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SSPC Pci Study Guide
SSPC Pci Study Guide
Table of Contents
Module Two: The Roles of Quality Assurance (QA) and Quality Control (QC)
Inspection Personnel on a Coating Project………………………………………...7
Module Five: Coating Mixing, Thinning, and Application: Equipment Overview and
Inspection Techniques……………………………………………………………...43
Appendix A
Quiz Answer Keys…………………………………………………………....A-1
Appendix B
Glossary………………………………………………………………………B-1
Appendix C
Arithmetic…………………………………………………………………….C-1
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PCI Study Guide- October 2007
Module One: Protecting Steel from Corrosion: The Role of Protective Coatings
Module one explains how coatings protect metals from corroding. Corrosion is a process
where man-made metals give up energy and return to their natural state. Some man-
made metals have a stronger propensity to corrode than others, but all man-made metals
corrode eventually. Only four elements need to be present for corrosion to occur: an
anode, a cathode, a metallic pathway, and an electrolyte. While the corrosion of man-
made metals cannot be completely halted, it can be controlled. The most widely used
method to prevent/slow corrosion today, particularly on carbon steel, is the application of
high performance coatings. Module One explains how today’s high performance
coatings use barrier protection, sacrificial or cathodic protection, and inhibitive protection
to protect modern day steel structures from the inevitable process of deterioration and
decay.
Learning Outcomes
At the completion of this module you should be able to:
- Identify the elements of a corrosion cell
- Describe the corrosion of man-made metals
- Explain how industrial coatings control corrosion
- Describe alternative methods used to protect carbon steel from corrosion
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Module One: Protecting Steel from Corrosion: The Role of Protective Coatings
Quiz 1
5. Which of the four elements in question 4 does a protective coating prevent from
contacting the steel? __________________________________________________
8. List two dissimilar metals that are intentionally coupled in the protective coatings
industry as a method of corrosion prevention?
________________________ and ____________________________
11. What two elements are prevented from contacting steel when a barrier-type coating
is employed? _____________________ and ___________________________
13. Thermal spray metallizing and galvanizing protect the steel by _______________
and ________________ protection.
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14. Borates, chromates, phosphates and other pigments protect the steel by
_________________.
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Module One: Protecting Steel from Corrosion: The Role of Protective Coatings
Supplemental Reading
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Module Two: The Roles of Quality Assurance (QA) and Quality Control (QC)
Inspection Personnel on a Coating Project
Module Two compares the roles of QA and QC inspectors on coatings projects. All too
often, the lines between the QC and the QA on a coatings project get blurred. When that
happens, the scope of work and responsibility for that work can get blurred in the
process. This module is designed to clarify the common roles and responsibilities of both
the contractor’s QC inspector and the Owner’s QA inspector. This is a textbook: the
way it would work in a perfect world, but it is helpful to know how things “could/should”
work before getting caught up in the day to day rush of a real world coatings project.
Module Two compares and contrasts the role of the QA and QC inspector on a typical
coatings project. The commonalities will be explored, including understanding the
specification, reviewing the product data sheets (the PDS) and the material safety data
sheet (the MSDS), comprehending the industry standard relevant to the specific project,
documenting hold or checkpoints, understanding paper trails, and taking responsibility
for ethics on the job. Module Two also explores the critical differences in the two roles,
including issues of authority, reporting, testing, and documentation (which again,
depends on the scope of work and the specification). Another issue explored by this
module is the management of nonconformities.
Learning Outcomes
At the completion of this module you should be able to:
- Describe the differences between quality assurance and quality control
- Describe the common duties of quality assurance and quality control personnel
- Describe the purpose and content of a pre-job conference
- Explain the purpose of an inspection procedure/plan
- Explain the importance of ethics of inspection personnel
Quality Assurance (QA) is defined as the process to verify that the quality of work
performed is actually what was reported by quality control. Quality assurance is typically
performed by the owner (e.g. facility project engineer) or a third party on behalf of the
Owner.
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QC inspection should occur first and any non-conforming items identified by QC should
be corrected, re-inspected and accepted by the QC. The QA observations should only
occur after the work (hold point) has been accepted by the QC. The QA should then
verify that the work that the QC accepted meets the requirements of the specification.
The pre-job conference should summarize the contractor’s approach to the project
including: schedule, location(s) of equipment, and manpower estimates.
The pre-job conference should review the specification and sequence of work, address
specification discrepancies, and discuss how QC and QA inspections will be coordinated
and implemented. It should include discussion of preparation of test sections, if required;
adequate lighting; inspector safe access; inaccessible areas; and other project-specific
considerations.
The final phase of the pre-job conference should include a discussion of all required QC
and QA documentation and submission schedules. The Owner should also address the
procedure that should be followed if there are discrepancies in the QC and QA
documentation.
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Module Two: The Role of Quality Assurance (QA) and Quality Control (QC)
Inspection Personnel on a Coating Project
Workshop: Ethics
As a group, review each of the scenarios below and discuss and answer the questions.
Have a group spokesperson prepared to discuss your group’s answers at the end of the
session.
SCENARIO 1:
You are performing part-time third party Quality Assurance services for the Owner. The
contractor blast cleaned and painted while you were not on-site. When you arrive on-site,
the Owner hands you a piece of paper that says “Tuesday, surface preparation OK.
Ambient OK 100 gallons primer applied, OK.” He asks you to record this information
on a dated inspection report and to sign it.
SCENARIO 2:
You are hired by a Facility Owner to provide third party QA. You’ve been assigned to
go out-of-town and are living in the same hotel as the contractor’s workers. You often see
them in the hotel bar. Every time you are at the bar, the contractor pays for your drinks.
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_________________________________________________________________________________
Question 2: If no, how might you prevent this from occurring or handle it ethically?
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
SCENARIO 3:
SCENARIO 4:
You’ve been working as the Facility Owner’s QA on the same out-of-town project with
the same contractor for over a year. You have a good working relationship. Your vehicle
breaks down and you cannot replace it. The contractor allows you to use the company
pick-up truck. He also gives you his credit card to use for gas.
SCENARIO 5:
You are the contractor’s QC. You measure the ambient conditions prior to the start of
painting with an epoxy primer and they comply with the specification. However, during
painting you notice that the weather is changing and obtain additional ambient
measurements that indicate the dew point temperature has now fallen below the surface
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temperature. You advise the foreman, who tells you that his application is underway and
that he’s going to finish painting, regardless of the conditions. He tells you to ignore it, to
not record the additional measurements, and just let him finish the job.
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Module Two: The Role of Quality Assurance (QA) and Quality Control (QC)
Inspection Personnel on a Coating Project
Quiz 2
6. When an _____________ __________ performs QA for the owner, he does not have
______________________ _________________________ with the contractor and can
only _________________ and document, and advise the __________________ QC.
10. Which party should inspect the completed work first, QA or QC? ______________
11. If the inspected area is deficient, which party should inspect the surface first after the
rework is completed, QA or QC? _____________________
12. ________ observations and test results typically supersede those of __________.
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16. The content of the “acceptance criteria” section for an inspection plan comes from the
_________________________________
17. A Work Plan should cover the individual _________________ of a project, including
both _________________________ and ___________________________.
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Module Two: The Role of Quality Assurance (QA) and Quality Control (QC)
Inspection Personnel on a Coating Project
Supplemental Reading
- Planning and Specifying Industrial Protective Coating Projects (SSPC Item #04-10)
- The Inspection of Coatings and Linings: A Handbook of Basic Practice for Inspectors,
Owners, and Specifiers, 2nd Edition (SSPC Item #03-14)
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Learning Outcomes
At the completion of this module you should be able to:
- Describe the importance and dual objective of proper surface preparation
- Define the SSPC, NACE, and ISO standards for surface preparation
- Describe common methods used to prepare surfaces for coating
- Describe methods used to control an environment during surface preparation
activities
- Measure and record surface profile
- Evaluate surface cleanliness
Define the SSPC, NACE, and ISO Standards for Surface Preparation
The SSPC, NACE and ISO surface cleanliness standards prescribe a minimum acceptable
level of cleaning, depending upon the specified degree of cleanliness required. The
standards are known as “consensus documents” that are created by industry experts for
inclusion in coatings specifications. They are not laws or regulations, but they become
“contract law” once they are invoked in a specification for a coatings project. There are
currently thirteen SSPC surface cleanliness standards. SSPC and NACE have jointly
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published seven of them; SSPC is the sole publisher of the remaining six. The written
standards for surface cleanliness are contained in Volume 2 of the SSPC Painting
Manual, “Systems and Specifications” and are available for individual download from
www.sspc.org. ISO currently has seven surface cleanliness standards. These standards
define the level of cleaning required, and many of them are accompanied by visual guides
that an inspector can use to verify that the minimum level of cleaning has been achieved.
These values (surface temperature and dew-point temperature) can be obtained using
sling or battery-powered psychrometers in conjunction with US Weather Bureau
Psychrometric Tables and surface temperature thermometers, or can be obtained using
direct read-out electronic psychrometers equipped with surface temperature probes. The
step-by-step use of this instrumentation is described below. It is important that the
inspector not rely on prevailing weather conditions from a local service (e.g., airport
weather station) as conditions at the project site and the specific work area can vary
considerably. Ambient conditions should be measured and recorded prior to initiating
final surface preparation and at 4-hour intervals thereafter, unless conditions appear to be
declining. In this case, more frequent checks may be required. If surface preparation
work will be done inside a facility, tank or inside of a containment, then the prevailing
ambient conditions inside of the areas (at the actual location of the work) should be
assessed. The location, date, time of day and the condition of air temperature, relative
humidity, dew-point temperature and surface temperature should be recorded. However,
since the only operation being monitored is surface preparation, the dew point/surface
temperature relationship is most critical. Typically, there is no specified range for air
temperature and relative humidity during surface preparation operations.
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Factors affecting the depth of the surface profile include (for abrasive blasting) the type,
hardness and size of the abrasive media employed, as well as the hardness of the surface
being prepared. Lesser factors include the distance from the blast nozzle to the surface.
For power tool cleaning, the type of tool and the configuration of the “impactors” will
oftentimes dictate the depth of the surface profile. Adjusting to changes in profile depth
requirements in specifications is best achieved by selecting a different sized abrasive.
For projects requiring a relatively shallow surface profile depth, a smaller abrasive should
be selected. For projects requiring a relatively deep surface profile, a larger abrasive
should be selected, but may be blended with a smaller abrasive to increase productivity.
There are four industry-recognized standards for measuring surface profile, including
ASTM D4417, “Test Methods for Field Measurement of Surface Profile of Blast Cleaned
Steel;” NACE RP0287, “Field Measurement of Surface Profile of Abrasive Blast Cleaned
Steel Surfaces Using a Replica Tape;” ASTM D7127 “Standard Test Method for
Measurement of Surface Roughness of Abrasive Blast Cleaned Metal Surface Using a
Replica Tape;” ASTM D7127 “Standard Test Method for Measurement of Surface
Roughness of Abrasive Blast Cleaned Metal Surfaces Using a Portable Stylus
Instrument.” These methods prescribe how to obtain measurements of surface profile
depth and peak count, but do not provide an acceptance criterion (e.g., “the surface
profile shall be 50-88 µm [2-3.5 mils…”]. Therefore, the project specification must
indicate the desired surface profile depth and the minimum peak count (as required).
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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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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 firm’s 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. The
exterior surfaces (underside of the bowl) also contain high levels of chloride (range of 50
to 100 µg/cm2), which is likely due to the proximity of the tank to the beach front.
Sun Spree Township awarded the surface preparation and coating application work to
Smith Bros. Contracting, a local QP1 certified 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 information provided below was excerpted from the project specification and only
pertains to surface preparation activities:
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Surface Profile of Interior and Exterior Surfaces Angular; 50-87.5 microns (2-3.5 mils);
Minimum peak count: 34/cm
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?
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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:
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
µm (4.2 mils), with a peak count of 40/cm.
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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 2°C (3ºF)
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.
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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
Yes No
Chloride 12 µg/cm2
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Quiz 3
1. Preparing a surface for coating application is the most _________ and typically
the most ____________________ step.
______________________________ ___________________________
______________________________ ___________________________
______________________________
8. List three methods that can be used to inspect surfaces for the presence of
grease/oil:
____________________ ________________ ____________________
10. Chemical contaminants like chloride trapped beneath a coating film can cause
____________________blistering, ____________________and
____________________failure.
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13. Suggested thresholds for soluble salt concentrations are found in the appendix to
_____________________________________________.
14. The depth and shape of the surface profile generated by abrasive blast cleaning is
determined by the ____________________and the ____________________ of
the surface.
17. The abrasive cleanliness requirements in SSPC abrasive specifications AB1, AB2
and AB3 are ____________________requirements of the SSPC abrasive blast
cleaning surface cleanliness standards.
18. List four tests that an inspector can perform in the field to verify conformance to
SSPC AB1:
______________________________ ___________________________
______________________________ ___________________________
22. List three tests that an inspector can perform in the field to verify conformance to
SSPC AB3:
______________________________ ___________________________
______________________________
23. List one test that an inspector cannot perform in the field to verify conformance to
SSPC AB2: ____________________.
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28. High pressure water jetting incorporates pressures from _______ to _____ MPa.
31. SSPC surface cleanliness standards become contract law once they are invoked by
the ___________________.
38. Which two SSPC surface cleanliness standards invoke a minimum surface profile
requirement? ___________________and ___________________
What is the minimum requirement? ___________________
39. List three possible “indirect requirements” of the SSPC abrasive blast cleaning
standards:
______________________________ ___________________________
______________________________
40. The amount of staining allowed by the SSPC abrasive blast cleaning standards is
based on what area? __________________
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47. SSPC-SP___/NACE No. ___, level WJ-2 allows up to ___% of the surface to
contain straining or tightly adhering matter.
