1 Is the electrical circuit in a corrosion reaction AC or DC?

a. D.C
2 Does corrosion occur at the cathode or at the anode?
a. Anode
3 Name the three factors needed for corrosion to occur.
a. Temperature, hygroscopic salts, aerobic conditions, Bi metallic contact, metal
eating Bacteria
4 What is meant by the term electrolyte?
a. Electrolyte is a substance which will conduct current and then broken down
by it
5 What is corrosion?
a. Degradation of metal by chemical or electro chemical by means
6 In the corrosion circuit do electrons flow from anode to cathode?
a. No, Negative to positive, from cathode to anode
7 Which gas is released at the cathode when the electrolyte is water?
a. Hydrogen
8 Which is the more noble metal, steel or Aluminium?
a. Steel
9 Which is more electronegative, steel or Aluminium?
a. Aluminium
10 If steel and copper were in contact in an electrolyte which would corrode?
a. Copper
11 Name two common hygroscopic salts.
a. Sulphate, Chloride
12 Name three metals used as sacrificial anodes on a steel pipeline.
a. Aluminium, Zinc, Magnesium
13 What is the approximate thickness of mill scale?
a. 25 – 100um
14 Which of the two metals would corrode if steel and zinc were coupled?
a. Zinc
15 Which other names relate to the Galvanic List?
a. Electro motive series, Electro chemical series
16 In which environment are you likely to encounter chloride salts?
 a. Marine
17 Which three compounds together form millscale?
a. Wustite, magnetite, haematite
18 If magnesium was coupled with zinc, which would corrode?
a. Zinc
19 In which environment would sulphate salts be found?
a. Industrial
20 What is an osmotic blister?
a. Slat formation in substrate will drawn the water from the paint film and it
build up like dome shape in the surface of paint film this is called Osmotic
blisters
21 What is an ion?
a. Ion is a charged particle it can be positive or negative
22 What is meant by polarisation?
It is charging of atom by less or gain of electrons
23 Is an anode positive or negative?
a. Positive
24 Can corrosion occur without an electrolyte?
a. No
25 Name a sub atomic particle.
a. Proton, electron
26 What is mill scale and when and where does it occur?
a. Top coat of the steel surface from the mill, it will formed from mill at a
temperature of 580 Deg above it will act as a cathode
27 Name three factors, which can accelerate corrosion reactions.
a. Temperature, hygroscopic salts, aerobic condition, Bi metallic principle,
Metal eating bacteria
28 Why is it considered essential to remove millscale prior to painting?
a. It is a cathodic production of steel, it will have the adhesion failure of paint
to parent metal,
b. we need to remove the mill scale for surface profile
29 Why does an un-coated steel plate corrode?
 a. Anode, cathode and electrolyte are connected in a circuit this will accelerate
corrosion
30 If corrosion occurs at anodic areas, why does steel corrode evenly all over the
surface?
a. Electrons are moving from cathode to anode and entering electrolyte
31 Which British standard would be used in determining the size of copper slag
abrasive?
a. BS 7079
32 Which British standard would be used in determining the size of metallic abrasives?
a. BS 7079
33 Which regulations prohibit the use of sand for blasting steel?
a. COSHH
34 What is meant by the term ‘key’?
a. Cross section of the blasted profile
35 Why is it important to have good surface preparation?
a. To improve the paint adhesion to substrate and to get long life paint
protection
36 What is meant by the term sliver?
a. Longitudinal crack is called silver or lamination
37 What is a hackle?
a. A small uplifted profile is called hackle maximum 13mm
38 Name two other terms that could be used for ‘anchor pattern’?
a. Amplitude, anchor pattern, profile,
39 What are the main advantages of using ‘Testex papers’ for measuring profiles?
a. Permanent records
40 What is meant by the term grade, relating to a blast finish?
a. Degree of cleanliness
41 What are the main factors governing the grade of a blast finish?
a. Speed and velocity of the abrasive, time spent on blasting
42 Can the grade of a blast finish be determined by using the surface comparators to BS
7079 Pt C3?
a. No
43 What profile range can be measured using X coarse Testex?
a. 37-115 um
44 What profile range can be measured using coarse grade Testex?
 a. 25-50um
45 What are the two theories of adhesion?
a. Molecular interference, molecular attraction
46 Briefly describe the mechanisms of the two theories of adhesion.
a. Molecular interference – physical bond
b. Molecular attraction - chemical bond, negative particles will attract positive
47 How many microns are in 1thou?
a. 25.4um
48 Give three different names for the cross section of a blast.
a. Amplitude, key, anchor pattern, profile, peak and though
49 What is the approximate speed of abrasives leaving a venturi nozzle?
a. 450 mph
50 What is the most common cause of flash rusting on a blasted substrate?
a. Rouge peaks
51 What would be considered to be an ideal shot grit mix?
a. 70-80 shot, 20-30 grit
52 What is the purpose of mixing shot and grit?
a. To get uniform profile, the grit will cut the profile and shot will control the
peaks
53 Which abrasive would have the effect of work hardening a substrate?
a. Shot
54 Name three methods of measuring or assessing a profile.
a. Visual eye, 7 X magnification, tactile
55 What is the most common cause of rogue peaks on a substrate?
a. Flash rust
56 In what situation would it be better to use steel grit in preference to copper slag
abrasives?
a. In closed blast operation, usually wheel abrator
57 If cracks or laminations are found on a substrate after blasting what steps should be
taken?
a. Inform to engineer, for UT checks
58 Using comparators to ISO 8503, what are the three main profile assessments?
a. Fine, medium, coarse
