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SSPC Pci Study Guide PDF
SSPC Pci Study Guide PDF
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These visual standards are designed for use as guides. In the event of a dispute, it is the
written surface cleanliness definitions that prevail. Also, the photographs in the standard
will likely not provide an exact match to the surfaces prepared on your project, because
the initial condition of the surface, the abrasive or tool employed, the surface profile,
lighting and other factors can affect the appearance of the surface. Therefore the visual
standards are truly designed as guides. In fact, many specifications now require the
contractor to prepare a project specific cleanliness standard on the actual structure to be
cleaned and coated. The project-specific standard represents the actual initial condition,
the actual abrasive or tool employed, the surface profile depth and other jobsite
conditions. The SSPC visual standards can be used during this process to establish the
minimum acceptable cleanliness level for the specific project. Once established, this area
can be preserved until the surface preparation portion of the project is completed.
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19
Environmental Conditions
8 hours
Work together in your teams to address each of the quality-related issues described
below. Elect a team spokesperson to present your answers to the class and be prepared
to defend them if questioned.
1. As the quality assurance inspector, how would you determine whether the abrasive
the contractor has mobilized on the project site conforms to SSPC-AB3?
20
2. The contractor spent extra time preparing the exterior surfaces, and even exceeded
the specified level of cleanliness (approached level SSPC-SP 10). However, the
surface began to rust bloom before the primer could be applied. By coincidence, the
amount of rust bloom did not exceed 33% of the surface. The contractor is claiming
that the surface meets the minimum level of cleanliness required by the specification
and wants to proceed with primer application. The surface preparation-to-primer
application time is within the 8-hour window. Explain how you would respond.
3. The cleanliness of the compressed air was assessed by the quality control specialist
upstream of the moisture and oil extractor. Comment as to whether this test was
performed properly.
4. The blast nozzle pressure was reportedly measured by the quality control specialist
before production blast cleaning was initiated and was recorded as 862 KPa (125
psi). During production abrasive blast cleaning, you ask the quality control
specialist to re-measure the blast nozzle pressure, and the gage read 620 KPa (90
psi). Based on this information, answer the following:
Does the during production pressure reading conform to the specification?
6. The quality control specialist tested the condition of the recycled abrasive and
recorded that the abrasive samples collected contained 2% of non-abrasive residue.
Does the abrasive meet the requirement for non-abrasive residue under SSPC-AB2?
7. After 5 hours of production blast cleaning on the interior of the tank, the surface
profile depth was measured by the quality control specialist and recorded as 107
m (4.2 mils), with a peak count of 40/cm.
21
Does the surface roughness meet the requirements of the project specification?
If no, describe what steps the contractor may take to correct the non-conformity.
If no, describe what the contractor could have done to avoid the non-conformity.
8. The quality control specialist assessed the amount of light inside the tank prior to
surface preparation operations. The amount of light was measured and recorded as
600 Lux (56 foot-candles).
The same amount of light was available when he assessed the surface cleanliness. Is
this acceptable? Explain.
9. The quality control specialist measured the ambient conditions and surface
temperature prior to abrasive blast cleaning. The surface temperature was 2C (3F)
above the dew point, but the conditions appeared to be improving, so the quality
control specialist allowed the contractor to proceed. Was this acceptable? Explain.
22
10. The quality control specialist reported the following levels after assessing the
cleanliness of the exterior surfaces. Do the surfaces meet the requirements of the
project specification?
Meets Specification
CHEMICALChemi LLEVEL
cal
Chloride
12 g/cm2
Ferrous Ion
3 g/cm2
Sulfate
None Detected
Yes
No
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___________________________
___________________________
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176
2 mL
___
12.25 cm2
___
120 S/cm
8.7 S/cm
___
78. Convert 35 S/cm to surface chloride concentration using the formula on Page
3-147.
___________________
79. A pH of 10 is considered ___________________.
80. A pH of 3 is considered ___________________.
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Good Painting Practice: SSPC Painting Manual, Volume 1, 4th Edition (SSPC Item
#02-14)
Systems and Specifications: SSPC Painting Manual, Volume 2, 2005 Edition (SSPC
Item #04-13)
SSPC-VIS 1 Guide and Reference Photographs for Steel Surfaces Prepared by Dry
Abrasive Blast Cleaning (SSPC Item #02-12)
SSPC-VIS 3 Guide and Reference Photographs for Steel Surfaces Prepared by Hand
and Power Tool Cleaning (SSPC Item #04-07)
SSPC-VIS 5 Guide and Reference Photographs for Steel Surfaces Prepared by Wet
Abrasive Blast Cleaning (SSPC Item #01-06)
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Instructions
Using the basic arithmetic skills taught in Module 4, solve each of the Problem Sets
below. Remember to use your calculator to avoid making simple math errors. You may
select the US standard or the metric exercises, depending on the prevailing system used.
Problem Set 1: Averaging Values
You have collected the following surface profile measurements. Calculate the average of
each area, then average all of the areas together.
Area 1
50 microns
75 microns
62 microns
Area 2
40 microns
43 microns
49 microns
Area 3
76 microns
80 microns
57 microns
Area 4
42 microns
58 microns
55 microns
Area 5
44 microns
71 microns
56 microns
Area 1
2 mils
3 mils
2.4 mils
Area 2
1.6 mils
1.7 mils
2 mils
Area 3
3 mils
3.1 mils
2.2 mils
Area 4
1.7 mils
2.3 mils
2.2 mils
Area 5
1.7 mils
2.8 mils
2.2 mils
Average of Area 1
Average of Area 2
Average of Area 3
Average of Area 4
Average of Area 5
______________
______________
______________
______________
______________
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Area 2
181 microns
233 microns
241 microns
Area 3
305 microns
295 microns
287 microns
Area 4
256 microns
214 microns
277 microns
Area 5
311 microns
298 microns
283 microns
Area 1
8 mils
12.3 mils
7.8 mils
Area 2
7.1 mils
9.2 mils
9.5 mils
Area 3
12 mils
11.6 mils
11.3 mils
Area 4
10.1 mils
8.4 mils
10.9 mils
Area 5
12.2 mils
11.7 mils
11.1 mils
Average of Area 1
Average of Area 2
Average of Area 3
Average of Area 4
Average of Area 5
______________
______________
______________
______________
______________
15%
65%
5%
52%
Decimal Format
_____________
_____________
_____________
_____________
33
________________
Use the space below to show the steps you took to arrive at the answers. You may also
want to draw and label the two beams with the dimensions for each to help visualize the
sizes.
35
According to the manufacturers product data sheet, the recommended amount of thinner
to add to a coating is 13 ounces per gallon of coating. If the mixed volume of coating is 5
gallons, how many ounces of thinner will be added?
What percentage of thinner will be added to the coating?
Problem Set 10: Converting VOC Content
The local air quality regulations for a recoating project do not allow coatings containing
VOC in excess of 2.1 lbs./gallon. The product data sheet that the coating manufacturer
provided for the solvent-borne primer only reports the VOC content in grams per liter,
which is 250 grams/liter. Can the coating be used on the project?
Based on the VOC content reported on the product data sheet, will the contractor be able
to thin the coating?
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Problem Set 14: Converting Units Used to Express Coating Thickness and
Surface Profile Depth
The coating specification requires a 2.0-3.5 mil surface profile depth. The actual surface
profile depth ranges from 63.5 to 83.8 microns. Does the area meet the specification?
After answering yes/no, indicate the actual surface profile range in mils.
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Show the metric version of the formula for calculating coating coverage here:
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Show the US Standard version of the formula for calculating coating coverage here:
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_____________
3-5 mils
84%
25%
20%
One pint per gallon
_________________________________________________________
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Project Description
The Sun Spree Township Municipal Authority (a suburb of Ft. Lauderdale, FL)
commissioned a coating condition survey of their 50-year-old elevated potable water
storage tank. The engineering firms report recommended total removal and replacement
of the lining on the interior of the tank, as well as removal of the coating on the exterior of
the tank, which contains both lead and chromium pigmentation in the existing coating.
Sun Spree Township awarded the surface preparation and coating application work to
Smith Bros. Contracting, a local firm that specializes in industrial surface preparation and
painting. Smith Bros. is responsible for providing a trained specialist to perform quality
control throughout the project. You are employed by Sun Spree Township as the resident
corrosion specialist, and will be performing quality assurance oversight on the project.
The interior of the tank has been prepared to achieve a Near-White Metal blast; the
exterior has been blast cleaned to conform to SSPC-SP 6, Commercial Blast. Both
surfaces are ready to be coated. The interior will be lined with a 3-coat NSF-approved
epoxy system. The three coats will be tinted different colors, but the manufacturer and
product no. are the same for each coat. The exterior will be coated with one coat of epoxy
and two coats of polyurethane (color coat and clear coat with dissipative dye).