50. ISO ___, “___________________” allows only stains to remain on the surface.
51. The SSPC/NACE and ISO cleanliness standards prohibit the use of
___________________ when inspecting surface cleanliness.
52. Prior to final surface preparation, it is recommended that the inspector verify that
the ___________________ temperature is at least ___oF (___oC) higher than the
___________________ temperature.
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55. Cooling air below the dew point for dehumidification of the air is the
___________________ method.
56. Products that absorb moisture from the air as a means of dehumidification use the
___________________ method.
57. Indicate the procedure for conducting a compressed air cleanliness test, below:
Conduct the test ___________________ stream of ___________________ and
oil separation. Position the air outlet ___” from the collector
Exhaust the compressed air onto the collector for approximately ______.
58. To conduct a “vial test,” fill a clear container with ___abrasive and an equal
amount of ___________________. Allow the shaken blend to settle for
___________________.
62. The visual standard reference “G2 SP14” in SSPC VIS 1 indicates:
___________________________________________________.
63. The visual standard reference “F SP3 PWB” in SSPC VIS 3 indicates:
______________________________________________________
64. The visual standard reference “D WJ3 M” in SSPC VIS 4/NACE VIS 7 indicates:
__________________________________________________________
65. The visual standard reference “C WAB 6 H” in SSPC VIS 5/NACE VIS 9
indicates: _______________________________________________
70. The ___comparator disc is selected for inspection of surface profile when garnet
abrasive is used to perform abrasive blast cleaning.
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74. The thickness of the Mylar film on replica tape is ___ mils.
75. Each grade of replica tape is most accurate in the ___ of the range.
78. Convert 35 µS/cm to surface chloride concentration using the formula on Page
3-147.
___________________
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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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Module Four reviews practical math skills used by the coatings inspector. Coating
inspectors frequently need to apply basic math skills to everyday inspections. This
module provides a review of common arithmetic associated with coatings inspection,
including: converting percentages to decimal format; calculating square footages;
calculating volume and converting ounces/gallon to percentage of thinner addition;
converting VOC values; converting temperatures; and converting units of measurement
for surface profile depth and paint thickness (mils to microns and back). A special
session on calculating coating material quantities based on theoretical and practical
coverage rates is included in this module.
Learning Outcomes
At the completion of this module you should be able to:
- Apply practical arithmetic to calculations relating to everyday jobs
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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.
You have collected the following surface profile measurements. Calculate the average of
each area, then average all of the areas together.
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You have collected the following coating thickness measurements. Calculate the average of
each area, then average all of the areas together.
A two-coat exterior coating system has been specified and the products have been
delivered to the project site. You have elected to calculate target wet film thickness and
the maximum amount of thinner that can be added to each. The coating manufacturer lists
the volume solids content and the allowable thinner as a percentage. You will need to
convert each of the percentages to decimal.
Decimal Format
Allowable percentage of thinner for the primer: 15% _____________
Volume solids content of primer: 65% _____________
Allowable percentage of thinner for the topcoat: 5% _____________
Volume solids content of topcoat: 52% _____________
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A cylindrical ground storage tank contains four (4) shell rings. Each shell ring is made
from eight (8) steel plates measuring 3 meters (10 feet) by 7 meters (23 feet). The interior
and exterior of the tank is to be coated (excluding the interior floor and interior ceiling, and
the exterior roof, which all appear to be in good condition). The tank owner has asked you
to verify that the contractor has ordered enough coating, so you will need to first calculate
the total area of the shell rings to be coated. Use the space below to show the steps you
took to arrive at the final answer.
The project specification for surface preparation of steel I beams in the fabrication shop
requires three (3) surface profile measurements every 30 square meters (100 square feet)
of prepared surface. There are two sizes of I beams on the project:
Beam Size A: 0.5 meter (18 inch) flanges (2.54 cm [1 inch] thick)
2 meter (6 foot) web
18 meters (60 foot) beam length
12 – stiffeners, each 2 meters (6 foot) x 10 cm (4 inches) wide
Beam Size B: 0.5 meter (18 inch) flanges (2.54 cm [1 inch] thick)
2.5 meter (8 foot) web
24 meters (80 foot) beam length
16 – stiffeners, each 2 meters (6 foot) x 10 cm (4 inches) wide
If the total project involves 12 beams of Size A and 15 beams of Size B, now many
surface profile measurements are required for the project? ___________________
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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.
According to the manufacturer’s product data sheet for the three-component coating in
Problem Set 6, the coating must be thinned 15%. What is the total volume of thinner that
must be added to the coating?
According to the manufacturer’s product data sheet, the recommended amount of thinner
to add to a coating is 50 milliliters per liter of coating. If the mixed volume of coating is 5
liters, how many milliliters of thinner will be added?
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According to the manufacturer’s 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?
Based on the VOC content reported on the product data sheet, will the contractor be able
to thin the coating?
A steel fabrication shop that also performs surface preparation and primer application
work is located in an area with very strict air pollution regulations. Coatings used by the
fabrication shop cannot exceed 375 grams/liter VOC. The shop wants to use a primer that
contains 3.9 lbs./gal. VOC. Can the primer be used by the shop?
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According to the coating manufacturer’s product data sheet, the air temperature must be
maintained between 40°F and 100°F during application. The air temperature is 34°C. Can
coating application work continue? After answering yes/no, indicate the actual
temperature in °F.
According to the coating manufacturer’s product data sheet, the coating storage area must
be maintained between 10°C and 49°C. The air temperature in the storage area is 125°F.
Does the storage temperature conform to the manufacturer’s requirements? After
answering yes/no, indicate the actual temperature in °C.
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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PCI Study Guide- October 2007
Problem Set 15: Converting Units Used to Express Coating Thickness and
Surface Profile Depth
The coating specification requires the primer and intermediate coats to be a combined
thickness of 203-305 microns. The thickness of the combined coats ranges from 6 to 10
mils. Does the area meet the specification? After answering yes/no, indicate the actual
coating thickness range in microns.
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A three-coat system has been specified for protecting a structure estimated to be 2,323
square meters in area. The volume solids content is 75% for the primer, 56% for the
intermediate coat and 46% for the topcoat. The specified thickness is 75-100 microns for
the primer, 125-178 microns for the intermediate coat and 50-75 microns for the topcoat.
The contractor will need to reduce the primer and intermediate coatings by 10% with
Thinner No. 2 and will need to thin the topcoat by 5% using Thinner No. 4. Mixing and
application losses are estimated to be 20% for each coating, and the surface profile is
expected to consume 15% of the primer. Based on this scenario, complete the chart
below:
Show the metric version of the formula for calculating coating coverage here:
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PCI Study Guide- October 2007
A three-coat system has been specified for protecting a structure estimated to be 25,000
square feet in area. The volume solids content is 75% for the primer, 56% for the
intermediate coat and 46% for the topcoat. The specified thickness is 3-4 mils for the
primer, 5-7 mils for the intermediate coat and 2-3 mils for the topcoat. The contractor will
need to reduce the primer and intermediate coatings by 10% with Thinner No. 2 and will
need to thin the topcoat by 5% using Thinner No. 4. Mixing and application losses are
estimated to be 20% for each coating, and the surface profile is expected to consume 15%
of the primer. Based on this scenario, answer the questions below:
Show the US Standard version of the formula for calculating coating coverage here:
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PCI Study Guide- October 2007
Quiz 4
1. Average the following set of surface profile measurements: 3.5, 3.7, 2.9, 3.1, 4.0
_____________
4. Calculate the area of a square that is 4.5 feet x 13.6 feet. _____________
5. Calculate the area of an I-beam that is 40 feet in length, has 12” wide flanges, a
48” web, and 8 stiffeners (4” wide x 48” long). _____________
6. Calculate the exterior surface area of a tank that is 45 feet in height and 90 feet in
diameter.
_________________________________________________________
10. Calculate the quantity of primer required to coat 15,000 square feet of blast
cleaned steel, based on the following data:
_________________________________________________________
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- Practical Math for the Protective Coatings Industry (SSPC Item #03-05)
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Module Five explains the inspection of coating mixing, thinning, and application.
Experts claim that poor application, along with inadequate surface preparation, cause the
majority of all industrial coating failures. This module provides an overview of the
various methods used to apply coatings, including conventional (air) spray, airless spray,
HVLP, air-assisted airless spray, and brush & roller. The advantages and limitations of
each method, along with proper technique will be emphasized. Module Five will
continue with the inspection of mixing, thinning, and coating application processes,
including measuring ambient conditions, witnessing and documenting mixing and
thinning procedures, wet and dry film measurements, use of the Tooke Gage (destructive
testing) to determine the thickness of individual layers in a coating system,
pinhole/holiday detection, adhesion, and coating hardness and curing tests.
Learning Outcomes
At the completion of this module you should be able to:
- Describe the procedures associated with proper mixing, thinning, and
application of industrial coatings
- Define the SSPC standards for coating application
- Describe the role of the coating inspector on a coatings project
- Use MSDS and product data sheets to verify safe and proper mixing, thinning,
and application of coatings
- Describe the inspector’s role regarding coating material receipt and storage
- Measure and record ambient conditions and surface temperature
- Calculate Wet Film Thickness
- Measure Wet Film Thickness
- Verify accuracy of nondestructive coating thickness gages
- Measure coating thickness using nondestructive gages
- Describe the SSPC standard for measurement of coating thickness
- Measure coating thickness using destructive methods
- Detect pinholes and holidays
- Measure coating adhesion
- Evaluate coating cure
- Measure coating hardness
- Describe methods used to verify intercoat cleanliness
Describe the Procedures Associated with Proper Mixing, Thinning, and Application
of Industrial Coatings
Proper coating mixing procedures are one of the most important steps in the successful
installation of a protective coating system. The procedures for blending single
component materials is straightforward and needs little instruction other than ensuring the
material is homogeneous by mixing all of the settled pigment and solids materials into the
liquid. Conversely, the mixing procedures for multiple component materials can be more
complex, and often requires the individual responsible for mixing the coatings and the
inspector to read and comprehend the product data sheets.
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Transferring the coating materials from the can to the surface can be accomplished in a
number of ways. Factors that should be considered when deciding on an application
method include the size and configuration of the surfaces to be coated, the desired or
required transfer efficiency, the type of coating, environmental regulations, the proximity
to other operations/conditions, the specification and the coating manufacturer’s
recommendations.
The seven methods of coating application that we will describe in this module include:
1. Brushes, rollers, and daubers
2. Airless spray
3. Conventional (air) spray
4. High Volume Low Pressure (HVLP) spray
5. Air-assisted airless spray
6. Metallized spray
7. Plural component spray
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Use MSDS and Product Data Sheets to Verify Safe and Proper Mixing, Thinning,
and Application of Coatings
Coating manufacturers technical bulletins or product data sheets (PDS) contain very
useful information about the products being used on the project. However, the
manufacturer is not limited to which product information they may or may not reveal.
While the PDS typically contains critical information about the content and use of the
coating products, in cases where the PDS and the specification differ (say on the
maximum humidity during application), the specification is the governing document,
except when the owner incorporates the manufacturer’s recommendations on the PDS
into the specification. When that occurs, the PDS becomes part of the project
specification.
Describe the Inspector’s Role Regarding Coating Material Receipt and Storage
Verifying that what was ordered (coating products, coating components, and thinners, if
permitted) was received at the project site in good condition and in the correct amounts is
called a material receipt inspection. This is typically a job for the contractor’s QC and
although it is not a difficult process, it can prevent a multitude of problems as the job
moves forward. The contractor should also verify that the coating products are properly
stored on the project site prior to use, and should record batch no’s. for each component
and thinner.
Ambient conditions should be measured at regular intervals both before and throughout
the application process, and anytime the weather conditions appear to be changing.
Perhaps the single most important temperature relationship is the relationship between
the dew point and the surface temperature. To prevent applicators from coating a “wet
surface”, the surface temperature should be at least 3°C (5°F) higher than the dew point
temperature. An inspector should not depend on national or regional weather service
information for weather conditions. Conditions must be measured at the correct time at
the exact location where the coating application will take/ is taking place.
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Surface profile or roughness affects dry film thickness gages. If a gage is verified for
accuracy on smooth steel blocks (and the coating will be applied to roughened steel) the
amount the gage is affected (called the Base Metal Reading or BMR) must be measured
and deducted from each cumulative coating layer. If a gage is verified for accuracy by
placing shims of known thickness on top of the peaks of the roughened steel (the same
surface the coating will be applied to), then there is no BMR to measure or deduct.
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Aside from the industry standards, coating thickness measurements should be obtained
after the application of each coat in a multiple coat system, not just after the final coat.
The vast majority of nondestructive coating thickness gages described in SSPC-PA 2 and
ASTM D7091 cannot distinguish individual coating layers, but rather measure the total
“gap” between the substrate and the gage probe.
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Different adhesion tests measure different coating adhesion mechanisms (peel back
versus pull-off). Two tests that are common for the field are the “Adhesion by Tape
Test” (ASTM D3359) and the “Knife Adhesion Test” (ASTM D6677). These two tests
are used to evaluate the coating’s “shear” or “peel” strength. The third test measures
tensile strength and is governed by ASTM D 4541, “Pull-off Strength of Coatings Using
Portable Adhesion Testers,” This test is used to evaluate the coatings resistance to a
perpendicular force on a pre-attached pull stub. All adhesion testing is destructive to the
coating film and should not be conducted unless required by the specification. The
specification should include repair procedures for the affected areas.