59 What are the other two assessments when the above three are not appropriate?
a. Finer then fine, coarser then course
60 What would be size of copper slag needed to give a profile of 50 to 75 um?
a. 75 um
61 What is the title of the BS 7079?
Preparation of steel substrate before application of paints and related products
62 What are the four characteristics of an abrasive?
a. Size, shape, density, hardness
Why are blast hoses carbon impregnated?
b. To avoid static current
63 Name the gauge used for measuring pressure at the blast nozzle?
a. Hypothermic needle gauge
64 Name four advantages of centrifugal blasting over open blasting.
a. Controlled quality, more production, operator safety, efficient use of
abrasive
65 According to BS 7079 is it possible to blast clean to an A Sa1?
a. NO
66 Is there any difference between an A Sa1 and B Sa1?
a. YES
67 Could you tell the difference between rust grades A and B blasted to Sa3?
a. Steel surface fully covered with adherent mill scale little rust if any
b. Steel surface begun to rust and mill scale begun to flake
68 Could you tell the difference between rust grades C and D blasted to Sa3?
a. Steel surface mill scale rusted away, and slight pitting visible under normal
vision
b. Steel surface mill scale rusted away and general pitting visible under normal
vision
69 What would be a typical speed of abrasives leaving a wheel abrator?
a. 220 mph
70 What is considered to be the most efficient blasting pressure?
a. 100 psi
71 What is meant by the term “burnishing”?
 a. Due to power tool cleaning the surface shall be polished and shining this is
called burnishing
72 What would be the equivalent to St2 in the Sa grades?
a. SA1
73 What is the neutral figure on the pH scale?
a. 7
74 How is pH measured?
a. With PH indicating strips
75 Why are inhibitors sometimes added to water in wet blasting?
a. To control the corrosion
76 Name two typical areas where needle guns might be used?
a. Rivet heads, welds
77 What is the Duplex Process of surface preparation?
a. Pickling and Passivation
78 Which pH range covers acids?
0 TO 4
79 Which pH range covers alkalis?
a. 7-14
80 What is the meaning of pH?
a. Potential hydrogen
81 Name three disadvantages of wet blasting.
a. Huge water slurry disposal, operator fatigue, high amount of water
requirement 60 l per minute, No profile achieved
82 Name two areas on a structure where flame cleaning cannot be done.
a. Oil and gas industries
83 Which three basic operations are performed during flame cleaning?
a. Expansion, dehydration, heat penetration
84 How does BS 7079 define Flame Cleaning standards?
a. AF1,BF1,CF1,DF1
85 What is a ‘Jasons Hammer’?
a. Tungsten needle with compressed air operated machine, it will leave coarse
profile , useful for cleaning difficult surface such as rivet heads and welds
86 What is meant by St2 and St3?
 a. Thorough hand and power tool cleaning, very thorough hand and power
tool cleaning
87 Two alloys are used to render wire brushes spark free, what are they?
a. Phosphor bronze, beryllium bronze
88 Why should ‘Burnishing’ be avoided?
a. Paint shall not give good adhesive in Shinny surface, so that the surface shall
be rouge by coarse emery
89 Name two major disadvantages of using a needle gun.
a. It will leave very coarse profile, sharp edged craters and rouge peaks
90 After phosphating, what would be a typical pH requirement prior to coating?
a. 4.5 - 7
91 What is understood by the term ‘knock out pot’?
a. Water vapour separator which is fitted in main air line it will separate the
water vapour from the air
92 If an operator was blasting with a nozzle pressure of 80 psi. What would be his
approximate efficiency?
a. 70 %
93 Which solvents are commonly used for degreasing?
a. Xylene
94 What is a ‘dead mans handle’?
a. Blasting operator handle, for his own safety when he want to operate he
should press the lock
95 Why is carbon impregnated into blast hoses?
a. To avoid the static current shock
96 How is abrasive cleansed in a wheel abrators system?
a. Air wash separator
97 What is the main disadvantage of high pressure jetting compared to other systems?
Operator fatigue, huge water requirement, water slurry disposal, No profile in
surface
a.
98 Name five methods of wet blasting.
a. High pressure water blasting up to 30000 psi,
b. high pressure blasting with abrasive 20000 psi,
 c. low pressure water plus abrasive 100 psi
d. air blasting with water injection
e. steam cleaning
99 What would be the typical temperature and concentration of Sulphuric Acid in the
pickling process?
65-70 deg
100 Describe the ‘Duplex Process’.
a. Clean the oil, grease in surface with xylene, immerse the material in 5-10 %
solution of Sulphuric acid and distilled water in 5 to20 minutes at a temp of
65-70, rinse with warm water, again immerse with 2 % phosphate or chromic
acid with iron filling 0.5 % for 2minitus and then rinse with warm water
check with PH Values
101 What would be a maximum pressure for high pressure water jetting?
a. 30000 psi
102 What are the disadvantages of wet blasting over dry blasting?
a. Huge water requirement, water and slurry disposal, operator fatigue, surface
without profile
103 Describe the phosphating process.
a. Immerse with 2 % phosphate or chromic acid with iron filling 0.2 % for
2minitus and then rinse with warm water check with PH Values
104 What would be considered to be advantages of wet blasting over dry blasting?
a. Spark free, environment friendly, best method to removing toxic coatings,
and idle for removing soluble salts
105 Why is the phosphating or chromating of steel done?
a. Passivation of the steel
106 What would be an acceptable remedy for burnished areas?
a. To abrading coarse emery paper on the surface to make profile
107 Would burnishing be expected on areas of St2 preparation?
a. No