The information provided below was excerpted from the project specification and only
pertains to coating/lining system installation activities:
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Environmental Conditions
Mixing Requirements
Thinning Requirements
Coating Thickness
SSPC-PA2
Primer Thickness
Topcoat Thickness
Stripe Coats
30 Days
50
Environmental Conditions
Mixing Requirements
Thinning Requirements
Coating Thickness
SSPC-PA2
Primer Thickness
Topcoat Thickness
30 Days
Work together in your teams to address each of the quality-related issues described
below. Elect a team spokesperson to present your answers to the class and be prepared
to defend them if questioned.
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1.
You arrive onto the project site and the contractor has already begun exterior
coating application. You measure the prevailing ambient conditions and the surface
temperature is within 3C (5F) of the dew point temperature, but the surface
temperature is higher than the dew point temperature. Based on this scenario,
answer the following:
Do you allow the contractor to proceed? _________________________________________
If no, why not?
2.
You measure the thickness of the primer and it is less than the specified minimum
by 1 mil. The contractor also measures the thickness of the primer and states that
it is within the specified range. How would you resolve this discrepancy?
3.
You were inside the tank obtaining dry film thickness measurements of the primer.
Meanwhile, the contractor proceeded with mixing and thinning 10 gallons of the
intermediate coat, which you were unable to witness. You inquired as to how
much thinner was added to the coating and the mixing crew responded, We didnt
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4.
The quality control specialist assessed the amount of light inside the tank prior to
inspecting the primer for dry film thickness. The amount of light was measured
and recorded as 600 Lux (56 foot-candles).
Does this conform to the project specification? __________________________________
The same amount of light was available when the contractor applied the primer to
the interior surfaces. Is this acceptable? Explain.
5.
The total square footage on the exterior of the tank was estimated to be 1,100
square meters (26,000 square feet).
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6.
5A:
How many 9 square meter (100 square foot) areas must be measured for
coating thickness? ____________________________________________________
5B:
5C:
5D:
What is the range of thickness for the spot measurements of the primer? _________
5E:
What is the range of thickness for the spot measurements of the primer +
intermediate coats? ___________________________________________________
5F:
What is the range of thickness for the spot measurements of the primer +
intermediate + finish coats?______________________________________________
The contractor begins to apply the clear coat to the exterior surfaces and you
notice that there is no dissipative dye in the coating as it is being applied. You
inquire, and the contractor responds that previous experience with another
product resulted in rework because the dye did not fully dissipate, so he refuses
to use it.
Do you allow the contractor to proceed? ________________________________________
If no, why not?
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7.
Application of the white primer to a portion of the exterior surfaces was done in
the early evening around 6:00 PM or so. The next day, you observe a yellowish
haze on portions of the surface, which is slightly tacky.
As an inspector, what do you suspect occurred? _________________________________
_________________________________________________________________________
Does the presence of this substance put the project at risk? _________________________
_________________________________________________________________________
How would you determine the nature of this substance? ___________________________
55
5-7 mils
72%
12.5%
__________________
3. During a material receipt inspection, the inspector should record the following
seven items:
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
______________________________
4. Most coating manufacturers prohibit mixing of __________________ kits.
5. Most industrial coatings must be mixed using a __________________-type
mixing blade.
6. Boxing a coating is not recommended for which two generic types of coatings?
__________________
__________________
7. When inspecting mixing of zinc-rich primers, the
__________________component should be slowly sifted into the
__________________component while under __________________.
8. Straining of a __________________primer is typically required by the
specification or coating manufacturers PDS.
9. Pot agitation is typically required for __________________primers, except
moisture-cured __________________zinc-rich primers.
10. What is the first step when considering adding thinner to a coating?
_____________________________________
11. What is the second step when considering adding thinner to a coating?
_______________________________
12. List three consequences of adding an unknown quantity of thinner to a coating.
_________________________________________________________________
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Module Six: Industrial and Marine Protective Coatings and Coating Systems
Module six introduces the basic components in an industrial coating: non-volatile and
volatiles. Subsequently, VOC (volatile organic compound) regulations will be explored
in the context of what a QC or QA inspector should know about monitoring and reporting
the addition of thinner to coating products and the actual quantity of VOC emitted into
the atmosphere during application. In Module Six, participants will also learn how
coatings cure. An overview of coating types and coating characteristics will be followed
by key inspection concerns by specific coating type. Module Six will conclude with an
overview of common coating systems used in a number of industries including: water
storage/tanks; power generation (both coal and nuclear); waste water treatment; pulp and
paper; lock and dam; chemical plants; buried pipeline; ships/marine vessels and
highway/bridges.
Learning Outcomes
At the completion of this module you should be able to:
- Identify basic differences between house paint and industrial/marine protective
coatings
- List volatile and non-volatile components of a coating
- Describe the functions of the resin, additives, pigments, and solvents in a coating
- Describe the methods by which coatings cure
- Describe the procedures used to identify service environments
- List advantages and limitations of various generic types of industrial/marine
coatings
- Describe functions of the primer, mid-coat and finish coat
- Identify common coating systems used by various industries
- Describe proper methods used to evaluate coating performance prior to full scale
installation
Identify Basic Differences Between House Paint and Industrial/Marine Protective
Coatings
Module Six begins by describing the differences between ordinary household paints and
industrial/marine protective coatings. One notable difference is the increased cost of
protective coatings, another is the reason behind the higher costs. The performance
requirements of industrial/marine coatings are much higher than those of house paints,
which are used primarily to improve aesthetics. Protective coatings, on the other hand,
may have to withstand immersion in water, chemical exposure, impact and abrasion, as
well as provide aesthetics.
List Volatile and Non-Volatile Components of a Coating
There are many different ingredients or raw materials that are used to formulate an
industrial/marine coating. This curriculum divides them into two categories:
1. Volatiles and non-volatiles
2. Pigmentation and vehicle
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68
70
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13. Most Type 1 and Type 2 DFT gages display the ___________________ thickness
of the galvanizing and coating layers.
14. On overcoating projects, the inspector should verify that visible ______________
and ________ contamination are removed prior to _______________
________________________.
15. Areas of sound coating adjacent to repair areas should be __________________
to ensure a smooth transition for the new coating and to prevent
________________ of the existing coating.
16. If a brush-off blast (SSPC-SP___) is specified for an overcoating project, the
inspector may be required to measure __________ _____________ and verify
proper abrasive type to ensure neither is too aggressive.
17. Pressure washing to remove dirt, chalking, etc. must be carefully inspected to
ensure _________________ removal prior to overcoating.
18. Prior to application of the overcoat material, an inspector should obtain
________________ measurements on the __________________ _____________.
19. The thickness of the overcoat can be isolated from the thickness of the existing
coating by using a ________ ___________.
20. List three toxic metals that may be in existing coatings:
_________________________________ _____________________________
_________________________________
21. A containment is designed to protect the ________________________________.
22. Ventilation inside a containment is designed to protect _____________________.
23. SSPC Class __ containment provides the highest level of protection.
24. Negative pressure is monitored _______________ or by reading a
_____________________ gage.
25. Air flow inside a containment can be monitored using a ______________
_______ ______________________________.
26. List two devices for monitoring air quality outside of a containment:
___________________________
____________________________
27. Pre- and post-project ____________ and/or ______________ sampling and
analysis may be required to verify effectiveness of the containment.
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28. List three things a coatings inspector should never do inside a regulated area:
_________________________________ _____________________________
_________________________________
29. Hazardous waste can only be transported by ______________ _______________.
30. List two SSPC Guides that govern containment and hazardous waste management
procedures:
_________________________________ _____________________________
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A-1
A-1
A-1
Cathode
Electrolyte
5. Which of the four elements in question 4 does a protective coating prevent from
contacting the steel? Electrolyte
6. When corrosion occurs, the anode depletes or decays.
7. If a copper pipe is connected to an aluminum pipe without an insulator, which metal
represents the anode? Aluminum
8. List two dissimilar metals that are intentional coupled in the protective coatings
industry as a method of corrosion prevention?
zinc and aluminum
9. What type of chemical will deteriorate uncoated weathering steel? Salt
10. Lamellar pigments form plate-like layers and provide barrier protection to steel
surfaces.
11. What two elements are prevented from contacting the steel when a barrier-type
coating is employed? Water (electrolyte) and air (oxygen).
12. Zinc-rich primers protect the steel by barrier and sacrificial protection.
13. Thermal spray metallizing and galvanizing protect the steel by barrier and sacrificial
protection.