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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 firm’s 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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Interior Lining
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Exterior Coating
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 3°C (5°F) of the dew point temperature, but the surface
temperature is higher than the dew point temperature. Based on this scenario,
answer the following:
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 didn’t
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measure, but we estimate probably about a gallon or so…” The product data sheet
allows up to 10% thinner addition. Based on this scenario, answer the following:
If yes, what do you record on your documentation regarding the amount of thinner
added?
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).
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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5A: How many 9 square meter (100 square foot) areas must be measured for
coating thickness? ____________________________________________________
5B: What is the minimum number of individual gage readings that must be
obtained?
____________________________________________________________________
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?______________________________________________
6. 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.
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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.
Does the presence of this substance put the project at risk? _________________________
_________________________________________________________________________
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Quiz 5
1. A product data sheet is considered an __________________for a coating.
3. During a material receipt inspection, the inspector should record the following
seven items:
______________________________ ______________________________
______________________________ ______________________________
______________________________ ______________________________
______________________________
6. Boxing a coating is not recommended for which two generic types of coatings?
__________________ __________________
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?
_______________________________
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13. Application of coating to welds, edges, bolt/nuts, and rivets prior to full scale
application is known as __________________.
14. __________________ are used to coat crevices and between back-to-back angles.
16. What is the paint pressure when the regulator on 45:1 airless spray pump is set to
60 psi? __________________
17. What does the marking 723 indicate on an airless spray tip?
__________________
18. Proper distance of an airless spray gun from the surface is __________________
inches.
22. The diameter of the holes in an HVLP spray air cap are __________________
than the holes in a conventional spray air cap.
23. Plural component spray is used to apply coatings with what characteristics?
__________________and __________________.
24. For plural component spray, what method is typically used to reduce viscosity of
the components? __________________
26. List ten common inspection checkpoints that are performed on nearly every
industrial coatings project:
______________________________ ______________________________
______________________________ ______________________________
______________________________ ______________________________
______________________________ ______________________________
______________________________ ______________________________
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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?
__________________ __________________
30. The wet bulb temperature is considered to be stabilized when two readings taken
within __________________seconds are within __________________of one
another.
31. A coating material with a six hour pot life and a 45 minute induction has a useable
pot life of __________________.
32. The wet film thickness reading on a wet film thickness gage is considered the
__________________numbered tooth (step) on the gage.
33. According to SSPC PA2, the accuracy of a coating thickness gage should be
verified __________________and __________________ each period of use.
39. The BMR is __________________ from the coating thickness to determine the
thickness of the coating above the __________________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? __________________.
41. 41. The BMR is not necessary to measure when a Type 2 gage is verified for
accuracy using __________________placed onto the __________________,
uncoated steel.
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44. The surface to be assessed for DFT represents 600 square feet
No. of areas to measure: __________________
Total No. of spots: __________________
Minimum no. of individual gage readings: __________________
45. The surface to be assessed for DFT represents 24,000 square feet
No. of areas to measure: __________________
Total no. of spots: __________________
Minimum no. of individual gage readings: __________________
46. The surface to be assessed for DFT represents an I-beam that is 40 feet in length,
has 12” wide flanges, a 48” web.
No. of areas to measure: __________________
Total no. of spots: __________________
Minimum no. of individual gage readings: __________________
47. According to SSPC PA2, what is the tolerance of a spot measurement for a
project specification that specifies 2-4 mils of primer? __________________
49. What is the cumulative thickness range of the primer and intermediate coats for a
project specification that requires 4-6 mils of primer and 8-10 mils of intermediate
coat? __________________
50. If the coating thickness is 12-15 mils, what Tooke gage tip should be used to
make an incision through the coating film to assess layer thicknesses?
__________________
51. The following data was acquired when viewing an incision (made with a 10X
cutting tip) through a Tooke Gage lens. What is the thickness of each layer?
52. Amine exudate or “blush” can occur on __________________ coatings that are
applied and/or cured during __________________conditions.
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53. Application of coatings over an amine exudate may result in what type of coating
failure? __________________
56. Low voltage, wet sponge pinhole detection is can be used on nonconductive
__________________ (up to __________________ mils) applied to a
__________________substrate.
58. According to NACE RP0188-99, the suggested voltage for testing a coating
system that is 41-55 mils thick is __________________.
59. The most reliable method for determining the cure of an ethyl silicate inorganic
zinc-rich primer is the __________________test.
60. If a 3H pencil will not scratch or gouge the coating film, but a 4H pencil will,
what is the pencil hardness of the coating? __________________
62. The cross-cut method (Method B) of the tape adhesion test is used for coatings
that are less than __________________ mils thick.
63. When a coating breaks cleanly from the substrate, the location of break is
__________________.
64. What is the primary difference between conducting an adhesion test per ASTM
D3359 (method A) and ASTM D6677? __________________
65. The gage for measuring the thickness of coatings on concrete (nondestructively)
employs an __________________principle of measurement.
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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
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In the first category, volatiles are part of the wet film, but evaporate into the air once the
coating is applied to the surface, while non-volatiles are part of the wet and dry film and
remain on the surface once the coating is applied.
Describe the Functions of the Resin, Additives, Pigments, and Solvents in a Coating
In the second category for coating components, pigmentation and vehicle, the vehicle
“carries” the pigmentation to the surface and binds it into the coating film. The vehicle
typically consists of the resin or binder, solvents, and any additives that may be included
in the formulation. While part of the vehicle evaporates (the solvents) once the coating is
applied, other components, like the resin, remain behind as part of the dry film. The resin
system cohesively bonds the pigmentation together and adhesively bonds the coating to
the underlying substrate or coating layer. In fact, the resin is so significant that the type
of resin in the formulation is often used to generically identify the coating. In many
cases, the resin system dictates the performance properties of a coating.
Additives are also a part of the vehicle that remains on the surface. Additives are added
to coating formulations to improve flow-out, surface wetting, and flexibility. Additives
can also be used to adjust the consistency of a coating, to resist ultraviolet light, and to
prevent settling in the can.
In the category of pigmentation and vehicle, the pigment gives the coating the ability to
hide the underlying surface. Pigments also give coatings their color and gloss, but
pigments may also provide corrosion protection. Pigments like iron oxide or barium can
be formulated into a primer to inhibit the corrosion process. Pigments like zinc powder
can be added to the primer in sufficient quantities to galvanically protect the underlying
carbon steel. Still other pigments, like micaceous iron oxide and leafing aluminum
pigments, provide barrier protection. These pigments are plate-like, and the way they
position themselves in the coating film forces any moisture that penetrates the coating
film to take a longer path to reach the substrate.
Extenders are pigments like clay, silica, and mica, which can be incorporated into the
formulation to improve film build. Extenders also increase the solids content of a coating
and provide added barrier protection. Remember that all pigments, regardless of their
individual functions in the coating, remain on the surface and become part of the dry
film.
When coating components are divided into volatiles and non-volatiles, the solvent system
is the volatile component. White it is part of the wet film during application, it is not
intended to be part of the dry film once the coating dries or cures. Typically, a blend of
solvents is used in the formulation of a coating and each type of solvent in the blend
performs a different function. As a general rule, primary solvents reduce the viscosity of
the resin, pigments and additives, so the coating can be properly atomized through a
spray gun or applied by brush or roller. Primary solvents evaporate from the coating film
first, while secondary or coalescing solvents typically remain in the wet film a little
longer to help the coating flow-out and knit together to form a uniform, continuous film.
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Many solvent systems (and thinners) are categorized as “volatile organic compounds” of
VOCs by the U.S. Environmental Protection Agency (EPA). The amount of VOC’s that
can be legally emitted into the atmosphere varies from location to location. Some
densely populated areas have very strict regulations, while less populated areas typically
comply with the Federal limit, which is less restrictive. In the field, the VOC limit is
usually dictated by the specification or the local air pollution agency for that project.
Fixed facilities like paint shops, however, are sometimes required to log the number of
gallons of paint used over a specific period, as well as the VOC content of each type.
The local environmental agency regulates the maximum quantity of VOC’s produced by
fixed facilities.
Coating manufacturers can formulate coatings to comply with VOC regulations by using
non-regulated solvents, like water and acetone, or by increasing the non-volatile content
of the coating. Since adding thinner in the field may increase VOC levels, the amount of
thinner added must be carefully monitored.
Solvent evaporation is perhaps the most commonly understood coating cure. In this
process, the solvent in the coating evaporates into the air after application, while the
resin, pigment, and additives remain on the surface to form a dry film. There is no
second step or subsequent curing reaction, so the resin can be redissolved by the same
solvent system that was used in the blended coating. Coatings that cure by solvent
evaporation should not be overcoated with a coating that contains strong solvents.
Coalescence also involves evaporation of solvents from the coating film, but in this case
there are primary solvents which evaporate first and coalescing solvents (secondary
solvents) which remain in the film a little longer (to help fuse the molecules together to
form a solid film). After the film has been formed, the secondary solvents also evaporate
from the film. This type of cure typically requires a minimum air temperature of 50°F.
Oxidation is a third method of coating cure. Components in the coating (drying oils)
react with oxygen (from the surrounding air) to form a film. One problem with this
method of cure is that the process of oxidation never really stops as long as the coating is
exposed to oxygen. Alkyds, which cure by this method, can become very brittle after
many years of service, since the resin continues to oxidize long after the coating is fully
cured.
A fourth method of cure or polymerization is more complex than the first three. Different
resin components are carefully measured by the manufacturer and packaged separately,
so that when these components are properly blended a chemical reaction occurs,
generating a new, resilient coating. The components must be blended in the correct
ratios (complete kits) for the chemical reaction (or polymerization) to produce the correct
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blend. Coatings that cure by this method are multi-component, and once they are blended
together, the pot life begins. The pot life may vary from a few minutes to several hours.
A few of the more common coatings that cure by polymerization are epoxies, aliphatic
acrylics, and polyester polyurethanes.
Moisture-cure is the fifth method of coating cure discussed. The coating components
react with moisture and require a minimum amount of moisture to cure. Moisture-cure
urethanes cure this way and release carbon dioxide (CO2) during the process, while
inorganic zinc-rich primers also cure by moisture cure, but release ethyl alcohol during
the process. The result is a very resilient coating layer, similar to that produced by
polymerization.
There are a number of questions to answer about a service environment before a coating
system is selected. Will the coating be subjected to immersion service? If so, will the
immersion be constant or intermittent (i.e., splash)? Will the immersion be in potable
water, waste water, salt water, solvent, acids, etc.? What is the likelihood and type of
physical damage that the coated substrate might sustain (i.e., the impact damage from
river debris on a set of dam gates)?
Once all the background questions are asked and answered, specifiers can look at the
history and performance records of coating systems that have been commonly used in
specific industries and service environments.
In addition, each layer must be able to perform the function intended for that layer. For
example, the function of the primer is to bond the coating system to the substrate. The
primer may also be selected to provide corrosion protection to the substrate. The primer
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must be equally compatible with the level of surface preparation beneath it and the
coating directly above it.
The intermediate coat is typically part of the coating system for the purpose of adding
barrier protection. It must also be compatible with the primer and the topcoat.
The topcoat is the first line of defense against corrosion and must be resistant to the
service environment. Typically, the topcoat must also be aesthetically pleasing (good
color and gloss) and be compatible with the underlying coating layer.
Describe Proper Methods Used to Evaluate Coating Performance Prior to Full Scale
Installation
Another consideration for the specifier when selecting a coating system for an industry is
past performance and testing. There are industry specific coating performance
evaluations that generate data based on testing that represents the service environment.
Once this data is generated, coating manufacturers can access the information and
establish their own qualified products lists. The advantage of this type of performance
evaluation is that many agencies within a given industry can access performance data
with little or no associated costs.
And a final method to evaluate a coating system prior to specifying that system is to
employ a combination of the performance evaluations described above. A bridge owner,
for example, may refer to industry specific coating performance evaluations, while they
simultaneously conduct their own testing for a variety of coating systems on panels of the
substrate at the actual site of a future project.
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Quiz 6
3. Solvents are part of the _______ film, but are not part of the ____ film.
5. Coatings that “dry” rather than cure form a solid film by a process known as
_____________________ ____________________.
11. Which coating system is recommended for use on surfaces with an elevated
temperature in a waste water treatment plant?
________________________________________________________________
12. Mounting test panels containing candidate coating systems in the actual
environment where the new coating will be installed is known as a
________________-________________ performance evaluation.
15. Prior to selecting a coating system, the facility owner must properly identify the
prevailing _______________________ ______________________________.
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- Protective Coating for Water and Wastewater Facilities (SSPC Item #06-01)
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Module Seven describes non-routine inspection projects that can pose special challenges
to the coatings inspector. Inspecting the surface preparation and coating application in a
steel fabrication shop presents a different set of challenges for a coatings inspector, as
does maintenance painting in the field when overcoating becomes the maintenance
strategy. Additionally, many existing industrial structures contain coatings with toxic
metal ingredients. The hazards associated with removal, handling and disposal when
these coatings are “disturbed” during maintenance painting operations must be
controlled. The inspector may have responsibility for verifying proper set-up and
maintenance of containment and ventilation systems, assuring proper worker protection,
monitoring air, soil and water quality, and assuring proper handling and disposal of
hazardous waste streams.
