2020 06 Sherwin Williams AIA CEU PCInspection PM NA

Paint and Coating Inspection
Bruce Snyder, Director – Technical Service
June 10, 2020

AIA
Sherwin-Williams is a registered provider with

the American Institute of Architects continuing
education systems. Credit earned on completion
of this program will be reported to CES records
for AIA members. Certificates of completion
for non-AIA members are available upon request.
This program is registered with the AIA/CES
for continuing professional education. As such,
it does not include content that may be deemed
or construed to be an approval or endorsement
by the AIA of any material or construction or any
method or manner of handling, using, distributing,
or dealing in any material or product. Questions
related to specific materials, methods and
services will be addressed at the conclusion
of this presentation.
© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

Learning Objectives
Define quality control and quality
1 4
Describe testing methods and tools
assurance and the roles of coatings
used in measurement of surface
inspector and manufacturer in the
profile
process
Explain the steps involved in final
2 5
Explain the importance of measuring
inspection including holiday/pinhole
ambient conditions and the tools and
detection, cure testing, gloss
testing methods involved
measurements and adhesion testing
3
Describe the two aspects of surface
preparation – surface cleanliness
and surface profile

Purpose of Inspection
Cross-section of concrete
Help ensure quality surface preparation

and coating application to ensure
compliance with the coating specification

Causes of Coating Failures
• Poor surface preparation

• Inadequate mixing and thinning
• Inadequate coating application
• Unfavorable environmental conditions
• Incorrect selection of coating
• Manufacturing issue with coating

Prerequisites to Performing QA/QC
• Knowledge of industry standards

• Knowledge of inspection standards
• Familiarity with project specification
• Knowledge of coatings application
• Communication skills
• Good common sense

Quality Control and Quality Assurance
• Quality Control (QC) is observation and test intended

to ensure that requirements are actually being met.
The contractor should be responsible for this testing
and documentation.
• Quality Assurance (QA) is the plan that guides QC
and gives confidence that requirements will be met.
QA provides the program for owner oversight.
• QA and/or QC may be delegated to an
engineering firm or third party inspector

Inspector Documentation
• Ambient Conditions
• Surface Preparation
• Product & Batch #s
• Coating Mixing & Thinning
• Application
• Thickness & Cure
Form courtesy of SSPC

Role of Coating Manufacturer
• Not responsible for QC or QA

• Understanding of specification
• Familiarity with inspection procedures
and instrumentation
• Proper material recommendation
• Participation in pre-job conference
• On-site technical support if necessary

Pre-Surface Preparation Inspection
CONDITION OF THE SUBSTRATE:

• Presence of grease, oil, dirt, etc.
• Presence of weld spatter
• Presence of sharpened edges
• Presence of excessive pitting
• Presence of existing protective coatings

Measurement of Ambient Conditions
• Air temperature
• Relative humidity
• Dew point temperature
• Surface temperature
• Verification that conditions meet
the requirements of the coating

INSTRUMENTATION:
• Sling or battery-operated psychrometers
(wet and dry bulb temperatures)
• Psychrometric charts (determination of
relative humidity and the dew point temperature)
• Surface temperature thermometer

RELATIVE HUMIDITY
The amount of moisture in the air,
as a percentage of total saturation
DEW POINT
The temperature at which moisture
in the air condenses on a surface; a surface
temperature at or below the dew point
temperature will result in condensation.
Substrate must be 5⁰F above dew point

Surface Thermometers

• Relative Humidity (RH)

• Air Temperature (Ta)
• Surface Temperature (Ts)
• Dew Point Temp (Td)
• Delta T (∆T) – Difference between Td and Ts
• Specific Humidity (SH)

Moisture in Concrete
DO A TEST TO DETERMINE WHETHER MOISTURE

VAPOR (MVE) COULD BE A POTENTIAL PROBLEM:
• ASTM D4263 — Plastic Sheet Method (Qualitative)
• ASTM F1869 — Calcium Chloride Method (Quantitative)

to determine how much moisture vapor emission
• ASTM F2170 — Standard Test Method for determining