14. Borates, chromates, phosphates and other pigments protect the steel by inhibition.
15. Cathodic protection can be in the form of sacrificial anode or impressed current.
16. Sacrificial anode is considered passive cathodic protection.
A-2
A-3
1. Quality Control is performing observations and tests, and documenting that the work
meets/exceeds the specification requirements.
2. Quality Control is the contractors responsibility.
3. Quality Assurance is the process to verify the quality of work performed as reported by
quality control personnel.
4. Quality Assurance is performed by the owner or a third party on behalf of the owner.
5. When an _owner performs QA with his direct staff, he has a contractual relationship
with the contractor and can exert control.
6. When a third party performs QA for the owner, he does not have a contractual
relationship with the contractor and can only advise and document, and advise the
contractors QC.
7. Independent of whether Quality Assurance personnel are on-site, the contractor
remains responsible for quality control.
8. When work is halted for an inspection, it is known as a hold point inspection.
9. List six common hold point inspections:
Pre-cleaning
Intermediate Coat Application
Surface Preparation
Topcoat Application
Primer Application
Cure
10. Which party should inspect the completed work first, QA or QC? QC
11. If the inspected area is deficient, which party should inspect the surface first after the
rework is completed, QA or QC? QC
12. QA observations and test results typically supersede those of QC.
13. Prior to a pre-construction conference an inspector should review the specification
.
A-4
A-5
1. Preparing a surface for coating application is the most critical and typically the
most costly step.
2. List five common responsibilities of a coatings inspector relating to surface
preparation:
Abrasive Cleanliness
Compressed Air Cleanliness
Removal of Grease/Oil Contamination
Surface Cleanliness
Surface Profile (roughness)
3. The two-fold purpose of surface preparation is to clean and roughen the substrate.
4. ASTM International and NACE International have prepared a standard and a
recommended practice for measurement of surface profile.
5. The specification dictates the required surface profile depth.
6. The surface profile or anchor pattern must be compatible with the entire coating
system.
7. List two fabrication defects that may be addressed in a coating specification.
Weld Spatter Edges/Corners
Laminations/Slivers
8. List three methods that can be used to inspect surfaces for the presence of
grease/oil:
Visual (rag) Black Light Water Break Test
9. Pack Rust occurs between mating surfaces, while stratified rust forms on the
surface of the steel.
10. Chemical contaminants like chloride trapped beneath a coating film can cause
osmotic blistering, underfilm corrosion and premature failure.
11. Testing for chemical contamination involves two steps: Extraction and Analysis.
12. Immersion environments are more conducive to coating deterioration caused by
chemical contamination beneath the coating film than atmospheric environments.
13. Suggested thresholds for soluble salt concentrations are found in the appendix to
SSPC SP12/NACE No. 5, High and Ultra-High Pressure Water Jeting
A-6
A-7
A-8
A-9
A-10
176
2 mL
352 g
12.25 cm2
28.7 g/ cm2
120 S/cm
8.7 S/cm
111.3 S/cm
78. Convert 35 S/cm to surface chloride concentration using the formula on Page
3-147.
E = 0.3 x S x (V/A)
0.3 x 35 x (212.25)= 1.71g/cm2
79. A pH of 10 is considered alkaline
80. A pH of 3 is considered acidic
A-11
0.39
5-7 mils
72%
12.5%
3. During a material receipt inspection, the inspector should record the following
seven items:
Name of Coating Manufacturer
Thinner Manufacturer
Product Name
Thinner Name/No.
Product No.
batch No. of Thinner
Batch No. of Each Component
4. Most coating manufacturers prohibit mixing of partial kits.
5. Most industrial coatings must be mixed using a shear-type mixing blade.
6. Boxing a coating is not recommended for which two generic types of coatings?
Inorganic zinc-rich primers Moisture-cure Urethanes
7. When inspecting mixing of zinc-rich primers, the zinc powder component should
be slowly sifted into the liquid component while under agitation.
8. Straining of a zinc-rich primer is typically required by the specification or coating
manufacturers PDS.
9. Pot agitation is typically required for zinc-rich primers, except moisture-cured
single component zinc-rich primers.
10. What is the first step when considering adding thinner to a coating? Determine
whether thinning is permitted by the manufacturer and specification
11. What is the second step when considering adding thinner to a coating? Determine
the type and amount of thinner to be added
12. List three consequences of adding an unknown quantity of thinner to a coating.
Net effect on VOC content is unknown
Target WFT is unknown
May result in sagging and/or accelerated surface drying
A-13
13. Application of coating to welds, edges, bolt/nuts, and rivets prior to full scale
application is known as stripe coating.
14. Daubers are used to coat crevices and between back-to-back angles.
15. Airless spray is the most common method used to apply industrial/marine
coatings.
16. What is the paint pressure when the regulator on 45:1 airless spray pump is set to
60 psi? 2,700 psi
17. What does the marking 723 indicate on an airless spray tip? 14 fan when gun is
positioned 12 from the surface; 0.023 tip opening
18. Proper distance of an airless spray gun from the surface is 12 inches.
19. The upper control on a conventional spray gun controls the shape of the fan
pattern.
20. The lower control on a conventional spray gun controls the amount of paint that
exits the spray tip.
21. Proper distance of a conventional spray gun from the surface is 6-8 inches.
22. The diameter of the holes in an HVLP spray air cap are larger than the holes in a
conventional spray air cap.
23. Plural component spray is used to apply coatings with what characteristics? Short
Pot Life and 100% Solids
24. For plural component spray, what method is typically used to reduce viscosity of
the components? Heated material hoses
25. An applicator should overlap spray passes 50% to build a consistent thickness.
26. List ten common inspection checkpoints that are performed on nearly every
industrial coatings project:
Verification of correct materials
Verification of correct materials
Verification of current shelf life
Verification of correct materials
Measuring ambient conditions & surface temp.
Mixing procedures
Measuring coating temperature
Assessing intercoat cleanliness
Measuring DFT
Verification of rcoat times/temperatures
A-14
27. What two values are used to determine the relative humidity and dew point
temperature when using a sling or battery powered psychrometer in conjunction
with the US Weather Bureau Psychrometric Charts?
Air Temperature
Depression of wet bulb thermometer (from dry bulb)
28. Ambient conditions should be measured where the work will be performed
29. The temperature of the surface to be coated must be at least 5oF (3oC) above the
Dew Point Temperature.
30. The wet bulb temperature is considered to be stabilized when two readings taken
within 20-30 seconds are within 0.5o of one another.
31. A coating material with a six hour pot life and a 45 minute induction has a useable
pot life of 5 hours & 15 minutes.
32. The wet film thickness reading on a wet film thickness gage is considered the
highest (wetted) numbered tooth (step) on the gage.
33. According to SSPC PA2, the accuracy of a coating thickness gage should be
verified before and after each period of use.
34. A Type 1 gage is known as a magnetic pull-off gage.
35. A Type 2 gage is known as an electronic gage.
36. The accuracy of Type 1 gages is verified using calibration blocks.
37. The accuracy of Type 2 gages is verified using non-metallic foils or plastic shims.
38. The effect of surface roughness on a coating thickness gage measurement is
known as a base metal reading.
39. The BMR is subtracted from the coating thickness to determine the thickness of
the coating above the peaks of the surface profile.
40. If the tolerance of a coating thickness gage is +/- 5% and the tolerance of the
standard used to verify gage accuracy is +/- 3%, what is the tolerance of the
reading on a 6.4 mil test block? 6-6.8 mils (+/- 6%, which is +/-0.4 mil)
41 The BMR is not necessary to measure when a Type 2 gage is verified for
accuracy using plastic shims placed onto the prepared, uncoated steel.
42. How many spot measurements are obtained within an area? 5
A-15
A-16
A-17
1. The resin, solvent and additives are known as the vehicle of a coating that carries
the pigment to the surface and binds it into the film.
2. List five functions of pigment in an industrial/marine coating:
Color
Barrier protection
Hiding power
Corrosion (inhibitive) protection
Gloss level of coating
3. Solvents are part of the wet film, but are not part of the dry film.
4. Primary solvents are used to reduce viscosity; secondary solvents are used to help
the coating flow and knit together.
5. Coatings that dry rather than cure form a solid film by a process known as
solvent evaporation.
6. Waterborne coatings cure by a process known as coalescence.
7. Coatings that cure by a reaction with oxygen cure by oxidation.
8. Multi-component epoxy and polyurethane coating cure by polymerization.
9. Coatings that hydrolyze are said to moisture cure.
10. What is the primary function of an intermediate coat? Barrier Protection
11. Which coating system is recommended for use on surfaces with an elevated
temperature in a waste water treatment plant? Inorganic zinc primer/silicone
topcoat
12. Mounting test panels containing candidate coating systems in the actual
environment where the new coating will be installed is known as a facilityspecific performance evaluation.