Learning Outcomes
At the completion of this module you should be able to:
- Describe the unique aspects of performing coatings inspection in a steel
fabrication or “blast & paint shop”
- Describe the unique aspects of performing coatings inspection on an overcoating
project
- Describe what the inspector’s role might include on projects involving
disturbance of coatings containing toxic metals
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and deterioration present, the thickness and adhesion of the existing coating, and the
generic type of the existing coating. Test patches can be applied and evaluated prior to
full scale overcoating when the condition of the existing coating is marginal. Surface
preparation inspection includes verification of oil/grease removal per SSPC-SP 1, and
inspection of spot touch-up areas for cleanliness, roughness (if required) and proper
feathering of the existing coating for a smooth transition. The remaining surfaces may be
brush blasted or pressure washed. These surfaces must be inspected to ensure the
existing coating was not severely fractured, and that surface dirt, chalk and other debris
has been adequately removed. Testing for chemical contamination may also be required,
if soluble salts were deposited onto the surfaces while in service. The inspector may be
required to measure and map the thickness of the existing coating, and may be required to
measure the wet film thickness of the overcoat material during application. The final dry
film thickness can be measured either nondestructively or using a destructive gage. If a
nondestructive gage is used, the thickness of the existing system must be deducted from
the measurements in order to isolate and document the thickness of the overcoat, or the
readings taken in spots where the existing had been totally removed. Adhesion of the
overcoat to the existing system may be assessed to ensure that the overcoat is properly
bonded, and is similar to the adhesion characteristics of the coating system on a test
patch, if one was prepared. Areas where destructive coating thickness and/or adhesion
testing were preformed should be touched up by the contractor to prevent premature
rusting in these areas.
Finally, the inspector may be responsible for verifying that the contractor is handling and
storing all of the waste (hazardous and non-hazardous) properly, and that the waste is
tested by an approved laboratory and hauled from the site by a licensed transporter. The
inspector may be asked to review the contractor’s site-specific, written worker protection,
environmental protection and waste management compliance plans prior to production
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work, and may be required to verify conformance to the written plans during production
work.
Module Seven: Specialty Inspection Projects
Quiz 7
1. The primer used on connection points of I beams must often have a Class A or
Class B _________________ ___________ if the connection is ________ critical.
4. What is the minimum surface cleanliness and surface profile depth for metallizing
applied to structures for marine or immersion service? ______________________
9. List seven inspection check points associated with powder coating application.
_____________________________ _________________________________
_____________________________ _________________________________
_____________________________ _________________________________
_____________________________
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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 _______________
________________________.
17. Pressure washing to remove dirt, chalking, etc. must be carefully inspected to
ensure _________________ removal prior to overcoating.
19. The thickness of the overcoat can be isolated from the thickness of the existing
coating by using a ________ ___________.
26. List two devices for monitoring air quality outside of a containment:
___________________________ ____________________________
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28. List three things a coatings inspector should never do inside a regulated area:
_________________________________ _____________________________
_________________________________
30. List two SSPC Guides that govern containment and hazardous waste management
procedures:
_________________________________ _____________________________
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Module Eight explains how knowledgeable coatings inspectors can help avoid coating
failure. The role of the coatings inspector and the types of inspection activities that can
play a role in preventing the failures are described. Case histories of actual coating
failures are presented. The cause, fault and repair procedures are explored, and
avoidance methods are discussed.
Learning Outcomes
At the completion of this module you should be able to:
- Describe how coatings inspection can help prevent premature coating failures
Describe How Coatings Inspection Can Help Prevent Premature Coating Failures
Coatings can fail for a variety of reasons. When a coating failure occurs, an investigation
is often performed to determine the cause, determine the part responsible and assess the
degree of repair necessary to ensure the integrity of the substrate. The consequences of
coating failure can include substrate repair or replacement, costly rework and down time,
and aesthetics. When investigating a coating failure, six issues should be considered,
including what was to be done; does it make sense; what was actually done; what caused
the failure to occur; who is the responsible party; and what can be done now. A coating
failure investigation includes both a site investigation and a laboratory investigation. The
site investigation includes document acquisition, a determination of the construction
sequence and obtaining the structure and painting history, visual observations, sample
and data collection, acquisition of batch retains and other coating samples, and
photography. The laboratory investigation can include a variety of forensic tests,
depending upon the nature of the coating failure. Coating inspection aids in coating
failure avoidance by detecting problems and nonconformities (and verifying they are
corrected) prior to putting the coating or lining into service. Coatings inspection however
cannot aid in failure avoidance when a coating is improperly formulated or when a faulty
specification is generated and work is completed based on a faulty contract.
The role of the coating inspector can be critical in a failure investigation. Well-prepared,
thorough records and photographic documentation can greatly help to narrow the cause of
the failure.
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Quiz 8
3. Describe how a coatings inspector can help prevent coating failures from occurring.
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
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- Visual Comparison Manual: Application and Coating Defects (SSPC Item #99-01)
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Module Nine describes basic inspector safety. Fabrication shops and construction sites
often pose significant safety concerns for a coatings inspector. While Module Nine is not
designed to provide comprehensive safety training, it makes the coatings inspector aware
of potential hazards and methods of prevention. Safety issues described in Module Nine
include fall prevention/protection, respiratory protection, sight and hearing protection,
protection from toxic metals, and confined space entry hazards. Module Nine also
describes the purpose of site specific environmental, safety and health hazards planning
and the inspector’s responsibility for personal safety.
Learning Outcomes
At the completion of this module you should be able to:
- List potential safety hazards associated with coatings inspection
- Describe the common personal protective equipment used by a coatings inspector
The coatings inspector can encounter hazardous materials, hazardous environments and
hazardous activities on a project. Hazardous materials include cleaning solvents,
abrasives and dusts, toxic metals, coating components, thinners, chemical strippers and
acidic and caustic solutions. Hazardous environments include heights, confined spaces,
electrical, fire and explosion hazards, slippery or obstructed walkways, excessive heat,
inadequate lighting, noise, vehicles and moving heavy parts on cranes, etc. Hazardous
activities include solvent cleaning, abrasive blast cleaning, high pressure waterjetting,
power tool cleaning and airless spraying.
Material Safety Data Sheets (MSDS) are mandated under OSHA’s Hazard
Communication (Hazcom) regulation and are the primary document that describes the
hazards associated with the chemicals used on a project and the personal protective
equipment required to safely handle the product.
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protection, a fall harness and shock absorbing lanyard (if working form heights greater
than 1.8 meters [six feet]), work boots and long sleeved coveralls.
Most battery-operated inspection equipment is not “intrinsically safe” and should not be
used in a hazardous environment (greater than 10% of the LEL) without the appropriate
permit.
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Quiz 9
2. A coatings inspector that observes an imminent hazard that may cause death or
serious injury should take _______________________ action to prevent the
_____________________.
3. Who should an inspector obtain guidance from regarding their role relative to
safety issues? ___________________________________________________
4. List an example of a “General Risk” that a coatings inspector may be exposed to:
_______________________________________
5. List an example of a “Personal Risk” that a coatings inspector may be exposed to:
_______________________________________
7. List two “hazardous materials” that will be present on every coatings project:
___________________________ _________________________________
11. List four items that are of the greatest value to an inspector on an MSDS:
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
12. What is the most frequent way solvents affect the body? ____________________
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15. Heights greater than _____________ above a lower level require fall protection.
17. List three items that an inspector should verify before entering a confined space:
________________________________ ____________________________
________________________________
21. Most coating inspection gages are not ___________________ safe and should not
be used in _______________________ environments.
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Module Ten explains the purpose and content of coatings specifications. The coatings
specification is the inspector’s “rule book” for a coatings project. It describes the scope
of work and the requirements of the contract, as well as lists the inspection checkpoints
for which the inspector is responsible. The importance of a properly prepared coatings
specification and the general layout and components in a specification are described in
Module Ten.
Learning Outcomes
At the completion of this module you should be able to:
- Describe the purpose and function of a coating specification
- List the various methods in which coatings are specified for use
- List the basic components of a coating specification
- Locate inspection check points in a coatings specification
There are two general types of specification for coating work: those involved with new
construction and those involved with maintenance painting of existing structures. The
content of the specification documents will be different in both cases.
List the Various Methods in Which Coatings are Specified for Use
There are a number of ways that coating systems can be specified for use on a project.
Some specifications are written around specific product trade names, and some are
written as “trade name or equal.” Others are based on a pre-established “Qualified
Products Lists” (QPL), or are based on a set of performance standards. While infrequent,
a coating system can also be specified based on a coating formulation or set of
formulations.
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Quiz 10
5. What likely becomes the governing document when there is no specification for a
coatings project? __________________________________________________
7. In which of the three Parts of a coatings specification listed in Question 6 are the
references and definitions found? _____________________________________
8. In which of the three Parts of a coatings specification listed in Question 6 are the
coatings listed that will be used on a project? ____________________________
10. In which of the three Parts of a coatings specification listed in Question 6 is the
thickness range of each coat listed? _________________________________
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Module Eleven describes the purpose and content of a pre-construction conference and
explains how to prepare an inspection plan. After a careful review of the project
specification during the Module Ten workshop, a preconstruction conference will be
conducted. Participants are provided with an agenda of discussion items, photographs of
the project site and Product Data Sheets and MSDSs for the coatings selected for the
project. The course instructors represent the painting contractor and the coating
manufacturer. The participants are divided into two groups; one group role play the
Quality Assurance Inspector representing the facility owner, while the other group role
plays the contractor’s Quality Control Inspector.
**It should be noted that this module is completed in a team setting, which is
considered key to completing the practical exam with success. Opting out of the
classroom portion of the course does not permit access to this workshop.**
Learning Outcomes
At the completion of this module you should be able to:
- Completion of Module Eleven will enable the coatings inspector to participate in
pre-construction conferences and prepare an inspection plan/procedure.
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Module Twelve includes an inspection workshop which enables the participants to apply
learned skills from the previous eleven modules. Ten inspection stations are equipped
with instruments, visual guides and miscellaneous equipment and test plates. Participants
work in small groups to perform inspections at each station, document the results of the
inspections and compare the results to the project specification provided in Module Ten
and the inspection procedures developed in Module Eleven. After all the groups have
completed all of the stations, the participants reconvene and discuss any problems and
non-conformities observed.
**It should be noted that this module is completed in a team setting, which is
considered key to completing the practical exam with success. Opting out of the
classroom portion of the course does not permit access to this workshop.**
Learning Outcomes
At the completion of this module you should be able to:
- Completion of Module Twelve will enable the coatings inspector to perform
coatings inspection, document inspection data, and compare inspection results to
specification requirements.
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Appendix A
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Appendix A
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Appendix A
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3. The use of protective coatings is the most widely used method of corrosion control.
5. Which of the four elements in question 4 does a protective coating prevent from
contacting the steel? Electrolyte
8. List two dissimilar metals that are intentional coupled in the protective coatings
industry as a method of corrosion prevention?
zinc and aluminum
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.
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19. Aluminum and copper are metals that form a protective oxidation layer.
20. When corrosion occurs, the steel is releasing (giving up) energy.
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1. Quality Control is performing observations and tests, and documenting that the work
meets/exceeds the specification requirements.
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
contractor’s QC.
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
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16. The content of the “acceptance criteria” section for an inspection plan comes from the
specification.
17. A Work Plan should cover the individual phases of a project, including both
production and inspection.
19. One of the most important responsibilities of a coatings inspector is to document the
results of inspections.
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1. Preparing a surface for coating application is the most critical and typically the
most costly step.
3. The two-fold purpose of surface preparation is to clean and roughen the substrate.
6. The surface profile or anchor pattern must be compatible with the entire coating
system.
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.
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”
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14. The depth and shape of the surface profile generated by abrasive blast cleaning is
determined by the type and size of abrasive and the hardness of the surface.
15. Abrasives fall into two general categories, Expendable and Recyclable.
17. The abrasive cleanliness requirements in SSPC abrasive specifications AB1, AB2
and AB3 are indirect requirements of the SSPC abrasive blast cleaning surface
cleanliness standards.
18. List four tests that an inspector can perform in the field to verify conformance to
SSPC AB1:
Water soluble contaminants Surface Profile Yield
Oil Content Particle Size Distribution (sieve analysis)
19. SSPC AB2 governs the quality of recycled ferrous metallic abrasives.
22. List three tests that an inspector can perform in the field to verify conformance to
SSPC AB3:
Size Cleanliness Conductivity
23. List one test that an inspector cannot perform in the field to verify conformance to
SSPC AB2: Lead Content
26. Centrifugal blast machines often incorporate a blend of steel shot and steel grit
abrasives.
27. Wet abrasive blast cleaning is used when airborne dust must be controlled.
29. Chemical strippers do not remove rust or mill scale and will not generate a
surface profile.
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31. SSPC surface cleanliness standards become contract law once they are invoked by
the specification.
33. SSPC-SP2 “Hand Tool Cleaning” requires the removal of all loosely adhering
rust, mill scale & paint.
34. SSPC-SP2 requires the use of a dull putty knife as the inspection tool.
35. SSPC-SP3 “Power Tool Cleaning” requires the removal of all loosely adhering
mill scale, rust & paint.
36. What is the primary difference between SSPC-SP15, “Commecial Grade Power
Tool Cleaning” and SSPC-SP11, “Power Tool Cleaning to Bare Metal?”
SSPC-SP15 allows up to 33% staining to remain in each 9 square inches of
surface, where SSPC-SP11 does not permit any staining.
38. Which two SSPC surface cleanliness standards invoke a minimum surface profile
requirement? SSPC-SP11 and SSPC-SP15
What is the minimum requirement? Minimum of 1 mil (25 microns)
39. List three possible “indirect requirements” of the SSPC abrasive blast cleaning s
tandards:
Solvent cleaning (SSPC-SP1)
Abrasive cleanliness Compressed air cleanliness (ASTM D4285)
40. The amount of staining allowed by the SSPC abrasive blast cleaning standards is
based on what area? 9 square inches (58 cm2)
41. SSPC-SP7/NACE No. 4, “Brush-off Blast Cleaning” requires the removal of all
loosely adhesring rust, paint & mill scale.