108 How many photographs of blast cleaning standards are shown in BS 7079 Pt A?
a. 14
109 Do the plates shown in Bs 7079 Pt A relate to grit blasting or shot blasting?
a. Grit blast
110 Name a third type of paint other than solvent free and solvent borne.
a. Powder
111 An epoxy resin would use which solvent?
a. Acetone, ketone,
112 Name four or more advantages of Chlorinated Rubber paints.
a. Very good resistance of acid and alkalis condition, toxic free, non flammable
after solvent release, high resistance to mould growth high resistance to
water vapour transmission, high resistance to mould growth
113 What are the three main disadvantages of Chlorinated Rubber paint?
a. Low solvent compatibility, low temperature tolerance, cobwebs
114 Which solvent could be used with a Phenolic Resin?
a. Turpentine, hexane upwards, white sprit, solvent naphtha
115 Chlorinated Rubber paint would contain which solvent?
a. Xylene, toluene, benzene
116 Would it be good practice to apply Chlorinated Rubber over Alkyd resin?
a. No
117 Which solvent would be used with an Alkyd Resin?
a. Turpentine, hexane, solvent naphtha
118 How was the word Alkyd derived?
a. Alcohol
119 What is meant by opaque?
a. Opposite to transparency, hiding power,
120 What is meant by vehicle?
a. Liquid portion of paint, which carry pigments and additives
121 Would it be acceptable practice to apply an Alkyd over Chlorinated Rubber?
a. Yes
122 Would it be acceptable practice to apply Chlorinated Rubber over Phenolic?
No
123 Would it be acceptable practice to apply Phenolic Resin over Chlorinated Rubber?
Yes
124 Would it be acceptable practice to apply Epoxy over linseed oil base?
No
125 Would it be acceptable practice to apply Chlorinated Rubber over Epoxy?
 Yes
126 Would it be acceptable practice to apply Epoxy Resin over Alkyd Resin?
No
127 What is another name for an un-pigmented paint?
a. Dye
128 What are the natural properties of a Resin?
Fast drying & very brittle
129 What are the natural properties of Oil?
Oils having slow drying properties usually mixed with resins to modify the film
properties Drying oil, semi drying oil, non drying oil,
130 How does paint using the barrier principle work?
Barrier forms a thick impermeable layer of a high electrical resistance
131 How does paint using the passivation principle work?
Chemical reaction between paint and the substrate (rust inhibitive primers )
132 How does paint using cathodic protection principle work?
Cathodic protection employs bi-metallic principle by using a less noble metal as
pigmentation, less noble coating self scarifies and protest the surface
133 Give another name for solvent free two packs.
a. MLC Multi Liquid compound
134 Name six properties of a binder.
a. Easy to apply, good adhesion, good abrasive, good water permeability,
bioelectric strength, good resistance with environment
135 Name three natural resins used in paints.
Copals, dammars, coumarones
136 Name five natural oils used in paints
a. Tung oil, linseed oil, palm oil, coconut oil, castor oil, olive oil, soya oil
137 What does oleoresinous mean?
Mixture of oil and resin is called oleoresinous
138 Name an Inorganic high temperature service binder.
a. Ethyl, methyl silicates
139 Name two pigments likely to be used for high temperature service.
Zinc. Aluminium
140 By what name would you call the basic unit of a polymer?
 Monomers
141 What is polymerisation?
a. Joining together of a string or structure of repeated units
142 Name three types of polymers.
a. Linear, branched, cross linked polymerisation,
143 What would be the characteristics of a short oil paint?
a. Oil to resin 45% below, non flexible and brittle nature paint ,faster drying
and suitable for steel works
144 What would be the characteristics of a long oil paint?
a. Oil to resin 60 % above , slow drying properties, suitable for domestic
application and decorative materials
145 What is meant by the term “opaque pigment”?
a. Colouring pigment, inert particles with excellent light scattering properties
in order to give covering power
146 What is a typical size of a pigment particle?
a. 1
/10th micron.
147 Briefly describe the difference between “saturated” and “unsaturated” when
referring to oils or polymers.
a. Saturated oils are non drying oils using in plasticisers, unsaturated oils are
rapid drying oils used in binders
148 Name two drying oils, which are unsaturated.
a. Tung oil, linseed oil
149 What is the main difference between a dye and a pigment?
a. Solid particles are dissolved in binder is called DYE, solid particles are not
dissolved in binder is called pigments
150 What are the sources of pigments?
a. animal, vegetable, minerals, and synthetic
151 If Titanium Dioxide was used in paint, what would be the colour?
a. White
152 Name three rust inhibitive pigments considered to be toxic.
a. Red lead, coal tar, calcium plum bate, zinc chromate
b. Name four commonly occurring minerals used as extender pigments.
c. Slate, chalk, clays, talcum
153 Name three laminar pigments.
 a. Micacious iron oxide, aluminium flake, mica, glass flake, graphite
154 If pigment was added way below the CPVC, how would it affect the film?
a. Low cohesive strength, good gloss, poor opacity, blister
155 The abbreviation CPVC means what?
a. Critical pigment volume concentration
156 Why are thixotropes added to a paint formulation?
a. To aid the shelf life and anti skinning agent
157 If carbon was used as a pigment what would be the paint colour?
a. Black
158 Name four properties that a binder contributes to a paint film.
a. Good resistance of abrasion, good resistance of adhesion, bioelectric
strength, high resistance of water permeability, cohesive,
159 Describe how a basic inhibitor works.
Inhibitors are usually water soluble chemicals it will delay the corrosion by
passivation
160 Which of the common extenders could not be used in whites and pastels?