13. Coatings contain two categories of ingredients: Non-volatile and Volatile.
14. Thinner addition increases the VOC content of a coating.
15. Prior to selecting a coating system, the facility owner must properly identify the
prevailing service environment.
A-18
1. The primer used on connection points of I beams must often have a Class A or
Class B slip coefficient if the connection is slip critical.
2. List four inspection concerns relating to application of primers on slip-critical
connections.
Primer thickness
Amount of thinner used
Type of thinner used Cure time prior to boling the connection
3. List three forms of metallized spray:
Flame sray Arc spray
Plasma spray
4. What is the minimum surface cleanliness and surface profile depth for metallizing
applied to structures for marine or immersion service? SSPC-SP5; minimum 2.5
mil angular surface profile
5. Which form of metallizing feeds two wires to a spray gun? Arc spray
6. When measuring the thickness of thermal spray coatings on flat surfaces, a
minimum of 5 readings are obtained in a line spaced 1 inch apart.
7. When measuring the thickness of thermal spray coatings on a complex geometry,
a minimum of 5 readings are obtained in a 1.6 square inch diameter spot.
8. Powder coating may be cured using heat or ultraviolet (UV) light.
9. List seven inspection check points associated with powder coating application.
Powder material
Thickness
Surface preparation Continuity
Curing
Hardness
Appearance
10. Application of a liquid coating over a galvanized surface is known as a Duplex
system.
11. Weathered galvanizing is optimum for coating, while new galvanizing is difficult
to coat.
12. If sweep blasting of galvanizing is specified, the inspector may be required to
measure the nozzle air pressure prior to sweep blasting operations.
A-19
13. Most Type 1 and Type 2 DFT gages display the total thickness of the galvanizing
and coating layers.
14. On overcoating projects, the inspector should verify that visible grease and oil
contamination are removed prior to surface preparation.
15. Areas of sound coating adjacent to repair areas should be feathered to ensure a
smooth transition for the new coating and to prevent lifting of the existing coating.
16. If a brush-off blast (SSPC-SP 7/NACE No. 4) is specified for an overcoating
project, the inspector may be required to measure nozzle air pressure and verify
proper abrasive type to ensure neither is too aggressive.
17. Pressure washing to remove dirt, chalking, etc. must be carefully inspected to
ensure adequate removal prior to overcoating.
18. Prior to application of the overcoat material, an inspector should obtain thickness
measurements on the existing coating.
19. The thickness of the overcoat can be isolated from the thickness of the existing
coating by using a Tooke Gage.
20. List three toxic metals that may be in existing coatings:
Lead Chromium
Hexavalent Cadmium
21. A containment is designed to protect the environment and the public
22. Ventilation inside a containment is designed to protect workers.
23. SSPC Class 1 containment provides the highest level of protection.
24. Negative pressure is monitored visually or by reading a magnehelic gage.
25. Air flow inside a containment can be monitored using a rotating vane
anemometer.
26. List two devices for monitoring air quality outside of a containment:
Total Suspended Particulate (TSP) Particulate matter 10 microns and smaller
(PM-10)
27. Pre- and post-project soil and/or water sampling and analysis may be required to
verify effectiveness of the containment.
28. List three things a coatings inspector should never do inside a regulated area:
Eat
Drink
Use tobacco products
A-20
A-21
A-22
1. The coatings inspector shares in the responsibility for the safety of other workers
and the public.
2. A coatings inspector that observes an imminent hazard that may cause death or
serious injury should take immediate action to prevent the accident.
3. Who should an inspector obtain guidance from regarding their role relative to
safety issues? Employer and/or counsel
4. List an example of a General Risk that a coatings inspector may be exposed to:
Explosion; hazardous atmosphere; scaffold collapse; Inadequate hazard
warnings around site
5. List an example of a Personal Risk that a coatings inspector may be exposed to:
Entering a confined/hazardous space; falling; breathing in toxic metals
6. What is the primary difference between exposure hazards associated with
inspection verses exposure hazards to painters? The magnitude or duration of
exposure may be less for an inspector
7. List two hazardous materials that will be present on every coatings project:
Solvents/thinners and coating components
8. The inside of a storage tank can be considered what type of hazardous
environment? Confined space
9. Why is airless spraying categorized as a hazardous activity? High pressure and
an injection hazard
10. The effect of hazardous materials on an inspectors health depends on the level,
duration and route of exposure.
11. List four items that are of the greatest value to an inspector on an MSDS:
Health hazards (sign & symptoms of exposure)
Primary routes of entry into the body
Precautions of safe handling and use
Controls measures and PPE
12. What is the most frequent way solvents affect the body? Skin contact
A-23
13. Polyurethane coatings contain a chemical known as isocyanates, which are strong
irritants and sensitizers.
14. Respirators equipped with HEPA filtration cartridges can filter respirable sizeddust.
15. Heights greater than six feet above a lower level require fall protection.
16. What type of lanyard is a component to a personal fall arrest system? Shockabsorbing
17. List three items that an inspector should verify before entering a confined space:
Verify it has been tested and cleared for entry
Proper personal protective equipment is employed
Current training
18. What electrical hazard cannot typically be locked-out/tagged-out? Energized 3rd
rails; overhead transmission wires
19. What hazard is associated with inadequate lighting? Trips and falls
20. List two basic types of respirators: Air purifying & Supplied air
21. Most coating inspection gages are not intrinsically safe and should not be used in
hazardous environments.
A-24
Glossary
A
Abrading. (1) Erosion by mechanical or particulate impact. (2) Surface preparation of
concrete that is intended to roughen the surface profile and remove foreign materials.
Methods classified as abrading include mechanical abrasion, waterjetting, and abrasive
blast cleaning. Abrading methods are defined in ASTM D 4259.
Abrasion Resistance. The ability of a coating to resist being worn away and to maintain
its original appearance and structure when subjected to rubbing, scraping, or wear.
[ASTM]
Abrasive. (1) A material used for wearing away a surface by rubbing. (2) A fine,
granulated material used for blast cleaning. Abrasive particles of controlled mesh sizes
are propelled by compressed air, water, or centrifugal force to clean and roughen a
surface. Blast cleaning abrasives often are simply referred to as metallic or non-metallic
and as shot- or grit-like. [PCG]
Abrasive Air Blast Cleaning. See Air Abrasive Blast Cleaning.
Abrasive Blast Cleaning. Also called abrasive blasting, a surface preparation method
that uses an abrasive propelled by air pressure, centrifugal force, or water pressure to
clean and usually to profile a surface. Stand-off distance, angle of attack, and dwell time
are the three most important variables under the control of an operator that can affect the
quality and effectiveness of the blast cleaning. [PCG]
Abrasive Blasting. See Abrasive Blast Cleaning.
Abrasive Mix. Also called work mix or operating mix, the mixture of metallic or
recyclable non-metallic abrasive sizes that results from the periodic addition of new
abrasive to recycled abrasive during a blasting operation to maintain cleaning rate and
surface profile.
Abrasive Wheels. Metallic wheels mounted on a rotary power tool, commonly used to
grind welds and remove weld spatter. Also used to remove rust and mill scale from
localized areas. See Power Tool Cleaning.
Accelerator. See Catalyst.
Activator. See Catalyst.
Adhesion. The degree of attraction between a coating and a substrate or between two
coats of paint that are held together by chemical or mechanical forces or both. Adhesion
often is called the bonding strength of a coating. Adhesion should not be confused with
cohesion, which is the force holding a single coating layer together. [PCG]
Adhesion Failure. A breakdown between two distinct coating layers or between the
substrate and the first layer of coating. See Adhesion Test, Tensile (Pull-Off).
Adhesion Test, Crosscut. Also called crosshatch test, a coatings adhesion test in which a
crosshatch pattern is scribed onto the coated surface, then tape is applied and pulled off.
Adhesion is assessed according to surface area from which flaking has occurred (ASTM
B-1
B-2
B
Ballast. Water stored in tanks on board ships to contribute to the trim and stability of the
vessel. Ballast is pumped in and out from the sea to adjust the draft and distribute weight
to control sag, hog, center of gravity, etc. This ballast can cause sweating on the exterior
surface, which can contribute to coating failure
Banana Gauge. An elongated magnetic dry film thickness gauge with a handle at one
end and a probe at the other end. Between the handle and the probe is a positioning base
and a thickness display dial. See Magnetic Gauge.
Barometric Pressure. Atmospheric pressure, referenced in the U.S. Weather Bureau
Psychrometric Tables. Used to aid in determining relative humidity and dew point, based
on the dry and wet bulb readings from the psychrometer.