43. The only difference between SSPC-SP 6/NACE No. 3, “Commercial Blast
Cleaning” and SSPC-SP10/NACE No. 10, “Near-White Blast Cleaning” is the
percentage of allowable staining. SP6 allows up to 33% staining, where SP10
allows up to 5% staining (of each 9 square inches of surface).
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46. SSPC-SP5/NACE No. 1 allows no paint, rust, mill scale or straining to remain.
48. The “L” in “SSPC SP12-WJ-3-L” indicates light flash rusting is permitted by the
specification.
49. ISO St2, “Thorough Hand and Power Tool Cleaning” requires removal of all
poorly adhering materials.
50. ISO Sa 2 1/2, “Very Thorough Blast Cleaning” allows only stains to remain on
the surface.
51. The SSPC/NACE and ISO cleanliness standards prohibit the use of magnification
when inspecting surface cleanliness.
52. Prior to final surface preparation, it is recommended that the inspector verify that
the surface temperature is at least 5oF (3oC) higher than the dew point
temperature.
55. Cooling air below the dew point for dehumidification of the air is the
Refrigeration method.
56. Products that absorb moisture from the air as a means of dehumidification use the
Dessication method.
57. Indicate the procedure for conducting a compressed air cleanliness test, below:
Conduct the test down stream of moisture and oil separation.
Position the air outlet 18” from the collector
Exhaust the compressed air onto the collector for approximately one minute.
58. To conduct a “vial test,” fill a clear container with 1/3 abrasive and an equal
amount of clean tap water. Allow the shaken blend to settle for 30 minutes.
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62. The visual standard reference “G2 SP14” in SSPC VIS 1 indicates:
Weathered coating system over mill scale with moderate pitting abrasive blast
cleaned to an “Industrial Blast” level
63. The visual standard reference “F SP3 PWB” in SSPC VIS 3 indicates:
Previously painted steel surface; mostly intact zinc-rick primer applied to a blast
cleaned surface, power tool cleaned using a power wire brush
64. The visual standard reference “D WJ3 M” in SSPC VIS 4/NACE VIS 7 indicates:
Rusted and pitted steel surface prepared by “thorough” water jetting; with
moderate rust back permitted
65. The visual standard reference “C WAB 6 H” in SSPC VIS 5/NACE VIS 9
indicates: Rusted steel surface prepared by wet abrasive blast cleaning to a
“Commercial Blast” level; with heavy rust back permitted
66. The visual standard reference “A Sa3” in ISO 8501-1:1988 indicates: Steel
surface containing adhering mill scale, blast cleaning to a “visually clean”level
69. An increase in peak count reportedly enhances coating adhesion and a greater
resistance to corrosion undercutting.
70. The G/S comparator disc is selected for inspection of surface profile when garnet
abrasive is used to perform abrasive blast cleaning.
71. “3.0SH76” on a comparator disc segment indicates: 3 mil surface profile; Shot
comparator disc; 1976.
72. Verify “zero-set” on a surface profile depth micrometer using a glass plate.
75. Each grade of replica tape is most accurate in the middle of the range.
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78. Convert 35 µS/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 (2÷12.25)= 1.71µg/cm2
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PCI Study Guide- October 2007
1. Average the following set of surface profile measurements: 3.5, 3.7, 2.9, 3.1, 4.0
3.4 mils
4. Calculate the area of a square that is 4.5 feet x 13.6 feet. 61.2 square feet
5. Calculate the area of an I-beam that is 40 feet in length, has 12” wide flanges, a
48” web, and 8 stiffeners (4” wide x 48” long). 491 square feet
6. Calculate the exterior surface area of a tank that is 45 feet in height and 90 feet in
diameter.
C = 3.14 x 90 feet = 283 feet
Area of roof (A) = 90 ÷ 2 = 45; 3.14 x 452 = 6359 sq. ft.
45 x 283 = 12,735 sq. ft.
12,735 + 6359 = 19,094 sq. ft.
Calculate the volume of water the tank in Question 6 will hold.
(3.14 x 452) x 45 = 286,133 cubic feet
286,133 cu. Ft. x 7.48 gallons/cu. Ft. = 2,140,275 gallons
10. Calculate the quantity of primer required to coat 15,000 square feet of blast
cleaned steel, based on the following data:
Specified Dry Film Thickness: 3-5 mils
Volume Solids Content: 84%
Mixing/Application Loss Estimate: 25%
Surface Roughness Loss Estimate: 20%
Recommended Thinner Addition: One pint per gallon
1604 ÷ 5 mils = 321 sq. ft./gal.
321 x 0.84 = 270 sq. ft./gal.
270 x 0.75 = 203 sq. ft./gal.
203 x 0.80 = 163 sq. ft./gal. 15,000 sq. ft. ÷ 163 sq. ft./gal. = 92 gallons
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PCI Study Guide- October 2007
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
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.
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
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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
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PCI Study Guide- October 2007
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.
37. The accuracy of Type 2 gages is verified using non-metallic foils or plastic shims.
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.
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44. The surface to be assessed for DFT represents 600 square feet
No. of areas to measure: 3
Total No. of spots: 15
Minimum no. of individual gage readings: 45
45. The surface to be assessed for DFT represents 24,000 square feet
No. of areas to measure: 26
Total no. of spots: 130
Minimum no. of individual gage readings: 390
46. The surface to be assessed for DFT represents an I-beam that is 40 feet in length,
has 12” wide flanges, a 48” web.
No. of areas to measure: 5
Total no. of spots: 70
Minimum no. of individual gage readings: 210
47. According to SSPC PA2, what is the tolerance of a spot measurement for a
project specification that specifies 2-4 mils of primer? 1.6 – 4.8 mils
49. What is the cumulative thickness range of the primer and intermediate coats for a
project specification that requires 4-6 mils of primer and 8-10 mils of intermediate
coat? 12-16 mils
50. If the coating thickness is 12-15 mils, what Tooke gage tip should be used to
make an incision through the coating film to assess layer thicknesses? 2X
51. The following data was acquired when viewing an incision (made with a 10X
cutting tip) through a Tooke Gage lens. What is the thickness of each layer?
52. Amine exudate or “blush” can occur on epoxy coatings that are applied and/or
cured during high humidity, cool conditions.
53. Application of coatings over an amine exudate may result in what type of coating
failure? Intercoat delamination
54. A pinhole is a tiny void in the coating that penetrates to the substrate.
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56. Low voltage, wet sponge pinhole detection is can be used on nonconductive
coatings (up to 20 mils) applied to a conductive substrate.
57. High voltage, spark testing is can be used on nonconductive coatings applied to a
conductive substrate.
58. According to NACE RP0188-99, the suggested voltage for testing a coating
system that is 41-55 mils thick is 4000 volts.
59. The most reliable method for determining the cure of an ethyl silicate inorganic
zinc-rich primer is the solvent rub test.
60. If a 3H pencil will not scratch or gouge the coating film, but a 4H pencil will,
what is the pencil hardness of the coating? 3H
61. Tensile adhesion testers assess the pull-off strength of coatings; while tape
adhesion assesses the coatings resistance to peel-back.
62. The cross-cut method (Method B) of the tape adhesion test is used for coatings
that are less than 5 mils thick.
63. When a coating breaks cleanly from the substrate, the location of break is
adhesion.
64. What is the primary difference between conducting an adhesion test per ASTM
D3359 (method A) and ASTM D6677? Tape is not used on the X-cut when
conducting testing per ASTM D6677
65. The gage for measuring the thickness of coatings on concrete (nondestructively)
employs an ultrasonic (ultrasound) principle of measurement.
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PCI Study Guide- October 2007
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.
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.
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 facility-
specific performance evaluation.
15. Prior to selecting a coating system, the facility owner must properly identify the
prevailing service environment.
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PCI Study Guide- October 2007
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.
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
9. List seven inspection check points associated with powder coating application.
Powder material Thickness
Surface preparation Continuity
Curing Hardness
Appearance
11. Weathered galvanizing is optimum for coating, while new galvanizing is difficult
to coat.
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PCI Study Guide- October 2007
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.
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.
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
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30. List two SSPC Guides that govern containment and hazardous waste management
procedures:
Containment: SSPC Guide 6 Waste: SSPC Guide 7
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PCI Study Guide- October 2007
3. Describe how a coatings inspector can help prevent coating failures from occurring.
By verifying that each step in the surface preparation and coating/lining installation
process meets the requirements of the project specification. By identifying deficiencies as
they occur and working with the contractor to bring the deficient areas into conformance
with the specification before additional work progresses.
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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
7. List two “hazardous materials” that will be present on every coatings project:
Solvents/thinners and coating components
10. The effect of hazardous materials on an inspector’s 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
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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 sized-
dust.
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? Shock-
absorbing
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
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.
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Appendix B
Glossary
A
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D 3359). Adhesion measured by the crosscut test is referred to as the shear (or knife)
adhesion.
Adhesion Test, Tensile (Pull-Off). A method for testing the greatest perpendicular force
that an area of coating can withstand before: (1) detaching from the surface (adhesion) or
(2) fracturing within a layer of coating or substrate (cohesion). The method can also be
used to determine whether a coating will remain intact at a particular applied tensile
force. This standard test method is defined in ASTM D 4541.
Aggregate. (1) A group of dry pigment particles held together by their surface forces; the
spaces between the particles are filled with air. [CED] (2) Granular material, such as
sand, gravel, crushed stone, crushed hydraulic-cement concrete, or iron blast-furnace
slag, used with a hydraulic cementing medium to produce either concrete or mortar.
[ACI]
Air Abrasive Blast Cleaning. Also called abrasive air blast cleaning, a surface
preparation method in which compressed air is used to propel abrasive particles against a
surface to be cleaned. “Open blast cleaning” indicates that a localized containment does
not surround the blast stream. “Closed blast cleaning” means that a localized containment
does surround the blast stream. [PCG]
Airless Spraying. A coating application method that uses hydraulic pressure instead of
air to atomize paint by forcing it through a spray nozzle with a small orifice at a pressure
of 2,000 to 3,000 psi (14-21 MPa). The spray pattern and flow of paint are controlled by
the size and shape of the orifice. The size of the orifice must be matched with the
viscosity of the paint and the size of the material pump. This process is aided if the
material is previously heated. [PCG]
Aliphatic. A class of organic hydrocarbon compounds composed of open chains. These
include paraffins, olefins, etc.
Alligatoring. Crazing or surface cracking with a definite pattern that looks like alligator
hide. The effect is often the result of weather aging of a coating. See also Cracking.
Ambient Conditions. The weather including: air temperature, relative humidity, dew
point, and wind velocity, which are monitored on the job site.
Amine. An organic compound derived from ammonia when one or more hydrogen atoms
is replaced with hydrocarbon radicals. It is used as a curing agent for epoxy resins.
Amine Blush. Surface opalescence (blush) on epoxy films caused by reaction of amine
co-reactant with carbon dioxide and water to form an amine carbamate.
Anchor Pattern. See Surface Profile.
Anhydrous. Moisture-free; a compound without water of crystallization. [PCG]
Anode. The electrode of an electrolytic cell at which oxidation occurs. Electrons flow
away from the anode in the external circuit. It is usually at the anode that corrosion
occurs and metal ions enter solution. Contrast with Cathode. [ASM]
Anodized. An electrochemical protective or decorative oxide film.
Anti-Fouling. A coating formulated to release noxious or poisonous substances at a
controlled rate to prevent the growth of barnacles, algae, and other organisms on the
underwater part of a ship hull. [PCG]
Arcing. Spraying a coating with the gun moving in an arc, rather than at a constant
distance from the substrate surface, so that a film of varying thickness results. Arcing
may also occur with abrasive blasting to produce a variable level of surface cleaning.
Arc Spraying. Metal spraying in which an electric arc is used to melt the metal.
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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.
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Brush Down. To remove dust from a surface with a clean, soft brush.
Brush-Off Blast Cleaning. Blast cleaning standard with the lowest quality requirements.
According to SSPC-SP 7/ NACE No. 4, a brush-off blast cleaned surface is free of all
visible oil, grease, dirt, dust, loose mill scale, loose rust, and loose paint. Tightly adherent
mill scale, rust, and paint may remain on the surface. [PCG]
Brushout. The application of paint on a small surface for testing.
Bulkhead. (1) An upright partition or wall separating compartments, as in a ship’s hold.
(2) Wall retaining soil along waterfront.
Burnish. To polish or rub to a smoother or glossier surface. [CED]
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]
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Centrifugal Wheels. Finned wheels on abrasive blasting equipment that pick up and hurl
abrasive at high speeds onto the steel plates or shapes in a centrifugal blasting machine.
See Abrasive Blast Cleaning.
Chalking. (1) Formation of a friable powder on the surface of a coating film caused by
the disintegration of the binding medium due to ultraviolet light breaking chemical bonds
in the binder. The chalking of a coating film is dependent upon the binder and
pigmentation, as well as the intensity of the ultraviolet light. The standard test method for
evaluating degree of chalking is described in ASTM D 4214. (2) Formation of a loose
powder resulting from the disintegration of the surface of concrete or of applied coating,
such as cement paint. [ACI]
Checking. (1) The development of breaks in the surface of a coating film that do not
penetrate to an underlying coating or the substrate. If an underlying coating or the
substrate is visible, the breaks are called “cracks.” Checking can be visible or
microscopic. See also Cracking. The standard test method for evaluating degree of
checking is described in ASTM D 660. [PCG, V1] (2) Development of shallow cracks at
closely spaced but irregular intervals on the surface of plaster, cement paste, mortar, or
concrete. [ACI]
Chemical Resistance. The ability of a material to resist degradation by reaction with,
dissolution by, or reduction of physical continuity from contact with a chemical agent or
agents, thereby retaining its capacity to perform as a structural or aesthetic entity. The
standard test method for chemical resistance of coatings is described in ASTM D 3912.
