Course Research Paper Paint Inspection 3/2

Q1 What kind of process is corrosion?

Corrosion is a process known as electrolysis.
Q2 What particular problem relate to the maintaining of an effective coating
system in the splash zone?
Problems in the splash zone include growth of algae, never dries properly; water
is an electrolytic solution promoting corrosion plus added impurities.
Q3 What factors influence the rate of corrosion?
Factors that influence the rate of corrosion are
1. oxygen content on the surface (wet or dry)
2. RH% (above 60% is critical)
3. Presence of impurities (salts)
4. Higher nobility (mill scale)
Q4 What is mill scale and why is it a particular problem when attempting to
protect steel?
Mill scale is formed during steel making and is a thin layer of oxidised iron, which
loosely adheres to the surface and if painted over will flake off causing premature
breakdown of the coating; mill scale is also higher nobility than steel.
Q5 What is the number of the Swedish standard contained within BS7079
and list the rust and blasting grades together with their brief relevant titles?
S-05-59-00
Rust Grades
A. Mill scale with little or no rust
B. Mill scale and rust mixed
C. Rust and light pitting
D. Heavy rust and pitting
Blast Grades
SA1 light blast cleaning
SA2 thorough blast cleaning
SA21/2 very thorough blast cleaning
SA3 blast cleaned to visually clean steel
Q6 Name three test for locating Hygroscopic salts and mill scale on a blast
cleaned substrate?
1. Potassium ferocynanide – test for soluble iron salts
2. Silver nitrate – test for soluble chlorides
3. Copper sulphate – test for mill scale
Q7 What factors influence how clean and how rough the surface becomes
after blast cleaning?
Size, shape, hardness and density of blast
Speed, angle, distance and time of nozzle
Q8 Regarding hand and power tool cleaning state what always concludes
this process and to what standards?
S-05-59-00 and finish with manual wire brushing surface must not be polished or
poor adhesion will occur
Q9 What three basic ingredients make up a traditional solvent carrying
paint?
Three main ingredients are binder, pigment and solvent
Q10 What are the functions of each of these three in a solvent carrying
paint?
Binder – holds particles together, gives finish, gives adhesion, gives flexibility
Pigment – gives colour, gives resistance to acids/alkalis and opacity
Solvent – evaporating part of process, thins paint, washes equipment and can
act as degreaser
Q11 Name five items that can be included in paint to improve its
performance or suitability for a certain use?
1. Extenders – to make paint go further
2. Anti-skinning – to stop paint skinning over in tin
3. Stabiliser – to stop the ingredients separating in the tin
4. Thixotropic agent – to enable high build
5. Dryer – to improve or enable drying
Q12 Identify six paints by their binder names?
1. Acrylic
2. Cellulose
3. Epoxy
4. Emulsion
5. Polyurethane
6.

Q13 Name four binder/solvent combinations?

1. Epoxy – acetone
2. Chlor rubber – xylene
3. Alkyd resin – white spirit
4. Emulsion – water
Q14 Name six opaque pigments together with their respective colours?
1. Red lead red
2. Zinc chromate Yellow
3. Titanium dioxide White
4. Carbon black
5. Coal tar Black
6.

Q15 Describe what a laminar pigment is?

A laminar pigment is a pigment that has leaf shaped particles and when drying
they interlock and from a coating which is highly impervious to water
Q16 What is the difference between a convertible and a non-convertible
coating?
A convertible coating is one that when fully dried cannot be softened or damaged
by its’ own solvent. A non- convertible coating is one that when fully dried can be
softened or damaged by its’ own solvent
Q17 Define the term induction period?
Induction period is the time that a two-pack paint must be left after mixing to
allow for removal of air bubbles and allow for chemical reaction as per
manufactures recommendations
Q18 Define the term pot life?
The term pot life is the time that paint remains usable after mixing and induction
as per manufactures recommendations
Q19 Define a Barrier system of coatings?
A barrier coating is a system that isolates a material using a low permeable
coating system
Q20 Define the term tie coat and give an example of its use?
A tie coat is used to tie two incompatible paint systems together i.e. maintenance
painting

Q21 What is the difference between thermosetting and thermoplastic?

Thermosetting once set cannot be changed in form thermoplastic can be heated
and have its’ shape changed
Q22 What is impressed current what problem can arise from its incorrect
setting up?
Q23 Name two types of paint mill and give two examples of each?
1. Direct charge mill – ball mill, high-speed disperser
2. Pre mix mill –
Q24 What is the title of BS 3900
Method of test for paints
How many tests are set in BS3900
Eight tests are set in BS3900
How are the test identified?
By letters A-H
Q25 What does a fineness of grind gauge measure?
A fineness of grind gauge measures the fineness of particle grind of pigment
Q26 What is flashpoint and in what apparatus is it measured?
Flashpoint is the point at which vapours will ignite if an external source of ignition
is introduced. Flashpoint is measured in a closed type abel cup
Q27 What is viscosity and what equipment is used to measure the viscosity
of 1. a free flowing paint 2. a thixotropic paint
1. Ford flow cup
2. Rotational viscometer
Q28 What is a density cup and give an example of its use?
A density cup is a small black aircraft alloy cup holding 100 ml and can be used
for checking if excess thinners has been used
Q29 Calculate the volume solids of paint if the Wet Film Thickness was
186m and the Dry Film Thickness was 93m?