Barrier Coat. (1) A coating or coating system that protects an underlying substrate by
minimizing or eliminating the penetration of moisture or vapors. (2) A coating used to
separate a layer of paint from a surface to prevent chemical or physical interaction.
[PCG]
Barrier Protection. See Barrier Coat.
Base. (1) The major component of a multicomponent coating system. In two-component
systems, the other component is usually called an accelerator, an activator, a
hardener, or a curing agent. (2) A subfloor slab or working mat, either previously
placed and hardened or freshly placed, on which floor topping is placed in a later
operation; also the underlying stratum on which a concrete slab, such as a pavement, is
placed. [ACI]
Bend Test. See Flexibility Test.
Binder. (1) Nonvolatile portion of the liquid vehicle of a coating. It binds or cements the
pigment particles together and the paint film as a whole to the material to which it is
applied. See Nonvolatile Vehicle. [CED] (2) Cementing material, either hydrated cements
or products of cement or lime and reactive siliceous materials; the kinds of cement and
curing conditions govern the general kind of binder formed; also materials such as
asphalt, resins, and other materials forming the matrix of concretes, mortars, and sanded
grouts.
Biofouling. Biological encrustation of surfaces in sea water by flora and fauna, e.g.,
barnacles.
Bisphenol A. Dihydroxydiphenyldimethylmethane, mol. wt. 224.1. Insoluble in water.
Used in the manufacture of phenolic and epoxy resins. Condensation product formed by
reaction of two (bis) molecules of phenol with acetone. This polyhydric phenol is a
standard resin intermediate, along with epichlorhydrin, in the production of epoxy resins.
[CED]
Bisphenol A Epichlorohydrin. Chemical name of epoxy resin that is reacted with
amines and other curing agents to form epoxy-based coatings.
B-3
B-4
C
Cadmium. Toxic heavy metal. Cadmium compounds have been used as color pigments
(e.g., orange, red, yellow) often mixed with other heavy metal compounds. Their use in
coatings is restricted because of toxicity.
Calcium Carbonate. A white crystalline substance used as an extender pigment. Also
known as calcite, marble dust, carbonate of lime, English whiting, limestone, and
cliffstone whiting. [PDC, PCG]
Calibrate. To check, adjust, or determine by comparison with a standard. [CED]
Calibration Plates. Precision plates used for calibrating magnetic dry film thickness
gauges. Most commonly used standard plates are from NIST.
Calibration Shims. Small color coded shims, usually plastic of various thicknesses that
are used for calibrating Type II (fixed probe) magnetic dry film thickness gauges.
Carbon Black. Finely divided carbon formed by any one of several processes. Synonym:
gas black. These carbon blacks vary in particle size and some of them may be surface
treated. [CED]
Carcinogen. A material that either causes cancer in humans, or, because it causes cancer
in animals, is considered capable of causing cancer in humans. [CED]
Catalyst. A reaction promoter. A substance that induces, alters, or accelerates a chemical
reaction. A true catalyst is unchanged by the reaction it creates. In the coatings industry,
catalysts (also called activators, accelerators, and promoters) are used to speed the curing
or crosslinking of certain coatings. Curing agents and hardeners (which enter into
chemical reactions) are also sometimes (incorrectly) referred to as catalysts. [PCG]
Cathode. The electrode of an electrolytic cell at which reduction is the principal reaction.
(Electrons flow toward the cathode in the external circuit.) Typical cathodic processes are
cations taking up electrons and being discharged, oxygen being reduced, and the
reduction of an element or group of elements from a higher to a lower valence state.
Contrast with Anode. [ASM]
Cathodic Disbonding. Mechanical lifting of a coating caused by hydrogen bubbles
formed when cathodic protection is excessive.
Cathodic Protection. (1) Reducing the corrosion rate by shifting the corrosion potential
of the electrode toward a less oxidizing potential by applying an external electromotive
force. (2) Partial or complete protection of a metal from corrosion by making it a cathode,
using either a galvanic or an impressed current. [ASM]
Caustic. A strong chemical base. [CED]
B-5
B-6
B-7
D
dB. See Decibel.
DBA. See Design Basis Accident.
Dead Mans Control. Safety cut-out device at blast nozzle connected to pressure relief
valve on blast-pot (blast-kettle). May be air operated or electrical.
Dechlorination. In wastewater treatment plants, treatment to reduce the chlorine level of
the effluent water before it is discharged. This can be done by injecting the effluent with
sulfur dioxide gas (at a 1:1 ratio to the amount of chlorine injected previously) as it leaves
B-8
B-9
E
Eddy Current Gauge. See Dry Film Thickness Gauge, Eddy Current.
Eddy Current Testing. Determining a coating dry film thickness on certain metals by
measuring opposing electrical (eddy) currents produced by the gauge.
Edge Failure. Undercutting (penetration of corrosion underneath the coating) as it occurs
at an unprotected or incompletely protected edge.
Edge retention. Percent of coating after application that remains on an edge as compared
to that remaining on a flat surface.
Edge-Retentive Coating. Coating with at least 70% edge retention.
Effluent. Any spent liquors or other waste material that are emitted by a source (waste
from plating shops, pickling tanks, sewage treatment plants, chemical manufacturing
plants, etc.). [IUPAC, CED]
Elastomeric. Rubberlike; relating to or having the properties of elastomers. [CED]
Electrical Conductivity. The property of a fluid or solid that permits the passage of an
electrical current as a result of an impressed electromagnetic field. It is measured by the
quantity of electricity transferred across unit area per unit potential gradient per unit time.
(In sampling and analysis, changes in this property are utilized to measure the presence of
certain ions and compounds such as sulfur dioxide.) [ASTM]
Electric Arc Gun. A type of thermal spraying equipment in which a metal wire is melted
continuously by electric arc and then atomized by an air jet. An electric arc gun is less
B-10
F
Fabricated Structural Steel. Steel members made by fastening steel shapes such as
plates and angles, together by riveting, bolting, or welding.
Feather Edging. (1) Reducing the thickness of the edge of a dry paint film, such as the
edge of a damaged area, by sanding or rubbing down prior to repainting. (2) Tapering the
edges of a coat of wet paint by laying off with a comparatively dry brush. [MPDA, PCG]
Ferrous. (1) A chemical compound that contains iron in the bivalent (2+) state. (2) Any
metal alloy based primarily on iron. [PCG]
Fiberglass. Glass in fibrous form used to provide reinforcement or other desirable
properties to a variety of products such as coatings and linings.
B-11
B-12
G
Galvanic Corrosion. Accelerated metal corrosion that occurs because of an electrical
contact with a more noble metal or nonmetallic conductor in a corrosive electrolyte.
[ASM] The term dissimilar metal corrosion is sometimes used when appropriate.
Galvanic Protection. (1) The selective use of galvanic corrosion to protect one metal
from deterioration by connecting it to another, more active (electrically negative),
sacrificial metal. Both metals must be in contact with the same body of an electrolytic
solution. Zinc, magnesium, or aluminum can be used as sacrificial metals for the galvanic
protection of steel. (2) Protecting a metal in contact with an electrolytic solution from
corrosion by the use of an impressed direct electrical current. (3) Protecting steel with
zinc-rich coatings. [PCG] See Cathodic Protection.
Galvanizing. Applying a zinc coating to steel by dipping it in molten zinc or by
depositing zinc on the steel electrolytically or mechanically. [PCG]
Gel Time. The period from the initial mixing of the reactants of a liquid material to the
time when gelation occurs, as defined by a specific test method. [ASTM]
Generic. (1) Belonging to an entire class or group. (2) Non-proprietary. [PCG]
Gloss. The degree to which a surface reflects visual images. It is a direct function of
coating formulation and the amount and size of pigment particles in the coating, the more
pigment particles and the larger the diameter, the lower the gloss. [PCG]
Gouge Hardness. In determining coating hardness by pencil testing (ASTM D 3363), the
hardest pencil that will leave the film uncut. See also Scratch Hardness.
Grit. (1) An angular material with sharp, irregular edges obtained from slag, steel,
minerals, and various other materials for use as a blast cleaning abrasive. (2) Small, hard
foreign particles sometimes found in paint and coating materials. [PCG]
B-13
H
Hackle. Thin, needle-like or sliver-like protrusions, ranging from 3 to 6 mils (75 to 150
micrometers), found on steel plates that have been blast cleaned with steel shot or grit.
[PCG]
Hand Tool Cleaning. The use of manually operated impact, scraping, sanding, and
brushing tools to remove loose paint, rust, and mill scale. Such tools include slag
hammers, chipping hammers, scrapers, and wire brushes. The specification SSPC-SP 2,
Hand Tool Cleaning, is a consensus standard covering the procedures necessary for handtool cleaning of steel surfaces. [PCG]
Hardener. (1) Chemical agent used to promote or control the hardening or curing
reaction in coating or resin systems. See Curing Agent. (2) A chemical (including certain
fluosilicates or sodium silicate) applied to concrete floors to reduce wear and dusting.