Chemical Treatment Tanks. Tanks used for the storage of the various chemicals in
either the water treatment or waste water treatment process. They may also be part of the
process system as to where the chemicals are injected into the tanks as the water passes
through them.
Chilled Iron. A metallic abrasive prepared by channeling molten metal into streams,
which then drop onto jets of water under pressure, atomizing the molten metal into
random sizes of shot that fall into a water-filled quenching pit.
Chipping. (1) Cleaning steel by removing paint or rust and scale, using a special
“chipping” hammer. (2) Flaking deterioration of dried paint film, usually as a result of
damage, impact, or wear. The ability of a coating or layers of coatings to resist total or
partial removal, usually in small pieces, resulting from impact by hard objects or from
wear during service. [PCG] (3) Treatment of a hardened concrete surface by chiseling.
[ACI]
Chloride Ion. Negatively charged ion (Cl-) derived from the element chlorine.
Chromium. Metal with salts (chromates) that are sometimes used as pigments in primers
for corrosion control.
Clean Air Act. U.S. Congress legislation designed to protect ambient air from pollution.
Closed Blast Cleaning. See Air Abrasive Blast Cleaning.
Coalescence. The formation of a film of resinous or polymeric material when water
evaporates from an emulsion or latex system, permitting contact and fusion of adjacent
latex particles. Action of the joining of particles into a film as the volatile evaporates.
Coal Tar. A dark brown to black cementitious material produced by the destructive
distillation of bituminous coal. [ASTM]
Coefficient of Thermal Expansion. Change in unit of length (or volume) accompanying
a unit change of temperature, at a specified temperature. [ASTM]
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the chlorine contact basins. Dechlorination is then completed by aerating the water either
through a cascade system or air injection.
Decibel. Abbreviated dB, unit of measurement for sound intensity.
Delamination. (1) The separation of a layer or layers of coating from the previous layer
or from the substrate. Failure of a coating to adhere to the previous coating. (2) In the
case of a concrete slab, a horizontal splitting, cracking, or separation of a slab in a plane
roughly parallel to, and generally near, the upper surface; found most frequently in bridge
decks and caused by the corrosion of reinforcing steel or freezing and thawing; similar to
spalling, scaling, or peeling except that delamination affects large areas and can often
only be detected by tapping. [ACI]
Density. A measure of mass per unit volume. The density of paint usually is expressed as
pounds per gallon or kilograms per liter. [PCG]
Depth Gauge. Instrument for measuring depth of a pit or crevice.
Depth Micrometer. See Depth Gauge.
Destructive Dry Film Thickness Gauge. See Dry Film Thickness Gauge, Destructive.
Detachment. See Delamination.
Detergent Cleaning. Removing contamination from a surface using an aqueous solution
of a surface-active agent.
De-Watering. (1) Term describing a type of accident in a nuclear power plant in which
water spills from the system to the extent that the fuel in the reactor is no longer
immersed. (2) Removing water from drydocks, locks, or other containments.
Dew Point. That temperature at which water pressure present in the atmosphere is just
sufficient to saturate it. When air is cooled below the dew point, the excess of water
vapor appears as tiny water droplets or crystals of ice depending on the temperature of
the air mass. [IUPAC, CED]
DFT. See Dry Film Thickness.
Disbonding. Failure of a coating to adhere to a substrate to which it is applied. Intercoat
disbonding is the failure of a coating to adhere to a previous coating layer or to the
substrate to which it has been applied. Intracoat disbonding is the failure of a coating
layer to cohere or hold itself together. See Adhesion, Cohesion.
Discontinuity. See Holiday.
Dissimilar Metal Corrosion. See Galvanic Corrosion.
Dolly. See Pull Stub.
Double Rub. The act of rubbing a solvent saturated cloth in one complete forward and
backward motion over the coated surface. [CED]
Dry Bulb Temperature. The temperature recorded by the dry bulb thermometer of a
psychrometer. [PCG]
Dry Bulb Thermometer. The thermometer on a sling or other psychrometer with a bulb
is directly exposed to the air (i.e., not covered with a wet sock). See Psychrometer.
Dry Film Thickness (DFT). Depth of cured film, usually expressed in mils (0.001 inch)
or micrometers (millionths of a meter). Standard methods for measuring dry film
thickness are defined in SSPC-PA 2, ASTM D 1005, ASTM D 1186, and ASTM D 1400.
Dry Film Thickness Gauge. An instrument used to measure the dry film thickness of a
coating.
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Dry Film Thickness Gauge, Destructive. Instrument used to determine dry film
thickness as described in ASTM D 4138. It is capable of measuring the thickness of
individual coating layers.
Dry Film Thickness Gauge, Eddy Current. A dry film thickness gauge that measures
the thickness of non-conductive coatings on non-ferrous metal substrates.
Dry Film Thickness Gauge, Magnetic. See Banana Gauge; Magnetic Fixed Probe
Gauge, Type 2; Magnetic Pull-Off Gauge, Type 1; and Pencil-Type Pull-Off Gauge.
Drying Oil. An oil that possesses to a marked degree the property of readily taking up
oxygen from the air and changing to a relatively hard, tough substance when exposed in a
thin film to the air. [ASTM]
Dry Spray. (1) A rough, powdery, non-coherent, discontinuous film produced when an
atomized coating partially dries before reaching the surface. (2) Overspray or bounce
back falling dry on unintended surfaces and producing an adherent, sand-like covering.
[PCG]
Ductility. Tendency of a material to undergo deformation and extension without cracking
or splitting. [CED]
Durability. A term indicating degree of permanency, used to describe individual
properties, such as the gloss, or general characteristics. [PCG]
Durometer Hardness. An arbitrary numerical value that measures how well as surface
resists indentation by the durometer’s blunt indentor point. The value may be taken
immediately or after a very short specified time. [ASTM]
Durometer. Instrument for measuring the surface hardness of rubber, plastic, or
protective coatings. [CED]
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
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maneuverable than an oxy-fuel gas gun, but the deposit rate of the metal is two to three
times greater. See Thermal Spraying. [PCG]
Electrostatic Precipitator. An electrical device used to attract and separate suspended
particles from an exhaust system
Electrostatic Spraying. A method of applying a spray coating in which charged coating
particles are attracted to a grounded, conductive substrate. The mist travels around
corners of the substrate with the result that the article is coated more uniformly on all
sides and edges with very little overspray and bounce back. [PCG]
Elongation. A method of measuring coating flexibility; the increase in specimen length
from the point of initial load application to the point of film rupture in a tension test.
ASTM D 2370 covers the measurement of elongation as well as tensile strength and
stiffness (modulus of elasticity) of organic coatings when tested as free films. [ASTM,
CED]
Emulsion. Two-phase liquid system in which small droplets of one liquid (the internal
phase) are immiscible in, and are dispersed uniformly throughout, a second continuous
liquid phase (the external phase). [CED]
Emulsion Coating. A coating in which the vehicle is an emulsion of binder in water. The
binder may be oil, oleoresinous varnish, resin, or another emulsifiable binder. Not to be
confused with a latex paint in which the vehicle is a latex. [CED]
Enamel. A finish coat that dries to a smooth, gloss surface. [PCG]
Encapsulation. The process of enclosing a surface, especially of one containing
hazardous materials, on all sides. Encapsulants include drywall, fiber-filled coatings,
wood, or other materials. [PCG]
Engineering Standard. A document that provides options for construction work such as
coating different types of structures.
Epichlorhydrin. A chemical used in the production of epoxy resins.
Exothermic Reaction. Chemical reaction that produces heat.
Expansion Dam. The part of an expansion joint serving as an end form for placing
concrete at a joint. Also applied to the expansion joint device itself.
Expansion Joint. (1) A separation provided between adjoining parts of a structure to
allow movement where expansion is likely to exceed contraction. (2) A separation
between pavement slabs on grade, filled with a compressible filler material. (3) An
isolation joint intended to allow independent movement between adjoining parts. [ACI]
Exposure. Placing a specimen in test conditions. [PCG]
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.
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Flocculent. Having a loose, fluffy organization resembling wool. Used to describe degree
of pigment suspended in paint vehicle.
Fluid Tip. The removable end of an air-spray gun from which the atomized paint is
sprayed and in which the needle is seated. The fluid tip works in conjunction with the
needle to regulate the flow of fluids before they are atomized. [PCG]
Fluidized Bed Coating. Method of applying a coating in which a heated or
electrostatically charged article is immersed or passed over a fluidized bed of powdered
coating (the coating material adhering to the hot metal), then fused in an oven to provide
a smooth, continuous film. [CED]
Fluorescence. Optical phenomenon characterized by the reemission of absorbed radiant
energy by certain chemicals or materials. [CED]
Foot Candle. Unit of illumination equal to one lumen per square foot. [ASTM] The
preferred unit of illumination is the SI unit lux (one lumen per square meter).
Form Release Agent. Compound such as petroleum oil, wax, and silicone applied to
concrete forms to allow easy removal from poured concrete after it has cured. [PCG]
Freezer Room. A room where food or food ingredients are kept frozen, usually between
32 and -15°F (0 and -8°C).
FRP. See Fiberglass-Reinforced Plastic.
Fusion Bonded Epoxy (FBE). A powder coating commonly applied to pipelines, rebar,
etc., for corrosion control.
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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 hand-
tool 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 ship’s bottom.
Hold Point. Critical point in an operation where work is stopped until the work to date
has been approved.
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Holiday. Application defect whereby a small area is left uncoated. Synonyms: miss, skip,
void, discontinuity, vacation. [CED]
Holiday Detector, High-Voltage. Also called a spark tester, an instrument for detecting
holidays in a nonconductive coating applied over a conductive substrate. A spark test
instrument applies a voltage to the surface with a probe that creates a spark whenever a
holiday, pinhole, or other defect is found. The spark triggers an alarm or light on the
instrument. The voltage used depends on the coating and thickness.
Holiday Detector, Low-Voltage Wet Sponge. An instrument that uses 5-90 volts DC to
detect holidays in a coating. It is typically used for films of less than 20 mils (510
micrometers) dry film thickness.
Holiday Test. Test for detecting small areas of paint film that are incompletely coated
(holidays). Standard methods for holiday testing are defined in ASTM D 5162, ASTM D
4787, and NACE RP0188-90.
Hot Flocking Method. A method of powder coating application that relies on a non-
electrostatic spray of powder onto parts that have been preheated above the softening
point of the powder. The powder melts and clings to the preheated parts. In some cases,
the coating is fused/cured by residual heat in the parts, while in others, a post-heating step
is required.
Hot Spraying. Spraying hot lacquers or paints, the viscosities of which have been
reduced to spraying consistency by means of heat instead of by adding volatile solvents.
By such a process, it is possible to apply materials with higher-solid content and therefore
better build. [CED]
Hull. The frame or body of a ship exclusive of masts, deck houses, superstructure, and
rigging.
Hydraulic Adhesion Test Equipment (HATE). Commercial hydraulic instrument for
determining coating adhesion to a substrate by the pull-off method. See Adhesion Test,
Tensile (Pull-Off).
Hydroblasting. A cleaning process in which pressurized water is directed through a
nozzle to impact a surface. The term is used generically to describe cleaning with water
without abrasives from low pressure water cleaning to ultra-high pressure waterjetting.
See also Hydrojetting and Waterjetting.
Hydrocarbon Solvent. Aliphatic, aromatic, or cyclic (cycloparaffinic, naphthenic)
solvent containing only carbon and hydrogen. [PCG]
Hydrochloric Acid. An aqueous solution of hydrogen chloride gas. Dissolves many
metals, forming chlorides and liberating hydrogen. Used extensively in industry for
numerous purposes including concrete surface preparation.
Hydrojetting. A generic term describing the process in which pressurized water is
directed through a nozzle to impact a surface. See also Hydroblasting and Waterjetting.
Hydrolasing. A term commonly used for high or ultra-high pressure water blasting. See
Waterjetting and Hydrojetting.
Hydrolysis. Chemical reaction consisting of splitting a compound into two parts, one of
which combines with the H+ ion of water, and the other combines with the OH- ion of
water. [CED]
Hygrothermograph. An instrument for measuring and recording the air temperature and
relative humidity.
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Hypodermic Pressure Gauge. A gauge with a hypodermic needle that is inserted into
the hose at various locations (e.g., just before the nozzle used with abrasive blasting
equipment) to determine air pressure.
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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.
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Leveling. A coating’s ability to flow out on a surface so that brush or roller marks or
other irregularities produced during application are not apparent. [PCG]
Leveling Agent. Chemical added to coating to increase the ability of the wet film to
settle to a uniform thickness.
LFL. See Lower Flammable Limit.
Limpet (Soltz) Cell. A rigid cell used to collect soluble salt from a contaminated surface
in order to determine its concentration.
Line of Demarcation. On ships, the line of demarcation is where the above-water paint
system meets the underwater paint system. It is usually the deep load line or draft line on
the vertical sides of the ship.
Line Travel Machine. A machine that performs one of the cleaning or coating processes
while moving continuously on wheels or another means along the length of the pipeline.