161 How would the film be affected if pigment was added above the CPVC?

a. Not wet the substrate, porous film, low cohesive strength

162 Which of the rust inhibitive pigments is the most common?

a. Zinc phosphate
163 Why are extenders used in paint formulation?
a. To get adhesion, cohesion, film strength and durability
164 If chromium was used as a pigment, what colour would the paint be?
a. Green yellow and orange
165 Why are plasticisers added to paint?
a. Gives flexibility, and reduce brittleness,
166 Two metals are commonly used as galvanic pigmentation, name them.
a. Zinc, aluminium
167 Why are driers added to oil based paint?
a. To accelerate drying
168 What is meant by the term ‘thixotropic’?
a. Jelly type paint
169 What is meant by the term ‘aggregate’ when referring to paint?
a. Cluster of pigments in binder
170 If an antioxidant was added to paint, what would it do?
a. Anti skinning agents to retard the skin formation on top of the paint surface
171 Give the names of two plasticisers.
a. Coconet oil, palm oil, castor oil
172 What is meant by the term solution?
a. Combination of solute and solvent, it is a resulting liquid
173 Give two examples of a solution.
a. Sugar and water, paint and solvent, salt and water
174 What is meant by the term dispersion?
a. Dispersion can be solid or liquid is surrounded by a liquid, where there is no
solubility
175 There are two types of dispersion, what are they?
a. Suspension, emulsion
176 If paint cures by chemical reaction is it reversible or convertible?
a. Non reversible or convertible
177 What type of polymerisation occurs in chemically curing paint?
a. Cross linked polymerisation
178 Name a paint, which dries solely by solvent evaporation.
a. Acrylic, chlorinated rubber, vinyl, asphalt, coal tar, cellulosic resin
179 What is meant by ‘non convertible’?
a. Non convertible or reversible this type of paints drying only solvent
evaporation, no chemical changes taken place, after curing the paint would
be softened or damaged when it come to contact its own solvent
180 What is meant by ‘non reversible’
a. Non reversible paints undergo chemical changes upon drying after curing
the will not softened or damaged when it come to contact with its own
solvent
181 Name four drying mechanisms.
a. Solvent evaporation, oxidation, chemical curing, coalescence
182 In a coating, which dries by solvent evaporation, what type of polymerisation
occurs?
a. Linear polymerisation
183 What is another term for Fineness of Grind?
 a. Hegman grind gauge
184 Which generic types of paint dry by solvent evaporation followed by oxidation?
a. Natural oils and resins, alkyds, phenolic
185 What type of polymer forms during oxidation?
a. Oxidative cross linking
186 What term applies to paint drying at ambient temperatures?
a. Air drying
187 What is meant by the term ‘co-alescence’?
a. Physically join together
188 What is meant by the term ‘pot life’?
a. The period of time after mixing in which the paint must be used
189 Name three curing agents used in epoxies?
a. Amides,amine, isocyanates
190 Is paint a solution or dispersion, qualify?
a. Both
191 What is an exothermic reaction?
a. Giving heat
192 What is meant by the term ‘induction period’?
a. The length of time paint has to stand after mixing and before application
193 What is the difference between ‘thermoplastic’ and ‘thermosetting’?
a. Thermo plastic material will soften by heat, thermosetting materials will cure
to apply heat
194 With a chemically curing paint, what type of polymerisation occurs?
a. Cross linked polymerisation
195 Two other terms relate to induction period, what are they?
a. Lead time, stand time
196 Does a phenolic resin have an induction period?
Yes
197 Which of the following binders are reversible?
198 Epoxy 201 Urethane 204 Cellulose
199 Phenolic 202 Chlorinated 205 Silicone
200 Vinyl Rubber
203 Alkyd
206 Is an epoxy powder paint thermoplastic or thermosetting
 a. Thermosetting
207 If a coating is permeable, what does it mean?
Degree of moisture penetration
208 What is meant by cross-linking, give two binders as an example.
a. Chemical curing and three dimensional polymerisation process, epoxy,
urethane
209 What is the opposite to exothermic?
a. Endothermic
210 What is the term used for paints needing temperatures in excess of 65oc to cure?
a. Stoving
211 What would be a typical induction period for Chlorinated Rubber paint?
20 – 30 Minutes
212 Name a material used as a dryer in paint formulation.
a. Octoic acid, naphthenic acid
213 Why would bentonite or wax be used in paint formulation?
a. Anti skinning agent
214 Name two materials used as plasticisers.
a. Palm oil, coconut oil, castor oil
215 What generic type of paints would use anti-oxidants
a. Oxidising oils, resins
216 How does a single pack, epoxy ester paint dry?
a. Moisture curing
217 How is Dewpoint defined?
a. This is the temperature at which water vapour in the air will condense
218 How is Relative Humidity defined?
a. The amount of water vapour in the air expressed as a percentage of the
amount of water vapour, which could be in the air at that same temperature
219 When using a whirling hygrometer which bulb should be read first and why?
a. Wet bulb
220 At what speed should the thermometer bulbs pass through the air?
a. 4m/sec
221 What should be used when wetting the wick on whirling hygrometer?
a. Ionised water, or distilled water, rain water
222 By what other name can we refer to a whirling hygrometer?
a. Aspirated hygrometer, psychrometer
223 When the air temperature rises does the air’s capacity to hold water increase or
decrease?
a. Increase
224 What is the stated criterion for acceptance, prior to calculations, on a whirling
hygrometer?
a. Substrate temperature , snow, rain, high winds,
225 Name two pieces of equipment used for taking steel temperature.
a. Magnet thermometer, touch pyrometer
226 Is it possible for a wet bulb temperature to be higher than the dry bulb?
a. No
227 Define viscosity.
a. Liquid Resistance to flow is called viscosity
228 What is meant by high viscosity?
a. Liquid high resistance to flow
229 Approximately, what is the viscosity of water?
a. One centi poises
230 Name the cgs and SI units of dynamic viscosity.
a. Newton second per square meter
231 Name three different flow cups.
a. Ford, ISI,DIN,zhan and Frikmar
232 When using a flow cup which unit of viscosity would be used?
a. SECONDS
233 In ‘Ford Flow Cup No 4’ what does ‘4’ relate to?
a. 4mm hole
234 Give the names of three different rotational viscometers.