[ACI]
Hardness. The property of a coating that allows it to resist damage or abrasion. [PCG]
Hardness Testing, Pencil Method. A method of testing coating hardness that uses a
series of lead pencils to determine which pencil will not cut through the coating and
which pencil will not scratch the coating. The hardest pencil that will leave the film uncut
defines the gouge hardness; the hardest pencil that will not scratch the film defines the
scratch hardness. This method is defined in ASTM D 3363.
Hazardous Waste. A solid waste, including liquid waste, that exhibits: ignitability,
corrosivity, reactivity, or toxicity, as defined in 40 CFR 261, Identification and Listing
of Hazardous Waste, or that is on a special list established by EPA. [ILPR, PCG]
HAZCOM. U.S. regulations governing hazardous chemicals in the workplace, issued by
OSHA in 1983; also known as the Right-to-Know regulations. The purpose of
HAZCOM is to ensure that workers are informed about chemical hazards in the
workplace, and that they are provided with information and training in how to safely
handle these chemicals.
Heat Resistance. The ability of a coating to resist deterioration when exposed
continuously or periodically to high temperatures at or below a given level, which
depends on the binder type and other coating ingredients. [PCG]
Heat-Shrink Sleeve. Cover, frequently polyethylene, that is placed around a structural
component, such as a pipe weld joint, and shrunk in place by heating.
Heavy Metal. Metallic element of high molecular weight, compounds of which are often
toxic.
Hiding Power. The ability of a coat of paint that has been properly applied to obscure
(hide) a surface or a previous coating on the surface. [PCG, V1]
High-Solids-Coating. A coating with a high non-volatile content. Currently, 70% solids
by volume is used as a benchmark measurement, at or beyond which a coating is said to
be high solids. Many new coatings contain no solvent and are called 100% solids
coatings.
Hog. The upward curvature of a ships bottom.
Hold Point. Critical point in an operation where work is stopped until the work to date
has been approved.
B-14
B-15
I
Immersion-Grade Coating. A coating suitable for use during immersion in water or
other liquids.
Immersion Service. Use of a coating under water or another liquid; in this service, the
coating is frequently called a lining. [PCG]
Impact Resistance. Ability of a coating to resist a sudden blow; ability to resist
deformation from impact. [PCG]
Impact Strength. Resistance to damage from collision with another body.
Impressed Current Cathodic Protection. Cathodic protection applied with an external
DC power source. See Cathodic Protection. [ASTM]
Indicator. Reagent used in chemical analysis that changes in color as the chemical
environment changes.
Induction Time. Sometimes called sweat-in time, the interval that must elapse after
mixing the components of multicomponent paint before application can begin. [PCG]
Infrared (IR). Invisible part of the electromagnetic spectrum between radio waves and
the red portion of visible light, with wavelengths between 0.78 and 1.0 micrometer (780
to 1,000 nanometers). It produces a heating effect on impact with an absorptive surface,
and sometimes is used to cure coatings. Infrared radiation is also used to chemically
characterize materials in infrared spectroscopy. [PCG]
Inhibitive Pigment. A pigment that when formulated into a coating provides active
corrosion inhibition to a metal substrate or inhibits some other undesirable effect. [PCG]
Inhibitive Primer. Primer containing inhibitive pigment or other chemical material.
Inhibitor. (1) General term for compounds or materials that slow or stop an undesired
chemical reaction, such as oxidation, corrosion, drying, skinning, mildew growth, etc. (2)
In wet cleaning methods for steel, a material that can be added to the water or applied as
a rinse to prevent flash rusting. [PCG]
Initial Condition. See Rust Grade.
Initiator. See Catalyst.
Intercoat Adhesion. The ability of one coat of paint to adhere to the next. [PCG]
Intrinsically Safe. Electrical equipment designed to separate sparking from the external
environment, so that the equipment can be used in hazardous environments.
Intumescent Coatings. A fire-retardant coating that when heated forms a foam produced
by non-flammable gases, such as carbon dioxide and ammonia. This results in a thick,
highly insulating layer of carbon (about 50 times as thick as the original coating) that
serves to protect the coated substrate from fire. [ASTM]
Ionic Contaminants. See Soluble Salt Contaminants.
Isocyanate. A compound containing one or more of the chemical group -N=C=O.
Isocyanates comprise one major component of two-component polyurethane coatings.
When the isocyanate groups are crosslinked with a hydroxyl-containing material (polyol),
a polyurethane polymer is formed; when combined with a amino-containing material, a
polyurea polymer is formed. [PCG]
B-16
J
Job Specification. Written, legal document, usually part of a contract, that precisely
describes an item of work that is to be accomplished. See also Specification.
K
Knife Adhesion. See Adhesion Test, Crosscut.
L
Lacquer. Coating composition based on synthetic thermoplastic film-forming material
dissolved in organic solvent, which dries primarily by solvent evaporation. Typical
lacquers include those based on nitrocellulose, other cellulose derivatives, vinyl resins,
acrylic resins, etc. They are re-soluble in their original solvent. [CED]
Laitance. A layer of weak and nondurable material containing cement and fines from
aggregates, brought by bleeding water to the top of overwet concrete; the amount is
generally increased by overworking or over-manipulating concrete at the surface by
improper finishing or by job traffic. [ACI]
Laminar. Arranged in, consisting of, or resembling thin plates or scales.
Laminations. Relatively large surface flakes, scales, or layers that are formed on steel
during the rolling process. [PCG]
Latex. A coating containing a stable aqueous dispersion of synthetic resin, produced by
emulsion polymerization, as the principal constituent of the binder. Modifying resins may
also be present. [ASTM]
Lattice. A framework of cut lines used in adhesion testing. See Adhesion Test, Crosscut.
Lead. A heavy metal. Lead compounds have been used extensively in the past as hiding
pigments and/or inhibitive pigments. It is hazardous to health if breathed or swallowed,
causing mental retardation in children and dangers to workers generating lead-containing
dust. Residential use of lead-containing paint pigments has been eliminated in the United
States, and industrial use has been greatly reduced.
Lead-Containing Paint. There is no consensus definition for lead-containing paint in
industrial maintenance applications. The following definitions have been developed for
related applications: (1) Consumer Products: A paint or other, similar surface coating in
which the lead content (calculated as lead metal) exceeds 0.06 percent by weight of the
total non-volatile content of the paint or the weight of the dried paint film. The 0.06
percent level is equivalent to 600 ppm. [ILPR] (2) Residential Use: A paint that contains
at least 0.5 percent lead by weight of the dried paint film. The 0.5 percent level is
equivalent to 5000 ppm. [PCG]
Leafing. Particles of certain metallic and other pigments in the form of thin flat flakes in
aligning themselves with or floating on or near the surface of the vehicle. [CED]
LEL. See Lower Explosive Limit.
B-17
M
Magnetic Base Reading (MBR). The measurement obtained when placing a dry film
thickness gauge on a magnetic substrate that has been blast cleaned.
Magnetic Fixed Probe Gauge, Type 2. A dry film thickness gauge that operates with
changes in magnetic flux within the probe or the instrument. The magnitudes of these
changes are an inverse (nonlinear) function of the distance between the probe and the
steel surface under the paint. Type 2 refers to the gauges designation in SSPC-PA 2.
Magnetic Gauge. See Dry Film Thickness Gauge, Magnetic.
Magnetic Pull-Off Gauge, Type 1. A dry film thickness gauge that uses a spring balance
to pull a small permanent magnet from the surface of the painted steel. The magnetic
force holding to the surface varies inversely as a non-linear function of the distance
B-18
B-19
B-20
O
Offshore Platform. A stationary steel structure in an ocean or bay that is used by oil and
gas industry operators for drilling or other production activities.
Oil Canning. Bowing edges of a steel plate caused by thermal expansion and
contraction. Oil canning can lead to a coating cracking at the edges.
Opacity. The degree to which a material obscures a substrate, as opposed to the
transparency, which is the degree to which a material does not obscure a substrate. [CED]
Open Blast Cleaning. See Air Abrasive Blast Cleaning.
Operating Mix. See Abrasive Mix.
Orange Peel. A coating film defect with the textured look of an orange peel. [PCG]
Organic Solvent. Liquid organic material including diluents and thinners that is used as a
dissolver, viscosity reducer, or cleaning agent.
Organotin. Tin compounds used in anti-fouling paints and wood preservatives. Their use
is currently curtailed because of toxicity concerns.