Relative Humidity in concrete floor slabs using in situ
probes (Quantitative)

Testing for Moisture Vapor Emission from Concrete
ASTM F 1869:
Standard Test Method for measuring
moisture vapor emission rate of
concrete using anhydrous calcium
chloride moisture emissions test
Maximum amount allowed:

3 lb. per 1,000 sq. ft. in 24 hours

Humidity Testing
ASTM F-2170

Measuring Moisture in Concrete, Wood, Plaster

Determination of Surface Preparation
TWO-FOLD PURPOSE OF
SURFACE PREPARATION:
• Surface cleanliness
• Surface profile (anchor pattern)

Importance of Surface Preparation
Surface preparation is the most important factor

affecting coating system performance
Surface conditions affecting coating life:

• Presence of oil/grease
• Presence of salts or other chemicals
• Presence of dust/dirt
• Presence of corrosion products

Visual Standards for Surface Cleanliness
• Establish a project-specific surface

cleanliness standard
• Ensure removal of abrasive and
dust from from surface prior to
primer application

Surface Profile
• Measurement of surface roughness

created by power tool cleaning or
abrasive blast cleaning
• Surface profile must be specified
separately from surface cleanliness
• Surface profile should be
approximately 20% - 25% of the total
coating system thickness

Measurement of Surface Profile
ASTM D4417
Method B (depth micrometer)
ELCOMETER MODEL 224

• Digital display prevents reading interpretation errors
• Measure profiles up to 20 mils in a single gauge

Stylus tip reaches into

the bottom of valleys
and records peaks, as
well to provide a more
accurate “picture” of the
entire surface.

ASTM D4417
Method C (replica tape and spring micrometer)
TESTEX PRESS-O-FILM REPLICA TAPE

• Coarse Minus (0.5-1.0 mils)
• Coarse (0.8–2.5 mils)
• X-Coarse (1.5–4.5 mils)
• X-Coarse Plus (4.6–5.0 mils)
Method will pick up surface debris and read

as surface profile. Surface must be clean.


Comparison of the Profile of Concrete
ICRI GUIDELINE
#03732 (310.2)
*Visual profile replicas

CSP 1 through CSP 10

Invisible (Chemical) Ionic Contamination
• Chlorides and sulfates from:

o Highway deicing salts
o By-products in chemical manufacturing
o Bleaching in pulp/paper industry
o Marine/Coastal environment
o Other
• Can cause osmotic blistering and under-film
corrosion to form
• Surface analysis may be required

Measurement of Invisible Surface Contaminants

Witnessing Coating, Mixing and Thinning
• Verify product data and SDS (most current)

• Verify correct coating materials and
thinners on-site (manufacturer, product
numbers, colors, batch dates)
• Verify current shelf life
• Verify correct quantity and ratio of components
(if multi-component coatings are specified)

Witnessing Coating, Mixing and Thinning
• Witness mixing and thinning procedures

• Verify induction or sweat-in (if required)
• Verify complete kits are mixed
• Verify correct type and quantity of thinner addition
• Monitor pot life of mixed materials
• Verify that application equipment meets
coating manufacturer’s requirements

Inspecting the Coating Application
MEASUREMENT OF WET FILM THICKNESS

• Proper use of wet film thickness gauge
• Verification that wet film thickness has been
properly calculated (if using thinner)

Calculating Wet Film Thickness
WFT = DESIRED DRY FILM THICKNESS
% Solids by Volume
Thinner addition reduces volume solids,

so the WFT increases!