a. Paddle, ball, disc
235 Give a reason for performing a viscosity test on site.
a. To know the amount of thinner to be add
236 Which viscometer would not be used on thixotropic paint?
a. Flow cups
237 Why is temperature very important when doing viscosity tests?
 a. Low temperature will lead high viscosity, high temperature low viscosity
238 What is the main difference between the rotathinner and Krebs Stomer?
a. Rotathinner is working driven by electric motor- dynamic viscosity,kerbs
stomer is working falling of weights- kinematic viscosity
239 Describe how to use a Ford Flow Cup.
Place the finger over the nozzle orifice and fill the paint up to brim, scrap the excess
paint in to the overflow rim by using scale Start the stopwatch the same time remove
finger from the orifice the paint run continual stream at first distinctive break or start
drip stop the watch and note down the time
240 Give another name for a Fineness of grind gauge.
a. Heg man grind gauge
241 Is a low flash point safer than a high flash point?
a. No higher flash point is safer
242 How and for what is a Hegman grind gauge used?
The Hegman Grind Gauge is a stainless steel block approximately 17.5cm x 6.5cm x
1.4cm and is highly polished Two grooves are precision ground tapering from 100 um
deep to zero along the total length of the gauge, 10um increment scale is engraved along
the length of the groove Paint is added to the deepest point of the scale and drawn along
to totally fill the groove using a specially profiled scraper bar. Within three seconds the
scale should be placed so that the eye looks almost parallel along the groove, to observe a
point along the groove where, within a 3mm band, five to ten aggregates break through
the surface of the paint.
243 Briefly describe how to do the volatile, non-volatile test to BS 3900 Pt B2.
Weight the clean watch glass and stir rod add 2 gm of paint re weight, place the
watch glass in hot air oven stir the volatile drive away Weight the dry paint with watch
glass and stir rod, Deduct from the initial weight, a simple calculation give us volatile and
Non volatile Ratio
244 Name the equipment used to determine the flash point of a solvent.
a. Closed Abel cup
245 What colour should the flame be at the flash point?
a. BLUE
246 What formula is used to calculate the density?
Weight/volume
247 What formula is used to calculate specific gravity?
Density of the x liquid / Density of the water
248 What is relative density?
Comparing the density of material with the water density
249 What are the other names for a density cup?
Relative density cup, weight per litre cup, weight per gallon cup, specific gravity
cup, pyknometer
250 What is a stoke, the unit for?
Kinematic viscosity, krebs stormer viscometer unit
251 Which test is used to determine Abrasion Resistance?
Taber rotary abraser test
252 Which equipment would be used to determine flexibility?
Conical mandrel
253 Which equipment would be used to measure Impact Resistance?
Koenig albert
254 For what reason would the Koenig Albert Apparatus be used.
To test hard coating
255 For which two reasons could a density cup be used on site?
To find out the thinner adding, to find the density
256 Name four accelerated test boxes.
Humidity cabin, salt spray cabin, water soak, prohesion testing, temperature cycling
257 Why would a tropical box be used?
High humidity environment
258 Would a paint be higher or lower density than water?
Higher
259 How would the density be affected if solvent was added to paint?
Reduce the density
260 What is the capacity of a density cup?
100 cc
261 What difference is there between SG and Density?
No difference
262 What information could be obtained from a water soak test?
Test for water absorption
263 What information could be obtained from a temperature cycling test?
Expansion and contraction cracks
264 What information could be obtained from a cold check test?
Low temperature contraction cracks
265 Name four drying and curing tests.
Ballatoni, BK drying recorder, Mechanical thump test, gold leaf test, hp pencil scratch
test, thumb nail test
266 What stage of the BK test would be recorded as the drying time?
No visible scratch in film
267 Name three methods of determining opacity.
Pfund crypto meter, trough type, black and white fused plates, hiding power chart
and micrometer
268 What affect the opacity of a paint film?
Hiding power, opposite to transparency
269 Why would a Pfund cryptometer be used?
Opacity
270 Give one reason why an inspector would use a PIG gauge?
Destructive gauge, to check DFT in Micacious iron oxide coating
271 Why is wet paint film thicknesses needed?
To find out required DFT
272 Name two methods of measuring WFTs
Eccentric wheel, comp gauge
273 What is the reason for taking WFTs immediately after application?
Because of solvent evaporation, to get correct WFT
274 Where could an inspector find information to determine if a 2 pack paint was mixed
in the correct proportions, using a density cup?
From the data sheet,
275 Can a banana gauge be used on non-ferromagnetic substrate?
NO
276 Could an eddy-current gauge be used on ferromagnetic substrates?
No
277 Can a horseshoe gauge be used on non-ferromagnetic substrates?
NO
278 As part of which test would a bar applicator be used?
Opacity
279 Which instruments would be used to measure reflectivity?
GLOSS METER
280 How does a gloss meter work?
Light reflection
281 Which factors in paint govern the degree of gloss?
Dispersion particle size, PVC, resin type, solvent type
282 In a primer/mid coat what would be the expected degree of grind?
40um
283 In a gloss paint what would be a typical degree of grind?
10um
284 What percent reading would be expected when measuring gloss on a glass panel?
100%
285 Using a gloss meter a reading of 25% would signify what?
Matt finish
286 If an aggregate size of 35 um was present in a paint of 30 um DFT what would be a
likely result when using a gloss meter?
Matt finish
287 Name three common tests for determining adhesion of a paint film?
Dolly test, cross cut test, v cut test
288 Which adhesion tests are quantitative?
Dolly test
289 Inter coat adhesion and primer to substrate adhesion are two adhesion faults name
the third?
Cohesive failure
290 What chemical solution is used to conduct a Cathodic Disbondment test?
Salt solution
291 Which gas evolved at the cathode causes disbondment?
Hydrogen
292 What criterion is used when assessing a Cathodic Disbondment test panel?