Osmotic Blistering. The raised areas (blisters) containing water that form on coating
films when water diffuses through the film to dissolve underlying solvents or salts. The
diffusion is caused by a difference in pressure or concentration between the metal-coating
interface and the exposed film.
Overblast. Areas where abrasive blasting has impinged on surfaces that were not
intended to be blasted.
Overspray. (1) Atomized coating particles that deflect from or miss the surface being
sprayed. (2) Spray particles that are not wet enough to fuse when they reach the surface
being sprayed. As a result, overspray may contaminate property beyond the surface being
sprayed. [PCG]
Oxidation. (1) In coatings, the introduction of oxygen into a molecule, thereby producing
a cured film. [Paint/Coatings dictionary] Alkyds and drying oil-based coatings cure by
B-21
P
Paint Thermometer. Instrument designed for measuring the temperature of liquid
coating materials by immersion.
Parts Per Million (PPM). Measure of proportional content (e.g., of small amounts of
contamination).
PEL. See Permissible Exposure Limit.
Pencil Testing. See Hardness Testing, Pencil Method.
Pencil-Type Pull-Off Gauge. A pencil-shaped magnetic pull-off gauge for determining
dry film thickness. See Magnetic Gauge.
Percent Solids. See Non-Volatile Matter.
Permissible Exposure Limit (PEL). The amount of a toxic material or harmful
substance to which a worker may be exposed under OSHA regulations. If OSHA has
established a PEL for a substance, by regulation the exposure must be kept at or below
that level. PELs are expressed as parts per million (ppm) or as micrograms per cubic
meter (g/m3) and typically are based on time-weighted average concentrations for a
normal 8-hour workday and a 40-hour work week. See also Threshold Limit Value.
[PCG]
Personal Protective Equipment (PPE). Devices worn to protect against hazards in the
environment. Respirators, gloves, and ear protectors are examples.
pH. The measure of the acidity or alkalinity of an aqueous solution. A pH of 7 represents
neutrality, i.e., the solution is neither acid nor alkaline. pH values from 0 to 7 are acidic,
the lower the pH value, the higher the degree of acidity; pH values from 7 to 14 represent
alkalinity. The higher the pH value above 7, the greater the degree of alkalinity. [CED]
Pigment. Finely ground, natural or synthetic, inorganic or organic insoluble particles
that, when dispersed in a liquid vehicle provide color and other properties, including
opacity, hardness, durability, and corrosion resistance to a coating. [IM]
Pigment Volume Concentration (PVC). Ratio of the volume of pigment to the volume
of total nonvolatile material (i.e., pigment and binder) present in a coating. The figure is
usually expressed as a percentage. [CED]
Pinhole. A holiday or discontinuity in a coating film approximately the size of a pin
point, and extending entirely through the applied film, normally caused by solvent
bubbling, moisture, or foreign particles. [PCG]
Pinhole Detection. See Holiday Test.
Pinpoint Rusting. Tiny, dispersed points of rust that can appear at pinholes and holidays
in a coating. Very dense pinpoint rusting can appear on painted steel surfaces where the
coating does not completely cover the blast cleaning profile. [PCG]
B-22
B-23
Q
Quality Assurance. The guarantee that the quality of a product is actually what is
claimed on the basis of the quality control applied in creating that product. Quality
assurance is not synonymous with quality control. Quality assurance is meant to protect
against failures of quality control. [IUPAC, CED]
Quality Control. The statement that a product specifically meets or exceeds some
minimum standard based on known, testable criteria. [CED]
Quantab Strip. Trade name for a commercial test strip used to determine the chloride
content of an aqueous solution.
B-24
R
Reference Cell. Standard receptacle containing an electrode and electrolyte used as a
point of reference for measuring electrical potentials; used in sacrificial anode and
impressed current cathodic protection.
Reflectance. The ability of a coating film to reflect or return the light that falls upon its
surface. [PCG]
Relative Humidity. The ratio of the actual pressure of existing water vapor to the
maximum possible (saturation) pressure of water vapor in the atmosphere at the same
temperature, expressed as a percentage. [ASTM, PCG]
Release Agents. Materials used to prevent concrete from bonding to a surface. [ACI] See
Form Release Agent.
Replica Tape. A specially constructed tape used to measure surface profile. It is pressed
against the surface to produce an impression of the profile; then, the impression in the
tape is measured with a micrometer. The use of replica tape is described in ASTM D
4417 and NACE RP0287.
Reservoir. Storage tank in which the diameter is greater than the height; the reverse is
true for a standpipe.
Resin. General term applied to a wide variety of more or less transparent and fusible
products, which may be natural or synthetic. They vary widely in color. Higher molecular
weight synthetic resins are more generally referred to as polymers. In a broad sense, this
term is used to designate any polymer that is a basic binder material for coatings and
plastics. [PCG]
Respirator. (1) A device that supplies oxygen or a mixture of oxygen and carbon dioxide
for breathing, used especially in artificial respiration. (2) A screenlike device worn over
the mouth or nose or both to protect the respiratory tract. There are quite a variety of
respirators, ranging from disposable dust masks to self-contained breathing apparatus. All
have specific uses and limitations. [CED]
Rigging. (1) The process of selecting and setting up supports, cables, and ropes, and
scaffolding systems to provide safe access to an elevated work area. (2) The cables,
ropes, and related equipment used with scaffolding. [PCG]
Right-To-Know Legislation. See HAZCOM.
Ring Extrusion Process. A method for extruding thermoplastic coatings onto pipe in
which the die slit encircles the advancing pipe and the thermoplastic is extruded without
seams as a plastic pipe over the steel pipe.
Rotary Peener. A rotary impact power tool that uses rotating action to impact different
shapes of heavy-duty steel cutters against a steel or concrete surface to remove heavy
coatings and contaminants. Rotary peeners also can be used to grind concrete. [PCG]
Rust Bloom. The first sign of rust on newly cleaned steel, indicated by slight surface
discoloration. See Flash Rusting. [PCG]
Rust Grade. In visual standards, the initial condition of unpainted steel before surface
preparation. SSPC-Vis 1, a visual standard for steel surface preparation, outlines four rust
grades: (1) Rust Grade A: the steel surface is completely covered with adherent mill
scale; little or no rust is visible. (2) Rust Grade B: The steel surface is covered with both
mill scale and rust. (3) Rust Grade C: The steel surface is completely covered with rust;
B-25
S
Sacrificial Protection. (1) The use of a metallic coating, such as galvanizing or zinc-rich
paint, to protect steel. In the presence of an electrolyte, such as salt water, a galvanic cell
is set up and the metallic coating corrodes instead of the steel. (2) The use of metal
anodes that are slowly consumed to protect immersed or buried metals. See also Galvanic
Corrosion and Galvanic Protection. [PCG]
Sagging. (1) A coating surface irregularity caused by the downward flow of wet paint
that produces an uneven film with a thick lower edge. [PCG] (2) Subsidence of shotcrete,
plaster, or the like, due generally to excessive water in the mixture; also called sloughing.
[ACI]
Sag Resistance. The ability of a wet coating film to resist the downward flow that results
in an uneven film with thick edges and runs. [PCG]
Salt Spray Test. Test used to evaluate the resistance of coated metals or alloys to
corrosion. It consists of a fine mist or fog of common salt (sodium chloride) solution
sprayed on the surface. The test is described in ASTM B 117. [PCG]
Sanding Disc. Flat, circular, powered implement used to abrade a surface.
Saponification. Alkaline hydrolysis of fats, drying oils, or other esters whereby a soap is
formed. A saponified coating may become sticky and discolored. In severe cases, the film
may be completely liquefied by saponification. Loss of adhesion may occur as a
saponified layer develops next to the substrate. [PCG]
Scaffold. Equipment in variety of types, sizes, and rigging configurations used to support
workers, materials, and equipment at elevated or otherwise inaccessible work sites.
[PCG]
Scaling Hammer. Impact tool used to remove corrosion products and other undesired
materials from metal surfaces.
Scratch Hardness. In determining coating hardness by pencil testing (ASTM D 3363),
the scratch hardness is defined by the hardest pencil that will not scratch the film. See
also Gouge Hardness.
Scrub Resistance. The ability of a coating to resist being worn away or to maintain its
original appearance when rubbed repeatedly with an abrasive material. Typically, the
rubbing procedure can employ a brush, sponge, or cloth, wetted with an abrasive soap
solution, in which case it is more accurately referred to as wet scrub resistance. [CED]
Secondary Containment. A second or backup holding vessel surrounding a primary
holding vessel. Under 40 CFR 264.193, the EPA lists requirements for lining secondary
containment vessels so that they meet the standards for impermeability and for containing
the liquid in the primary containment vessel should a leak or spill occur. [PCG]
Sedimentation. Action or process of depositing matter (sediment) that settles to the
bottom of a liquid (sediment).