DFT X 100 93 X 100 9300 =50%

VS%= WFT 186 186
Q30 Calculate the WFT of paint if the VS% was 66% and the DFT was 88m

100 X DFT 100 X 88 8800 =133.35m

WFT= VS 66 66
Q31 Calculate the DFT of paint if the VS% was 44% and the WFT was
234m

VS X WFT 44 X 234 10296 =103m

DFT= 100 100 100

Q 32 Calculate the density of paint if a 5-lt. tin weighed 15 Kg?

Weight 15
Volume 5 =3 g/cm3
Q 33 Calculate the density of a two-pack material if part (A) was 1.5 g/cm 3
and part (B) was 0.5 g/cm3 (assume mix ratio of 1:1)?

1.5 2/2 =1g/cm3

+0.5
2.0
Q 34 Name an example of a non destructive DFT Gauge and a destructive
DFT?
A non-destructive test gauge is a Banana Gauge
A destructive gauge is a Paint Inspectors Gauge
Q35 Name four artificial weathering devices and say what they are
designed to simulate?
1. Water soak to test permeability
2. Cold box to test for cold cracking and contraction
3. Salt spray to simulate a marine environment
4. Temperature box to test for flexibility alternating hot and cold
Q36 Name two drying curing tests and state how they ate operated?
Stylus test –A test block is painted and needles of differing tension are pulled
along a scale is on top in hours can test for wet, tack, hard and fully cured
Balltoni test- A test block is painted and tiny glass balls are dropped on at regular
intervals can test for wet tack and dry
Q37 What does a cryptometer measure and give two examples of a
cryptometer?
A cryptometer measures the opacity of paint two examples are
1. Hiding power charts
2. Pfund cryptometer
Q38 What determines the degree of gloss a paint may posses?
The degree of gloss a paint posses is down to the fineness of the pigment grind
Fine - high gloss course – dull
Q39 Name three adhesion tests and describe how one of them is carried
out?
The three adhesion tests are cross cut, cross hatch, and dolly test.
To perform a dolly test
1. Paint a sample and let fully cure.
2. Attach a dolly using regular aralidite and let harden for 24 hours at 25 0c.
3. Cut around dolly to isolate paint underneath.
4. Pull of dolly and record pulling force required also record if failure is
adhesive or cohesive.
Q40 State the conditions under which British gas allow painting to take
place?
Conditions required are
1. Substrate temperature must be 30c above dew point
2. Relative humidity must be less than 90%
3. With manufactures specifications
Q41 Name eight duties of a paint inspector?
1. Learn specification
2. Assess condition of substrate preparation
3. Check all consumables
4. Check all temperatures and humidity
5. Check all dry and wet film thicknesses
6. Witness application of paint regularly
7. Make reports
8. Ensure safe working is carried out
Q42 List eight-contractor malpractices?
1. Using unqualified people
2. Unsafe working condition
3. Incorrect paint
4. Incorrect thickness applied
5. Reusing expendable shot
6. Incorrect storage of paint
7. Using paint after specified pot life
8. Incorrect use of thinners
Q43 Name three methods of applying paint and compare the advantages
and disadvantages of each in terms of quality and cost effectiveness?

1. Brush
Slow and small coverage but good finish and works paint into substrate very well,
labour intensive. Cheap cost of brushes and easy to clean.
2. Roller
Produces an uneven coat but can be used in areas out of reach by use of
extension poles, faster than brushing and does not work paint into substrate.
Covers medium sized areas.
3. Spray
Fast and covers large areas not as much labour required, can cause explosive
atmosphere due to atomised paint and requires large reservoir of paint.
Equipment requires regular cleaning for best performance. Awkward areas may
be better covered due to paint being forced out at pressure at substrate
Q45 What is BS 4800 and how is it used in the construction industry?
BS 4800 is the specification for paint colours for building purposes.
Q46 how do BGAS define the following?
 Long term protection ---------- approximately 10 years
 Medium term protection------- approximately 5 years
 Short term protection ---------- approximately 2-3 years
 New galvanising------------------ Shiney and no oxide layer
 Weathered galvanising--------- dull and oxide layer formed
Q47 What is the procedure for removing oil and grease from a surface
before preparation commences?
To remove oil and grease before preparation commences clean with solvent, or
for large areas wash with 2% detergent low-pressure wash and rinse with fresh
water and dry
Q48 What is the procedure for removing oil and grease from a surface if
found after preparation has taken place?
If oil and grease is found after preparation, clean with solvent wash with 2%
detergent wash rinse with fresh water and re-blast.
Q49 What is the procedure for removing algae and mould growth from
pipework?
To remove algae and mould treat with a killer for 24 hours scrub with stiff brush
or power-wash rinse with fresh water and dry.
Q50 Under what conditions must paint be stored?
Paint must be stored as per manufactures conditions
I.e. cool; dry, in flameproof containers and in accordance with health and safety
and coshh regulations
Q51
 What is ‘T’ wash?
 What is it used for?
 What colour is it?
 How is it checked for correct reaction when using it?
1. ‘T’ wash is etch primer
2. T’ wash is used for priming zinc
3. T’ wash is blue in colour
4. T’ wash will turn black if used correctly
Q52 What two coats are applied at works?
The two coats applied at works are
1. high solids solvent based epoxy primer
2. epoxy Mio
Q53 What distance must be left at areas to be welded when painting?
A distance of 150mm either side of weld area must be left.