293 Name the two methods of applying Cathodic Protection.

 Sacrificial anode system, impressed current system
294 What is used to determine the potential of a pipeline?
Half cell reference electrode
295 Would it be advisable to refill a pipe trench with carbonaceous backfill?
No
296 Does a Cathodic Protection System eliminate corrosion?
It will control, not eliminate
297 Can the external surface of a tank be protected?
No
298 Could a crude oil tank be fully protected internally?
No up to the liquid level
299 What voltage would be used on a 250 um thick paint using a sponge type pinhole
detector?
9v
300 What voltage would be used on a 450 um thick coating with a sponge type pinhole
detector?
90v, or 67v
301 When using a wet sponge, what other liquid is added to the water?
Detergent,
302 What function does the above additive perform?
Immediate penetration to pinhole
303 Would it be advisable to do wet sponge detection on galvanising?
No
304 Why work upwards on a vertical surface with a wet sponge?
To avoid the false indication
305 Does a sponge detector work on AC or DC current?
DC
306 Other than the wet sponge, which other equipment could be used to determine the
presence of pinholes/holidays?
High voltage holiday detector
307 Name two categories of paint mill.
Ball mill, colloid mill, high speed disperser, single, triple roll mill, bead mill
308 What is the main reason for processing paint in a mill?
Grinding or milling the paint
309 Briefly describe how a ball mill works.
Ball mill is a horizontal steel drum approximately 1m dia x 1.5 m long the mill is
filled with 50% of various type of balls having 1” to 1.5”Steel balls for darker colour and
flint for light colour The mill base is added up to cover the balls approximately 50 % of the
drum The hatch is sealed off then starts drum rotating so that the balls cascade down and
do not stick the drum walls due to centrifugal forces Then the shear force applied to the
mill base so that the balls cascade between balls to balls and vessel walls
310 Briefly describe how an attritor mill works.
Attritor mill is vertical version of ball mill more efficient and also static; the paddle drive
the balls, mill base is circulating through pump bottom to top it gives dispersion
311 When would steel balls not be used in a ball mill?
Milling of lighter colours
312 A bead mill is sometimes called by which other names?
Sand mill, pearl mill
313 How does a colloid mill work?
Colloid mill or high speed stone mill using stone grinding discs containing carborundum
having 10” wheel top stone is stationary and the lower stone is rotating fast at 3600Rpm
gravity fed low viscosity slurry fed enter the centre of top of stone and its passed between
two disc due to centrifugal force The dispersion achieved due to extreme turbulence and
shear force
314 Name eight items of information listed on a materials data sheet.
Service temperature, colour, flash point, shelf life, pot life, application method,
recoating interval, specific gravity, curing time
What do you understand from the term Halogenated Hydrocarbon?
Is called degreaser
315 How can we determine the viscosity of high viscosity paint?
Ford cup
316 Briefly describe the principles of CP.
Works on a system of bi metallic corrosion, less noble materials can be used as anode,
this material will corrode first
317 What function does a primer have in a paint system?
Very good adhesion on substrate and provide key to further coats, low volume solid,
318 In a mordant primer what is the main working constituent?
 4% Phosphoric acid 96 % ketone
319 What advantages do electrostatic application methods provide?
Uniform coating, less paint wastage, voltage can control the thickness,
320 Which is the most expensive type of brush filling?

321 What is cohesive failure in paint, give the main cause?

With in the coat failure of cohesion, due to mainly Solvent entrapment, incorrect ratio mix
of a two pack, lack of proper polymerisation
322 Why does a zinc rich paint need a strong binder?
In order to hold high concentration of Zinc particles together
323 Why are etch primers not spray applied?
Because of acid contain
324 What do you understand by the term over spray?
More then required WFT or DFT
325 Name four methods of determining DFTs.
Test panels, calculation, Destructive test, Non destructive test
326 What is a psychrometer used for?
To find wet & dry bulb temperature
327 What colour should a galvanised surface be after application of ‘T’ wash?
Black
328 How soon can a ‘T’ washed substrate be coated?
As soon as dry
329 Other than pigment, base and curing agent name two other constituents of FBE
powder paint.
330 Give the main differences between airless and conventional spray.
Conventional Airless
Slow application due to fluid delivery.
Excellent application rates.

Low air pressure 40 – 75 PSI

Can need 100 PSI to operate the pump.

Delivery pressures greater than 6000 PSI,

Delivery pressure greater than 20 PSI dependant on pump ratio.

Need special paint containers.

Uses manufacturer’s containers.
 Guns can be unwieldy, two lines to
supply the gun. Single line supplies pressurised paint.