Lining. (1) A material used to protect a container against corrosion and/or to protect the
contents of the container from contamination by the container shell material. Sprayable
linings, sheet liners, and drop-in liners can be used for this. [PCG] (2) Any sheet, plate, or
layer of material attached directly to the inside face of formwork to improve or alter the
surface texture and quality of the finished concrete. [ACI]
Litmus Test. The use of litmus or pH paper to measure the acidity or alkalinity (pH) of a
water solution. [PCG]
Loading Fixture. A component of an instrument (e.g., an adhesion tester) to which a
force (load) is applied to determine a physical property such as bonding strength.
Lockout. A means of protecting workers from injury or death caused by the accidental
start-up or release of stored energy from equipment. It involves blocking the flow of
energy from the power source to the piece of equipment with a padlock or chain, or by
removing a component such as a fuse or circuit breaker. See also Tagging.
Lower Explosive Limit (LEL). The concentration, at ordinary ambient temperatures, of
a compound in air below which an explosion will not occur if the mixture is ignited. The
concentration is expressed as a percent of the gas vapor in air by volume. When the
concentration of a substance in air is above the lower explosive limit and below the upper
explosive limit (UEL), the mixture will burn and explode. [PCG]
Lower Flammable Limit (LFL). The minimum concentration of a combustible
substance that is capable of propagating a flame through a homogeneous mixture of the
combustible and a gaseous oxidizer under the specified conditions of test. [ASTM]
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 gauge’s 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
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between magnet and steel, i.e., the thickness of the dry paint film (plus any other films
present). Type 1 refers to the gauge’s designation in SSPC-PA 2.
Mandrel. In bend testing, the tool used to control the strain on the concave side of a bend
in a wrap-around bend test and also to apply the bending force in a semi-guided or guided
bend test. [ASTM]
Manufacturer’s Technical Data Sheet. Product instructions and information.
Mastic. (1) A high-build coating. (2) An adhesive material. [PCG]
Material Safety Data Sheet (MSDS). OSHA’s established guidelines for the descriptive
data that should be concisely provided on a data sheet to serve as the basis for written
hazard-communication programs. The thrust of the law is to have those who make,
distribute, and use hazardous materials be responsible for effective communication.
[CED]
MBR. See Magnetic Base Reading.
Mechanical Adhesion Testing. Adhesion testing performed with a pull-off instrument.
An aluminum pull stub (loading fixture) is bonded onto a coated surface. After the
bonding adhesive cures, the force on the pull stub is continuously increased and
monitored until it detaches or until a specific force is attained (ASTM D 4541; Annex
A.1).
MEK. See Methyl Ethyl Ketone.
Mercury. A toxic heavy metallic element that is liquid at usual temperatures. Mercury
compounds have been used extensively in the past in paints as mildewcides. The
toxicities of these products vary depending upon the chemical compound in which they
occur.
Metallizing. Spraying a coating of metal onto a surface. See also Flame Spraying,
Plasma Spraying, and Thermal Spraying. [PCG]
Metal Spray Coating. A film of molten metal, often zinc or aluminum, dispersed
(sprayed) onto a surface, such as steel, for corrosion control.
Methyl Ethyl Ketone (MEK). A low-boiling strong solvent, similar to acetone but less
volatile. [PCG]
Methyl Ethyl Ketone Peroxide. A chemical used in small amounts to accelerate the
curing of polyester coatings.
Methyl Isobutyl Ketone (MIBK). A medium-boiling strong solvent. [PCG]
Microbiologically Influenced Corrosion (MIC). Corrosion that is affected by the action
of microorganisms in the environment, e.g., sulfate-reducing bacteria found in some
petroleum products and in sewage.
Micrometer. (1) One millionth of a meter, abbreviated as µm. Also sometimes called a
micron. Coating thickness often is expressed in micrometers; 25.4 micrometers = 1 mil.
(2) A stationary or hand-held instrument used to measure thickness of free (unattached)
films. [PCG]
MIL. One thousandth (0.001) of an inch. 1 mil = 25.4 micrometers. Coating thickness is
often expressed in mils or in micrometers. [PCG]
Mil Profile. See Surface Profile.
Mill Coating. Shop coating.
Mill Scale. The heavy, bluish oxide layer formed during hot fabrication or heat treatment
of steel and other metals. [PCG]
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Mineral Abrasive. Blast cleaning abrasive made from naturally occurring minerals, such
as silica sand, olivine, staurolite, flint, garnet, zirconium, novaculite.
Mineral Spirits. A petroleum-derived solvent used for thinning paint. Odorless mineral
spirits have been refined to remove some odorous constituents. [PCG]
Mist Coat. Also called a fog coat, a thin layer applied in a spray mist and used as a tack
or adhesive coat. [PCG]
Mixing Ratio. The ratio, usually by volume, of mixed components for a thermosetting
coating specified by the manufacturer for complete curing into the desired film.
Moisture Meter. Instrument used for determining water (moisture) content of materials,
such as wood or concrete, by measuring its conductivity.
Monomer. The starting compound for a polymerization reaction. A monomer can link
with itself or with other monomers to form a polymer. [PCG]
Monolithic. Material of uniform composition applied as a continuous surface or
structure. [ASTM] Monolithic concrete is concrete cast with no joints other than
construction joints. [ACI]
MSDS. See Material Safety Data Sheet.
Mud Cracking. A paint failure that looks like cracked mud. It normally is caused from
shrinkage of excessive thicknesses of coatings during curing. [PCG]
Muriatic Acid. An industrial form of hydrochloric acid used to clean concrete and
masonry. [PCG]
NDT. See Non-Destructive Testing.
Near-White Blast Cleaning. According to SSPC-SP 10/NACE No. 2, Near-White Blast
Cleaning, a near-white blast cleaned surface is free of all visible oil, grease, dirt, dust,
mill scale, rust, paint, oxides, corrosion products, and other foreign matter and staining is
limited to no more than 5% of each unit area of surface. [PCG]
Needle Gun. A power impact tool with a bundle of steel needles with chiseled ends
mounted in front of a piston that strikes them several times per second and pushes them
against the surface being cleaned. Needle guns work best at removing loose or brittle
material. Because each needle hits the surface individually, needle guns are useful for
cleaning irregular surfaces, such as corners and crevices, or around bolt and rivet heads.
[PCG]
NIST Standard Thickness Plates. Small, thin reference squares of 1010 steel covered
with different thicknesses of a non-magnetic metal (copper-chromium alloy with a nickel
finish); used to calibrate magnetic dry film thickness gauges; made by the National
Institute of Standards and Technology (NIST).
Non-Conductive. A surface or material that will not conduct electricity.
Non-Contact Thermometer. An instrument that determines surface temperature by
measuring the amount of energy the surface emits.
Non-Convertible Coating. Film-former which, after being deposited from a solution,
dries to give a film that is unchanged chemically from its original composition and can be
redissolved in a solvent from which it was originally deposited. See Thermoplastic.
[CED]
Nondestructive Testing (NDT). Determining physical or chemical properties without
damaging item being investigated.
Non-Ferrous. Not containing iron; pertaining to metals other than iron.
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Nonvolatile Matter (NVM). Of a coating, the solid material remaining after the volatiles
(solvent) have been driven from the film under specified test conditions. The total
percentage volatile present is obtained by subtracting the nonvolatile content from 100.
Nonvolatile Vehicle. The coating binder dissolved or dispersed in the solvent (volatile
vehicle) that remains to form a film after solvent evaporation.
Non-Woven Abrasive Pad. A web of nylon fibers embedded with abrasive material in
different sizes and densities. These pads can be used to remove dried soil, debris, and
loose paint from many different surfaces, as well as loose rust and loose mill scale from
steel. They can also be used to feather, or blend the edges of a repair area, with the
surrounding surface. [PCG]
Notch Gauge. See Wet Film Thickness Gauge, Notch Type.
Novolac. Class of resins produced by the chemical reaction of phenol and formaldehyde;
often used in high performance phenolic or epoxy coatings. See Bisphenol F.
Nozzle Orifice Gauge. A tapered metal rod that can be inserted into the rear of a blast
cleaning nozzle to determine the size of its orifice. The nozzle normally is replaced when
the orifice size increases by 1/16 inch (1.6 mm). [PCG]
Nuclide. A species of atom characterized by the constitution of its nucleus and hence by
the number of protons, the number of neutrons, and the energy content.
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
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oxidation. Oxidation during weathering can also destroy a film. (2) Metal corrosion and
degradation of other substances caused or accelerated by oxygen in the air. [PCG]
Oxygen Deficiency. Low oxygen in the atmosphere, generally below 19.5%, is a health
hazard.
Oxygenated Solvent. An organic solvent containing oxygen as part of its molecular
structure. Alcohols, esters, and ketones are oxygenated compounds often used as coating
solvents. [EPA, PCG]
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Pitting. (1) Localized corrosion on a metal surface, confined to a point or small area, that
takes the form of cavities. [ASM] (2) In concrete, pitting is localized disintegration, such
as a popout. [ACI]
Plasma Spraying. A spray application process in which metallic or thermoplastic
powders are introduced into a plasma arc cavity that contains the gas stream of a plasma
gun. After being melted, the powders are projected onto the surface being coated via the
flow of the plasma jet. See also Flame Spraying, Metallizing, and Thermal Spraying.
[PCG]
Plasticizer. (1) A paint, varnish, or lacquer additive designed to soften and promote
flexibility in the coating. [PCG] (2) A material that increases the plasticity of a fresh
cement paste, mortar, or concrete. [ACI]
Plural-Component Spraying. A coating application method that automatically
proportions and mixes two or more components of a paint material in the process of
delivering them to the spray gun. Plural-component spray equipment is used to apply
coatings with a pot life that is too short to permit mixing and application by conventional
air and airless spray equipment. [PCG]
Pneumatic Adhesion Tensile Strength Testing Instrument (Patti). An instrument for
determining the tensile adhesion of coatings to a surface, according to ASTM D 4541.
This instrument is self-aligning, and consists of detachable loading fixtures having a flat,
cylindrical base, a central grip for engaging the loading fixture, and a pressurized gas
system for applying a continuous pull to the loading fixture. See Adhesion Test, Tensile
(Pull-Off).
Pneumatic Power Tool. Tool that is run by air pressure.
Polymerization. Chemical reaction in which two or more small molecules (monomers)
combine to form large molecules (polymers, macromolecules) that contain repeating
structural units of the original molecules and have the same percentage composition as
the small molecules if the small ones were of the same kind. [CED]
Porosity. (1) Small interconnected voids, such as in concrete, which allow fluids to
penetrate an otherwise impervious material. (2) The ratio, usually expressed as a
percentage of the volume of voids in a material to the total volume of the material
including the voids. [ACI]
Pot Life. The time during which a coating material can be successfully applied to a
substrate after the container is opened, or after catalysts, activators, hardeners, or other
ingredients are added to initiate the curing reaction. Pot life often depends on temperature
and/or humidity. [PCG]
Powder Coating. (1) A 100% solids coating applied as a dry powder which, when baked
at a sufficiently high temperature, melts out to form a continuous film. For thermosetting
materials, a chemical reaction, either condensation or additional polymerization, also
takes place. This fused film has the uniformity, color, toughness, and other properties
generally associated with protective and decorative coatings. (2) A coatings application
method that utilizes a solid binder and pigment. The solid binder melts upon heating and
results in a pigmented coating upon cooling. [CED]
Power Grinding. Abrading a metal or other hard surface with a motor-driven tool.
Power Washing. The use of pressurized water (typically less than 5000 psi [34 MPa])
with or without chemical additives, detergents, etc., to remove contamination and debris
from a surface. [PCG]
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Power Wire Brush. A power tool with a brush made of knotted or crimped wire bristles
in the form of a wheel or a cup used to clean steel, concrete, or masonry surfaces. [PCG]
PPE. See Personal Protective Equipment.
PPM. See Parts Per Million.
Pre-Job Conference. Meeting held before construction work is started to permit the
contractor, owner, and other concerned parties to come to a common understanding of all
work requirements.
Primary Containment. (1) The main method of storing a product, e.g., a steel storage
tank. (2) That portion of a nuclear power plant reactor building housing the nuclear
reactor, a Class I area.
Primer. First full layer of coating applied to a surface when a multicoat system is being
used. Primers provide adhesion to a new substrate (wood, metal, masonry, or concrete),
protect the substrate, and aid in the adhesion of additional coats of paint. The type and
condition of the substrate and the painting system specified for a job affect the selection
of the primer. Primers for steel work contain special anti-corrosive pigments. [PCG]
Procurement Documents. Written records that describe the general terms and conditions
of construction or other contracts.
Profile Depth. A measure of surface roughness based on the distance between its peaks
and valleys, sometimes expressed as an average. See Surface Profile. [PCG]
Profile Depth Gauge. Gauge with instrumented probe for determining the profile height
(depth) of abrasive blasted steel, as described in ASTM D 4417, Method B.
Psychrometer. An instrument used to measure the wet and dry bulb temperatures of air.
With the aid of psychrometric tables, these measurements can be used to determine the
dew point and relative humidity of the air. [PCG]
Psychrometric Tables. U.S. Weather Bureau Tables, originally published by the U.S.
Department of Commerce, used to determine the relative humidity and dew point
temperature from the dry and wet bulb readings obtained from the psychrometer.
Pull-Off Adhesion Test. See Adhesion Test, Tensile (Pull-Off).
Pull-Off Gauge. See Magnetic Pull-Off Gauge, Banana Gauge, and Pencil-Type Pull-
Off Gauge.
Pull-Off Strength. Force necessary to pull a bonded probe from a coated surface in a
coating adhesion test.