Q54 How much must new paint overlap on repairs?

New paint on repairs must overlap by 100mm on either side.
Q55 What is the maximum allowed time for priming to take place following
preparation and by what method is primer applied?
The maximum time allowed is 4 hours and applied by spraying
Q56 What do Bgas class as hot duty service?
Bgas classes hot duty service as surface temperature above 99 0c
Q57 What must all pneumatically and electrically operated power tool
equipment be?
All pneumatically and electrically operated equipment must be earthed and in
safe working condition.
Q58 What type of sheeting may and may not be used for protection against
spillage and spotting?
Fireproof sheeting must be used for protection against spillage and spotting,
tarpaulin must not be used.
Q59 What must not be used to clean out paint kettles or to dispose of
rubbish?
Fire or flames must not be used for the disposal of rubbish or cleaning paint
kettles.
Q60 Give rules for the mixing of paints regarding sizes?
When mixing paint always follow manufactures recommendations, never split
cans for a small amount always use full amounts to ensure correct mixtures.
Q61 What are osmotic blisters and what can cause them?
Osmotic blisters are blisters where water or solvent or water is trapped below the
paint surface. may also be caused by hygoscopic salts left after blasting
Q62 Some metals are difficult to prepare name three of these and describe
how you might prepare them?
Aluminium prepare by etching
Brass prepare by etching
Stainless steel prepare by etching
Q63 Where a pipeline leaves the ground what problems would you find and
how might you treat this?
Where a pipe leaves the ground you might find
 algae
 knocks and bumps
 water paths
To treat this use a pipe which has a hard permanent coating (e.g. plastic) which
extends above ground level
Q64 What additional information would you record when maintenance
painting a pipeline without removing the previous coats?
 Condition of previous coating
 Method of cleaning and abrading
 Type of paint system used
 Colour and opacity checks
 Any reactions on test samples
 Corrosion and breakdown of existing paint
 Temperature checks
 Type of application
 Details of wft / dft
 Details of tie/strip coats
Q65 Name five paints and state their drying or curing method?
1. Emulsion coalescence
2. Alkyd solvent evaporation then oxidation
3. Chlorinated rubber solvent evaporation
4. 2 pack epoxy solvent evaporation and chemical reaction
5. fusion bonded epoxy heat cured
Q66 Name a black pigment in common use apart from coal tar?
Another black pigment in common use is carbon
Q67 What is a holiday and pinhole detector, what does it detect, and how
does it work?

Earth
Coated pipe

Brass wire Brush Holiday

connected to detector
Holiday detector

A holiday detector detects any pinholes or breakdown in the coating.

From the holiday detector an earth lead is attached to bare metal, another cable
is attached to a brass wire brush. As the brush is pulled slowly along the coated
surface any pinholes or holidays (poorly coated areas) cause a current path
between brush and earth which causes a buzzer to sound in the holiday detector
box.
Q68 If you worked on a contract where frequent stoppages occurred for
poor weather, what additional information would you record?
1. Extra temperature, humidity and dew point readings to be taken
2. Time started and time stopped painting
3. Type of weather conditions
4. Areas painted and type of coating
5. Condition of paint
Q69 If a pipeline was in direct contact with acoustic cladding what paint
system might be applied if we wished to maintain it every three years, or
not at all?

Q70 What is important about selecting a paint system suitable for a certain
environment?
A paint system must be designed for an environment taking cost, service,
preparation and life expectancy into consideration
Q71 What information do Bgas require to be on a paint tin and what Bgas
document deals with the properties and performance of paints?
Properties and performance of paints is dealt with by P9
Q72 What is unusual about the preparation of surfaces which are dealt with
under spa4?
The surfaces in spa 4 are areas where condensation cannot be avoided
Q73 State the principles of being able to use a banana gauge for taking dft?
1. Select a shim closest to thickness of fully cured paint being measured
2. Place shim on blasted surface and place banana gauge(used only with
ferromagnetic substrate) onto shim ensuring magnet takes hold
3. Adjust wheel until magnet detaches
4. Align pointers
5. Calibration complete
Q74 Give one advantage of using testex tape and plastic disposable wft
combs?
Q75 Describe what you know of H.A.S.A.WA. and C.O.S.H.H.?

H.A.S.A.W.A. Health and safety at work act deals with safety in the
workplace, responsibilities and duties.

C.O.S.H.H. Control of substances hazardous to health deals with

substances which we use details ways to use and
what information should be available upon use