331 Brush application has advantages over spray application, what are they?
No spitting, less wastage, dust in substrate will removed while brushing the primer
332 What is the main consideration when selecting a metallic pigment for a sacrificial
paint?
Less noble material
333 What is meant by shererdizing?
After cleaning the components are tumbled in the powdered zinc, impact fuses the zinc
onto the components and in effect, “cold welds” the powder onto the metal.
334 Name three types of paint feed for a conventional spray.
Gravity feed, suction feed, pressure pot
335 What is the calorising process?
Component is dip it into molten aluminium at a temperature of 625oc or also be
done by immersing a component in a mix of fine sand and aluminium powder and
heating
336 Why would a sealer be applied to Aluminium metal spray?
To hold the high concentration of aluminium particles
337 What is the BS 2015 term for skipped or missed areas?
Holidays
338 A colour has three properties, what are they?
Hue, brightness, saturation
339 Why would paint be applied by ‘hot spray’?
When paint is heated it reduces in viscosity (flows easier) and the cure or drying starts
quicker. It is therefore easier to apply and wets out better, and reduces the need for
solvent addition
340 On an airless spray tip how are blockages cleared?
Cleared by turning the tip through 180o
341 How atomisation is achieved using conventional sprays?
When paint and air exit meets paint is atomised in to very minute droplets
342 How atomisation is achieved using airless sprays?
Atomisation occurs by forcing the paint by pressure up to 2000 to 2500 psi and it comes
through the tip
343 What is dip coating?
The component is dipped in to paint and hang to dry
344 What do you understand from the term ropiness?
Brush marking
345 What is efflorescence and how does it occur?
Salt crystal on the substrate shall shown Whitish crystalline formation
346 Name two ways of melting aluminium to enable it to be sprayed.
Electric arc system, wire and pistol system
347 What is flocculation?
Loose cohesive pigments agglomerates on the paint surface
348 What could be the cause of bittiness in a paint film?
Presence of particles of gel flocculated material
349 What is a tie coat?
Used to tie two incompatible systems together, when there are adhesion problem,
350 How many depressions of the bellows are needed for the Dräger test?
2
351 What are the hazard signs for Toxic, Very Toxic, Harmful and corrosive?
Black symbol of skull and crossbones, Black diagonal cross on an orange square,
showing a tilted test-tube dripping onto a hand with a chunk out
352 What is saponification?
The formation of soap by the reaction of a fatty acid ester and an alkali
353 What units are used for measuring toxicity?
PPM
354 Which material would have to be used on a perpetually damp surface?
Moisture curing epoxy, polyurethane
355 What is padding?
Mainly DIY Pads of mohair or foam are used to apply paint
356 What air inlet pressure is needed to give 2500 psi delivery with 35:1 pump?
71.42 psi
357 What causes lifting of a paint film?
As a result of the application of a subsequent coat
358 What is cissing and how is it caused?
Coating material has receded leaving holidays in the film.
359 What is meant by the abbreviations: OES, OEL, MEL, UEL, LEL and RAQ?
OES – Occupational exposure standard, Occupational Exposure Limits, Maximum
exposure limit,
360 Why would a paint inspector use potassium hexacyonoferrate?
Soluble iron salts
361 What would be an average thickness for galvanising?
100 um
362 How can you tell the difference between blooming and chalking?
Blooming - loss of gloss and dulling of colour.
Chalking - Powdery layer on the surface of the film
363 What could be the reasons for inter coat adhesive failure?
Mainly Solvent entrapment
364 How would you determine quality of added thinners in thixotropic paint?

365 Why are manufacturers developing solvent free, water borne and powders?
To avoid the hydrocarbon hazards for human and ozone

366 In less than 30 words, explain the duties of a painting inspector.

General, familiar with specs and procedures, Inspection test plan and safety
regulations Before start work – check Environmental, Relative humidity, steel
temperature, wind condition , plotter paper check, hypothermic needle gauge check,
abrasive check ,paint certificates , induction period , percentage of solvent add,
During painting, wet film thickness,
After painting - DFT, after curing Adhesion test
367 Name five documents, which a painting inspector might need on a contract.
Specification, data sheet of paint, procedure, quality plans, drawings, code BS 7079,
Waste management
368 What information should be given on a daily report sheet?
Painting system, temperature, Type of blast and profile, WFT, DFT
369 Curtains, Sags, Runs and Tears are a result of what?
Excess paint application
370 Some binders can be modified to use water as a solvent, name four.
Acrylic, chlorinated rubber, alkyds, polyurethanes, epoxy
371 What is meant by the term stripe coat?
Brush application of primer shall be done prier to spray in corners, welds, rivets, bolt
nuts etc
372 How many cm3 are there in 4.5 litres?
4500cc
373 A paint data sheet provides a wealth of information, name eight items.
Density, application temperature, pot life, induction period, drying time, solvent
type
374 What is the specified course of action for grit inclusions?
Re prepare the affected area and re apply the completed system
375 The term ‘long term protection’ refers to what?
Protection for 10 years
376 What is the difference between new and weathered galvanising?
New galvanising – cohesive oxide layer not yet formed, weathered galvanising
Cohesive oxide layer formed
377 What criterion determines which paint system should be used?
Cost, application, and temperature,
378 When can ladders and other means of access be removed?
After painting of Gas holder
379 Two materials are specified for used on damp surfaces, what are they?
Moisture curing polyurethanes, high solid multi – component epoxy paints
380 After removal of a non-drying paint, which type of primer is recommended?
White sprit based primer
381 Some non-ferrous substrates are painted for aesthetics only, name four.
Stainless steel, pre painted cladding, Glass reinforced plastics, Fusion bonded epoxy,
Concrete
382 Which three non-ferrous substrates are painted for anti corrosion purposes?
Aluminium, stainless steel, galvanised steel
383 According to PA 10 in which situations would ‘T’ wash be used?
Where sweep blasting and is not possible
384 How many coats of primer are specified on surfaces at 100 – 149oc?
2 coats
385 Give preferential order of coating systems for surfaces 150 – 340oc.
 Mask the surface, remove surface contamination, blast SA3, and apply system
386 Is it mandatory for a contractor to produce a test area?
No
387 List four items needing masking off prior to blasting and painting.
Fire protection equipment, weld end preparations, atmosphere sensing heads,
Spray heads, flame traps, lubrication points, name plates
388 Which Aluminium substrate would not be sweep blasted?
Thin gauge aluminium
389 Which three paint systems are specified for use on Aluminium?
Water-borne acrylic, Epoxy high build, Alkyd or modified alkyd
390 What differences are there in new and maintenance painting specifications for
substrates below 100oc?
New painting – blast clean SA 2.5, clean the surface, apply primer, apply MIO
Maintenance - blast or wire brush where paint to be removed, spot primer and MIO,
Over all or spot area to be paint upper coat and finish coat
391 Toxic coatings need special considerations for removal from substrates, name two
methods which comply.
Wet blast system, enclosed recovery blast system
392 Does PA 10 cover internal coatings on pipes?
No
393 What is the specified overlap on repair areas?
4 inch
394 What would be the specified surface preparation and coating system for Aluminium
cladding?
395 What would be the procedure for removal of algae and mould?
High pressure jetting with abrasive
396 Is it permissible to prepare paint by stirring?
Yes
397 What would be the surface preparation method for new galvanising?
Sweep abrasive blast
398 When would it be necessary to apply a sealer to inorganic zinc silicate?
Operating temperature above 340 Deg
399 How could areas of a paint breakdown be prepared for repainting?
400 What information should be on paint can label for BG?
401 When measuring DFTs over galvanising what allowances are made?
100um
402 What is the first coat applied to galvanised substrates and why?
403 Properties and Performances of paint are covered in which BG specification?
404 What are the considerations when selecting a paint system?
Cost effective method of surface preparation
Cost effective paint system to give required service life
405 According to PA 10 which two coats are applied ‘at works’?