B-26
B-27
B-28
B-29
T
Taber Abraser. An instrument used to measure abrasion resistance (ASTM D 4060).
Specimen on a turntable rotates under a pair of weighted abrading wheels that produce
abrasion through side slip. [CED]
Tack-Free. Absence of tack or stickiness in an applied coating. A coatings freedom
from tack after suitable drying time. [PCG]
Tagging. A means of protecting workers from injury or death caused by the accidental
start-up or release of stored energy from equipment. It involves placing a tag on the
power source as a warning not to restore energy to the piece of equipment. See also
Lockout.
Tape Test. See Adhesion Test, Crosscut.
Tensile Adhesion Test. See Adhesion Test, Tensile (Pull-Off).
Tensile Strength. The maximum tensile stress that a material is capable of sustaining.
Tensile strength is calculated from the maximum load during a tension test carried to
rupture and the original cross-sectional area of the specimen. [ASTM]
Test Strip. Paper strip dipped into solution to estimate of amount of contaminant or other
material present.
Thermal Spray Coating (TSC). Solid coating materials melted before dispersion
(spraying) on a surface.
Thermal Spraying. A process for applying metallic wire, metallic powder, and
thermoplastic powder. The material is melted and sprayed onto a surface to produce a
uniform coating. Gas wire and electric arc guns are used for spraying metallic wire;
plasma guns are used for spraying metallic and thermoplastic powders. See also Flame
Spraying, Metallizing, and Plasma Spraying. [PCG]
Thermit Reaction. Explosive effect that occurs when aluminum and iron oxide are
heated. Aluminum pigmented paints associated with rusty steel are susceptible to the
effect, leading to potential problems in hazardous environments such as gas, fuel oils, etc.
Thermoplastic. A material that becomes soft when heated and hard when cooled without
undergoing chemical change. While the material is soft, it can be reformed or molded. As
used in the coatings industry today, the original meaning of the term thermoplastic has
changed somewhat. It is now used to classify coating types according to how the resins
cure, and the solubility of the cured film. The term thermoplastic is virtually synonymous
with the term non-convertible. See Non-Convertible Coating. [PCG]
B-30
B-31
U
Ultrasonic Gauge. Instrument for measuring material thickness by the time sound takes
to travel through it.
Ultrasonic Thickness Measurement. Determining thickness of a solid substrate, such as
steel, through equipment that applies wave energy above the normal hearing range and
then times its retroreflection.
Ultraviolet (UV). A band of electromagnetic radiation between 10 and 400 nanometers
in wavelength. The part of the UV spectrum in the actinic region (280 to 315 nanometers)
is especially destructive to paint films. Ultraviolet energy also sometimes is used to cure
a coating. Black light is a popular term for UV radiation. [PCG]
Undercutting. The penetration of a coating and the spread of delamination or corrosion
from a break or pinhole in the film or from unprotected edges. [PCG]
Upper Explosive Limit (UEL). The concentration at ordinary ambient temperatures of a
compound in air above which an explosion will not occur if the mixture is ignited. UEL
is expressed as a percent of the gas vapor in air by volume. When concentrations of a
substance in air are below the upper explosive limit and above the lower explosive limit
(LEL), the mixture will burn and explode. See also Lower Explosive Limit. [PCG]
V
Vacuum Blasting. Abrasive blast cleaning using a vacuum shroud to capture dust,
debris, and other materials while they are being generated and prevent them from
escaping into the environment. See Abrasive Blast Cleaning. [PCG]
Vehicle. The liquid portion of paint, in which the pigment is dispersed; it is composed of
binder and thinner. [CED]
Viscometer. An instrument for measuring flow properties. [CED]
Viscosity. The quality or property of a fluid (i.e., paint) that causes it to resist flow. A
high viscosity coating is thick; a low viscosity coating is thin. [PCG]
Viscosity Cup. A laboratory or field instrument for measuring the viscosity of a liquid by
timing the liquids flow through an opening in the bottom of a small bowl.
Visual Comparator. One of several systems used to visually estimate the profile of an
abrasive blasted steel surface. See Surface Profile Comparator.
VOC-Compliant. Conforming to VOC regulations. See Volatile Organic Compound.
B-32
W
Washability. Ease with which the dirt can be removed from a paint surface by washing;
also refers to the ability of the coating to withstand washing without removal or
substantial damage. [CED]
Wash Primer. A carefully balanced one- or two-component system containing an
inhibiting chromate pigment, phosphoric acid, and a synthetic resin binder mixed in an
alcohol. On clean, light alloy or ferrous surfaces, and on many nonferrous surfaces, such
primers provide excellent adhesion, partly due to a chemical reaction with the substrate,
and a corrosion-inhibiting film that is a good basis for the application of subsequent coats
of paint. [CED]
Water Blast Cleaning. A water cleaning method in which abrasive is injected into the
water stream.
Waterborne Coatings. Paint, the vehicle of which is a water emulsion, water dispersion,
or ingredients that react chemically with water. Also called water-based and waterreducible coatings.
Water Break. The appearance of a discontinuous film (beads) of water on a surface,
signifying nonuniform wetting and usually associated with a surface contamination.
[ASTM, CED]
Water Cleaning. A method of using pressurized water, heated or unheated, with or
without detergent, to prepare surfaces for coating. Low-pressure water cleaning uses
pressures up to about 34 MPa (5,000 psi); high-pressure water cleaning ranges from 34
MPa (5,000 psi) to 170 MPa (25,000 psi); and ultrahigh-pressure water cleaning uses
pressures above 170 MPa (25,000 psi). When pressures exceed 69 MPa (10,000 psi), a jet
nozzle is used and the process is called waterjetting.
Waterjetting. The use of water at high or ultrahigh pressure to prepare a surface for
recoating. High pressure waterjetting is cleaning performed at pressures from 69 to 170
MPa (10,000 to 25,000 psi). Ultrahigh pressure waterjetting is cleaning performed at
pressures above 170 MPa (25,000 psi). [SSPC-SP 12/NACE 5].
Water Trap. A structural feature in which liquid (such as rainwater) may accumulate
from the environment.
Weathering. Behavior of coating films when exposed to natural weather or accelerated
weathering equipment, characterized by changes in color, texture, strength, chemical
composition, or other properties. [CED]
Weathering Topcoats. Exterior finishes designed to resist deterioration from ultraviolet
light, rain, and other natural destructive elements in the atmosphere.
Weld Spatter. Beads of metal produced during the welding process that adhere to the
surface near the weld. [PCG]
B-33
X
Xylene. An aromatic solvent used in the manufacture of paints. It also is used widely as a
thinner and cleanup solvent. The flash point of xylene is about 80F (27C). [PCG]
Z
Zinc. A hard, metallic element with a bluish tinge. Zinc or its compounds are used as
reinforcing and corrosion-resistant pigments. Zinc dust is used in zinc-rich coatings to
provide galvanic protection to steel. It is also the basis for galvanizing and sprayed zinc
coatings.
B-34
Bibliography
ACI: Cement and Concrete Terminology. ACI International: Farmington Hills, MI, 2000.
ASM Metals Handbook. ASM International: Metals Park, OH, 1987.
ASTM Annual Book of Standards. ASTM: West Conshohocken, PA, 2003.
Bridge Inspectors Training Manual/90. U.S. Department of Transportation/Federal
Highway Administration: Washington, DC, 1979.
Coatings Encyclopedic Dictionary (CED). Stanley LeSota, ed., Federation of Societies
for Coatings Technology: Blue Bell, PA, 1995.
Dictionary of Architecture and Construction (DAC). C.M. Harris, ed., McGraw-Hill:
New York, 1975.
EPA: Glossary for Air Pollution of Industrial Coatings Operation. U.S. Environmental
Protection Agency: Washington, DC, 1983.
Industrial Lead Paint Removal Handbook (ILPR). Kenneth A. Trimber, ed., SSPC:
Pittsburgh.
IUPAC Glossary of Atmospheric Chemistry Terms. Atmospheric Chemistry Division,
National Center for Atmospheric Research: Boulder, CO, 1990.
MPDA: The Master Painters Painting and Decorating Terminology Glossary. Master
Painters & Decorators Association: Burnaby, B.C., 1997.
PDC: Painting and Decorating Craftmans Manual and Textbook. Painting and
Decorating Contractors of America: Fairfax, VA, 1975.
Protective Coatings Glossary. SSPC: Pittsburgh, 2000.
B-35
Arithmetic
C-1
C-2
C-3
C-4
C-5
C-6
C-7
C-8
C-9
C-10
C-11