Pull Stub. Also called a dolly or loading fixture, the part of an adhesion testing apparatus
that is affixed to the coated surface being tested.
PVC. Pigment Volume Concentration; Polyvinyl Chloride.
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.
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little or no pitting is visible. (4) Rust Grade D: The steel surface is completely covered
with rust; pitting is visible. [PCG]
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).
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from batch to batch and from source to source. Typical slag abrasives include copper and
nickel slag from metal smelting and coal slag from electric power generation. [PCG]
Sling Psychrometer. A psychrometer with wet bulb and dry bulb thermometers and a
swivel handle that allows the instrument to be whirled through the air to obtain constant
wet and dry bulb temperature readings. These temperatures can be used with
psychrometric tables to determine the relative humidity. See Psychrometer. [PCG]
Slurry Blasting. Surface preparation method using pressurized air to propel an abrasive
slurry. See Wet Abrasive Blast Cleaning.
Solids By Volume (%). The volume of the nonvolatile portion of a composition divided
by the total volume, expressed as a percent. Synonym: volume solids. [CED]
Soluble Salt Contaminants. Water-soluble inorganic compounds (such as chlorides and
sulfates) that contaminate a product. When soluble salts are present on a prepared steel
surface, they may cause premature coating failure.
Solvent. (1) Liquid, usually volatile, which is used in the manufacture of paint to dissolve
or disperse the film-forming constituents, and which evaporates during drying and
therefore does not become a part of the dried film. [CED] (2) Liquid used to dissolve and
remove oil, dirt, grease, soil, and waxes from metal surfaces. [PCG]
Solvent Cleaning. The use of organic solvents, detergents, alkaline cleaners, and steam
cleaning to remove oil, grease, dirt, soil, and other, similar organic compounds from a
surface. The specification SSPC-SP 1, Solvent Cleaning, is a consensus standard
covering the procedures necessary for solvent cleaning of steel surfaces. [PCG]
Solvent Resistance. The ability of a coating to resist solvent attack, solution, or
disfigurement. See Solvent Rub Test. [CED]
Solvent Rub Test. A practice for assessing the solvent resistance and/or cure of an
organic coating that chemically changes during curing. ASTM D 4752 is the preferred
solvent resistance test for ethyl silicate zinc-rich primer. [CED]
Spark Tester. See Holiday Detector, High Voltage.
Specification. A word that is used in several ways in the coatings industry. The term “job
specification” refers to the written, legal document, usually part of a contract, that
precisely describes an item of work that is to be accomplished. Many technical
organizations prepare documents called specifications that describe products, procedures,
or conditions. For example, SSPC’s Volume 2 includes many specifications covering
surface preparation, abrasives, paints and paint systems, and paint application. Military,
federal, state, and other agencies also have paint and related specifications. The Army
and Navy also have documents called “guide specifications” (formerly called “type
specifications”), which are called “engineering standards” by private industry.
Specular Gloss. Reflection of light in one path, as from a mirror, as opposed to diffuse
reflection in all directions.
Spiral Wrap. The technique for applying a continuous ribbon or tape to a length of a
pipe. The ribbon is positioned at an angle (less than 90 degrees) to the axis of the pipe
such that each revolution of wrap results in one side of the ribbon being applied over the
previous wrap and the other side being applied to the bare pipe surface. The amount of
overlap is governed by the width of the ribbon and the angle the ribbon makes with the
pipe. Compare to Cigarette Wrap.
Spot-Blast. Localized high-pressure cleaning as used in surface preparation for
maintenance painting.
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Spray Pattern. Shape of the area where atomized paint is deposited during air or airless
spray application. [PCG]
Squaring Up. A field term often used where production blasting and painting is
conducted on a large area that will require several days for completion. An area (e.g.,
1,000 ft.2) is chosen each day, using natural partitions as far as possible, that can be
readily blasted, inspected, and primed (squared up) that day. The term may also be used
to describe the application of topcoats on subsequent days according to a selected time
schedule.
Stainless Steel. Any of several steels containing 12 to 30% chromium as the principal
alloying element; they usually exhibit passivity in aqueous environments. [ASM]
Steel Abrasive. Cast steel shot or grit used for abrasive blast cleaning. Cast steel shot
consists of nearly spherical particles of steel obtained by granulating a molten stream of
metal with water or air, or by other methods. Cast steel grit consists of angular particles
produced by crushing steel shot. [PCG]
STEL. See Short Term Exposure Limit.
Stitch Welding. See Skip Welding.
Stress Corrosion Cracking. Cracking caused by corrosion together with the stresses in a
metal. [PCG]
Striping. Painting the edges of a surface or welds to give them extra protection. Striping
is done before priming or before the application of a full coat of paint. [PCG]
Superplasticizer. A (high-range) admixture capable of reducing water or flowability
without causing undue set retardation or air entrainment in mortar or concrete. [ACI]
Superstructure. (1) The part of the ship above the main deck. (2) The entire portion of a
bridge structure that primarily receives and supports highway, railway, canal, or other
traffic loads and in, its turn, transfers the resulting reactions to the bridge substructure.
The superstructure may consist of beam, girder, truss, trestle or other types of
construction.
Surface Conditioner. Chemical material that prepares a surface to receive a coating or
other material.
Surface Preparation. Any method of treating a surface to prepare it for coating. Surface
preparation methods include washing with water, detergent solution, or solvent; cleaning
with hand or power tools; water washing or jetting with or without abrasive; or abrasive
blast cleaning. SSPC and NACE International have a number of written and visual
standards describing surface preparation prior to coating application. [PCG]
Surface Profile. The contour of a blast-cleaned surface on a plane perpendicular to the
surface. For steel, surface profile is the roughened surface that results from abrasive blast
cleaning or power tool cleaning to bare metal, also call the anchor pattern. For wood and
concrete, surface profile is simply the texture of the cleaned surface. Surface profile of
steel is classified by its depth and its texture (rounded or angular). Surface profile depth is
defined as the average peak-to-valley height of the roughness and typically ranges from
less than 1 mil up to 5 mils (25 to 127 micrometers). See Profile Depth.
Surface Profile Comparator. An instrument used to determine the profile of a blast
cleaned surface by visual or tactile comparison of the surface with a series of reference
surfaces of known profile depths. [PCG]
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Thermoplastic Powder. Powdered organic polymeric materials that are melted by heat;
some are sprayed through a flame to melt them, applied to a substrate as a liquid, and
then solidified on cooling to form a protective film without undergoing chemical change.
Thermosetting. A material that permanently sets when subjected to heat, catalysts,
ultraviolet light, or chemical reaction, and cannot be softened and reformed by reheating.
As used in the coatings industry today, the original meaning of the term thermosetting
has changed somewhat. It is now used to classify coating types according to how the
resins cure, and the solubility of the cured film. Thus, the term thermosetting is virtually
synonymous with the term convertible. See Convertible Coating. [PCG]
Thinner. (1) The portion of a paint, varnish, lacquer, or printing ink, or related product
that volatilizes during the drying process. [ASTM] (2) Any volatile liquid used for
reducing the viscosity of coating compositions or components; it may consist of a simple
solvent or diluent or a mixture of solvents and diluents. [CED]
Thixotropic. Having a gel consistency that becomes liquid when stirred or brushed to
permit application but returning to its original consistency upon standing. Thixotropic
coatings are less likely to drip from a brush than other types and can be applied in rather
thicker films without running or sagging. [V1]
Threshold Limit Value (TLV). The TLV is the concentration of chemical substances in
the air that workers may be exposed to daily without adverse effect. TLVs are
recommended exposure limits and are not required by law to be met. [PCG]
Tie-Coat. A paint specifically formulated to provide a transition from a primer or
undercoat to a finish coat. Tie-coats may be used to seal the surface of a zinc-rich primer,
to bond generically different types of coatings, or to improve the adhesion of a
succeeding coating. [PCG]
Tie Rod. A mechanical connection in tension used to prevent concrete forms from
spreading due to the fluid pressure of fresh unhardened concrete. Also called a form tie.
[ACI]
Time Weighted Average (TWA). Maximum allowed exposure to toxic materials over a
working period, usually 8 hours.
Tin. A soft, silvery-white metallic element. Organotin compounds, once widely used in
anti-fouling coatings, have been widely restricted because toxic tin compounds were
picked up by marine organisms and got into their food chain.
Titanium Dioxide TiO2. A high-opacity, bright white pigment, used as a prime pigment
in paints, rubber, plastics. [CED]
Titration. In chemical analysis, determining the reactive capacity, usually of a solution,
especially, the analytical process of successively adding measured amounts of a reagent
(as a standard solution) to a known volume or weight of a sample or sample solution until
a desired end point is reached. [ASTM]
Tolerance. The total range of variation (usually bilateral) permitted for a size, position,
or other required quantity; the upper and lower limits between which a dimension must
be held. [ASTM, CED]
Toluene. An aromatic solvent used in paint manufacturing and as a thinner and cleanup
solvent. The flash point of toluene is about 30˚F (-1˚C). [PCG]
Tooke Gauge. See Destructive Dry Film Thickness Gauge.
Top Coat. The last coating material applied in a coating system, specifically formulated
for aesthetic and/or environmental resistance. Also referred to as the finish coat. [PCG]
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Topside. The area on the sides of the ship’s hull that are above the deep load line.
Topside usually refers to the area from the deep load line to the rail (above the boottop).
Sometimes the word encompasses the decks and areas above deck, such as hatches,
masts, pipes, etc. These areas are exposed to the weather as opposed to immersion in the
sea.
Total Solids. See Nonvolatile Matter.
Toxicity. The capacity of a substance to injure by chemical means. [PCG]
Turbidity. Term used to indicate the degree of water sample cloudiness, which is caused
primarily by the presence of colloidal matter. [IUPAC, CED]
Type 1 Magnetic Pull-Off Gauge. See Magnetic Pull-Off Gauge, Type 1.
Type 2 Magnetic Fixed Probe Gauge. See Magnetic Fixed Probe Gauge, Type 2.
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]
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 liquid’s 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.
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Volatile. (1) Easily evaporated. (2) Any liquid that evaporates quickly. [PCG]
Volatile Organic Compound (VOC). (1) Any organic compound that reacts in the
atmosphere with nitrogen oxides in the presence of heat and sunlight to form ozone. (2)
Any organic compound (other than those designated by EPA as having negligible
photochemical reactivity) that is emitted into the atmosphere during the application or
curing of a coating. It is detected by reference methods such as EPA Method 24 or
ASTM D 2369. [PCG]
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 water-
reducible 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]
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Wet Abrasive Blast Cleaning. Surface preparation method using conventional dry
abrasive blasting equipment supplemented with modules to inject water into the abrasive
stream. Ideally, the water encapsulates the abrasive particles with a thin film of moisture
to suppress and contain the dust generated by the impact of the abrasive with the
substrate.
Wet Bulb Depression t – tw. The difference between the dry-bulb temperature and the
wet-bulb temperature. [ASTM]
Wet Bulb Temperature, tw. The temperature recorded on a wet bulb thermometer. See
also Dry Bulb Temperature and Psychrometer. [PCG]
Wet Bulb Thermometer. The thermometer on a sling or other psychrometer with a bulb
covered by a wet cotton sock. See Psychrometer.
Wet Film Thickness (WFT). Thickness of the liquid coating film immediately after
application. [CED]
Wet Film Thickness Gauge, Notch Type. Gauge with one or more faces cut in a series
of notches that is used to determine coating wet film thickness as described in ASTM D
4414.
Wetting. Ability of a vehicle to spread uniformly and rapidly over the surface of pigment
particles. A vehicle with good wetting properties assists in the grinding or dispersion of
pigments and the ability to wet the surface to which the finished coating is applied.
[CED] (2) The ability of a coating to come into close contact with the surface over which
it is applied. [PCG]
Wetting Agent. Material used in a coating to reduce the surface tension of the vehicle or
binder in order to assist in grinding or dispersing pigments or to improve the ability of the
coating to wet the surface. [PCG]
White Metal Blast Cleaning. Highest grade of blast cleaning. According to SSPC-SP
5/NACE No. 1, a white metal blast cleaned surface is free of all visible oil, grease, dirt,
dust, mill scale, rust, paint, oxides, corrosion products, and other foreign matter. [PCG]
Wire Brush Cleaning. Cleaning a surface with a hand or power tool wire brush. [PCG]
Work Mix. See Abrasive Mix.
Work Permit. Formal instruction, issued daily or weekly, to allow work to take place in
a hazardous environment.
Woven Roving. A cloth consisting of glass fibers woven in a pattern to impart strength
when used to reinforce a coating or other composite system.
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 80°F (27°C). [PCG]
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.
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Zinc-Rich. High in zinc dust content; a generic type of coating described in SSPC Paint
20.
Zinc-Rich Coating. Anti-corrosive coating for iron and steel. Zinc-rich coatings use zinc
dust in a concentration sufficient to provide electrical conductivity in the dried film. This
enables the zinc metal to corrode preferentially to the ferrous substrate, giving galvanic
protection. [PCG] See also Galvanic Protection.
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 Inspector’s 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 Painter’s Painting and Decorating Terminology Glossary. Master
Painters & Decorators Association: Burnaby, B.C., 1997.
PDC: Painting and Decorating Craftman’s Manual and Textbook. Painting and
Decorating Contractors of America: Fairfax, VA, 1975.
Protective Coatings Glossary. SSPC: Pittsburgh, 2000.
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Appendix C
Arithmetic
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C-2
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C-3
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C-4
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C-5
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C-6
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C-7
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C-8
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C-9
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C-11