406 Give the criterion for when and when not, painting can take place.
Rain, high wind, fog, snow, RH more than 85%
407 What should be the substrate reaction when ‘T’ wash is applied to a newly
galvanised substrate?
Black
408 Which two materials are specified for use on damp surfaces?
Moisture curing polyurethanes, high solid multi – component epoxy paints
409 What is the maximum time lapse from surface preparation to coating?
4 hours
410 Which is the most common pigment used in high temperature paints?
Zinc
411 What would be the result of over thick application of zinc silicate?
Mud cracking
412 According to PA 10 is roller application permissible?
No
413 Which primers are specified for weathered galvanising?

Water-borne acrylic micaceous iron oxide (65 um minimum)

414 According to PA 10 is flame cleaning allowed?

415 According to PA 10 is thinning of paint allowed?

Yes

416 What temperature range is covered by ‘hot duty service’?

417 When blast cleaning on an AGI what precautions are taken?
418 What would be the procedure for degreasing prior to surface preparation?
419 What would be the procedure for degreasing after to surface preparation?
420 What is the total DFT of the compliant epoxy system?

421 What is the total DFT of the water borne system?

422 What would be the cause of grinning on a paint film?

423 How can ‘bleeding’ be avoided?

424 In which situations is a Permit to Work required?

425 Which primers are specified for non-weathered galvanising?

426

427 WFT calculations

428 What WFT would need to be applied to give a DFT of 45 um using a paint of 56% vs?

429 What WFT would need to be applied to give a DFT of 60 um using a paint of 40% vs?

430 A paint of 38% vs was used to give a DFT of 45 um what wad the WFT?

431 A DFT of 55 um was obtained from a paint of 55% vs, what was the WFT applied?
432 What WFT would be applied to leave a DFT of 65 um using a paint of 49% vs?

433 What would be the DFT if 20 litres of paint, vs. 45% covered an area of 9m x 12m?

434 25 litres of paint, vs. 65% was used to cover a circular area of 10m diameter. What
would be the resulting DFT?

435 What DFT would be obtained if a paint vs content 42% was applied at a WFT of 84
um?

436 What would be the resulting DFT if a WFT of 130 um, what would be the resulting
DFT?

437 A paint, vs 65% was applied at a WFT of 130 um, what would be the resulting DFT?

438 A DFT of 53 um was obtained from a WFT of 110 um, what was the vs% of the paint?
439 A paint was applied at 120 um WFT. The resulting DFT was 65 um, what was the vs
%?

440 What would be the vs% of a paint if it was applied with a WFT of 120 um and a DFT
of 68 um was obtained?

441 What was the vs% of a paint with a DFT of 36 um, when the WFT was 108 um?

442 A DFT of 62 um was measured, from a WFT application of 100 um, what would be
the vs% of the paint used?

443 What volume of paint would be required to cover an area of 300 square metres, to a
specified DFT of 65 um, using a paint of 45% vs?

444 How much paint would be required to coat a tank, roof and side sheets to a DFT of
100 um? The tank is 5 metres diameter and 6 metres high. The paint to be used is
solvent free.

445 How much paint would be needed to cover a circular area of 10 metres diameter,
using a paint 65% vs to a DFT of 60 um?
446 A circular area of 7 metres radius is to be coated to a DFT of 45 um. What volume of
paint would be required if the vs content was 48%?

447 How much paint would be needed, at 55% vs, to coat an area of 250 square metres to
a DFT of 60 um?

448 What would be the weight of 16.5 litres of paint with a SG of 1.45?

449 What is the density of a paint if 7.5 litres weighs 9.75 kg?

450 What would be the relative density of paint in question two?

451 If the weight of 25 litres of paint is 37.5 kg, what would be the SG?
452 A 2 pack epoxy should be mixed at one part base to one part activator, the base has a
density of 1.4gm/cc and the activator 0.9 gm/cc. What would be the density of the
mixed components?

453 A 2 pack paint is mixed at a ratio of six parts pack A (density 1.3gm/cc) to one part
pack B (density 0.9gm/cc). What would be the density of the combined parts?

454 A mixed 2 pack paint has a density of 1.35gm/cc. The density of the base was
1.5gm/cc and the activator 0.9gm/cc. The mixing ratio was 3:1. Has the paint been
mixed correctly?

455 A mixed 2 pack paint has a density of 1.35gm/cc. Mixed at a ratio of 6:1, base
density 1.45gm/cc, activator density 0.95gm/cc. Has the paint been mixed correctly?

456