT=
250 m
% VS
DFT =
50 %
250 x 50=
125 m
Example:
DFT
% VS
WFT
% VS
100 m
=
65 %
100 x 100
= % 154 m
Formula: WFT
Example:
% VS
DFT
= 100 m
% VS
= 65 %
Added thinner
= 20 %
WFT
100 x (100 % + 20
%) m
=185
65 %
100 microns
65 %
=
20 %
=
1 litre
=
=
65
1,2
New % VS:
0,2 litre
1,2 litre
Formula:
DFT
% VS
10
=
=
100 microns
=
65
Factor
= 6,5m2/litre
Spreading rate:
65 x 10
100
m2/litre
(1 of 2)
Consumption
% VS
85 %
50 %
=
litre
(1 of 2)
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
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
Dead volume, l/ m2
0.02
0.03
0.04
0.05
0.06
0.07
Steel
Specified thickness
Uneven steel surface
Paint will fill the valleys
Steel
Dead volume
% VS
200
85
50
50
500 x 200
=
10 x 85 x 0,6
39 litre (EM)
83 litre (EM)
100 x 100
60
=
167 litre
100
0,6 (loss factor)
Cd-4932-100
PIG
Paint Inspection Gauge
Mainly for laboratory use
4932-100
ISO 2808 - 97
ISO 2808 - 97
ISO 2808 - 97
Cd-4932-82
Inspection \ Dryfilmthickness1
SSPC - PA 2
SSPC - PA 2
Area
Selection of Measurements
1.
10 m2
2.
30 m2
3.
Up to100 m2
4.
ASTM D 4752-87
Glove
MEK
Rag
Rubbing 50 x
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
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
Adhesion testing
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
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
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
Failure:
Adhesion failure: Between coats or between or substrate and 1st coat
Cohesion failure: Inside a coat
ISO 4624
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
Cd-4932-92
0002-004
Inspection / Pore_detection1
ASTM G 62 Method B
Cd-4932-93
0002-005
ASTM G 62 Method B
Inspection / Holiday_detection1
ISO 12944
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
ISO 8504 - 2
Abrasive blast-cleaning
Methods
Effectiveness
Fields of application
ISO 8504 - 3
Methods
Equipment to be used
Procedure to be followed
Paint dissolves:
Physically drying
No reaction:
Chemically curing
Steel
2 coat paint
Lifting/Wrinkling:
Oxidatively curing
Inspection / Determine_generic1
Salt spray
Natural weather exposure
Weather-o-meter
Cathodic disbonding
Cathodic protection
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
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
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
Standards
Comments
ISO 2409
ISO 4624
ISO 1510
ISO 1520
ISO 2815
ISO 6272
ISO 2813
ASTM D 4060
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
Standards
Comments
ISO 4628/2
ISO 4628/3
ISO 4628/4
ISO 4628/5
ISO 4628/6
ASTM D 1654
ISO 2431
Viscosity
ISO 2884
Application properties
Flow time
Abrasion resistance
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
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