Measurement of Dry Coating Thickness
(Non-Destructive)
SSPC-PA2: SSPC METHOD FOR MEASUREMENT

OF DRY PAINT THICKNESS WITH MAGNETIC GAUGES*
• Type 1 (magnetic pull-off gauges)
• Type 2 (constant pressure probe gauges)
o Verification procedures
o Adjustments for profile
o Frequency of measurements
*Use and calibrate in accordance with ASTM D7091…

Non-Destructive Measurement of Dry Film

NIST-Traceable Verification Standards
Verification is required prior to,

during and after each use

Measurement of Dry Coating Thickness using SSPC PA-2
• Frequency of measurements
• Determines dry film allowable deviation
• States procedure for correction
of nonconforming areas
• States method of calibration for
Type I and Type II dry film gauges

Measurement of Dry Coating Thickness (Destructive)
TOOKE GAUGE
• Used to measure total coating thickness and the thickness
of individual layers of coatings in multi-coat films
• ASTM D 4138, Measurement of Dry Film Thickness
of Protective Coating Systems by Destructive Means
• Can be used on multiple substrates

Overcoat / Recoat Limitations
• Verify minimum and maximum recoat times are followed

(see manufacturer’s product data sheets).
• Verify surface is dry, clean and free of foreign matter
before applying subsequent coats.

Final Inspection
• Holiday/Pinhole Detection
• Cure Testing
• Adhesion Testing

Final Inspection
HOLIDAY/PINHOLE DETECTION
• Holiday — skip or miss
• Pinhole — tiny hole which may or
may not be visible to the unaided eye
• Often mandatory for lining systems
• Often performed after next to last
or last coat applied, but before
fully cured

Holiday / Pinhole Detection NACE SP0188
LOW VOLTAGE (WET SPONGE)

• Non-conductive coatings over conductive
substrates
• Up to 20 mils coating thickness
• Use wetting agent in water > 10 mils DFT
(e.g., Kodak Photo-Flo)

Holiday / Pinhole Detection
HIGH VOLTAGE (SPARK TESTING)

• Non-conductive coatings over
conductive substrates
• Over 20 mils coating thickness
• Typically 100 to 125 volts per mil (or
as required by coating manufacturer)
• 40 mil coating = 4,000 – 5,000 volts

Holiday Detection with
Optically Active Pigment (OAP) Technology

SSPC Fluorescent Coating Documentation

Inspect Right Away with OAP

White Light versus Flourescent Inspection

Low Film Build Also Revealed

ASTM E 2501-06

Cure Testing
SOLVENT RUB TEST

(ASTM D5402 OR D4752 (IOZ)
• Saturate cloth (of opposing
color to coating) with solvent
(e.g., MEK)
• Use medium pressure and
count number of “double
rubs”
• Visually assess whether
coating dissolved onto cloth
and compare number of rubs
to specification requirements

Adhesion Testing
ASTM D 4541
(tensile adhesion)
ASTM D 3359
(shear [tape/knife] adhesion)
ASTM D 6677
(adhesion by knife only)
NOT common on new paint jobs

Adhesion Testing
ASTM D 3359 (shear [tape/knife] adhesion)

• Method A, “X-Cut”
o Use for coatings greater than 5 mils
o Rate result according to description standard
• Method B, “Cross-Cut”
o 0–2 mils = 1mm spacing between cuts
o 2–5 mils = 2mm spacing between cuts
o Rate result according to adhesion chart in standard

Shear Adhesion Test Kits

Adhesion Testing
ASTM D 4541 (tensile adhesion)

• Mechanical, pneumatic or hydraulic testers
• Attach pull stub to surface using epoxy adhesive
• Tensile force required to detach pull stub
is measured in psi
• Location of detachment
o Adhesion break
o Cohesion break
o Glue failure

Test for Galvanized Steel

pH

Summary
Define quality control and quality assurance and the roles of

coatings inspector and manufacturer in the process
Explain the importance of measuring ambient conditions and
the tools and testing methods involved
Describe the two aspects of surface preparation – surface
cleanliness and surface profile
Describe testing methods and tools used in measurement of
surface profile and coating application
Explain the steps involved in final inspection including
holiday/pinhole detection, cure testing and adhesion

Thank You
Bruce Snyder
bksnyder@sherwin.com
For PDH credits contact:
swcoatingswebinars@sherwin.com
For more information on upcoming webinars visit:

sherwin-williams.com/protective

2020 06 Sherwin Williams AIA CEU PCInspection PM NA

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Paint and Coating Inspection

Bruce Snyder, Director – Technical Service

June 10, 2020

Sherwin-Williams is a registered provider with

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

Define quality control and quality

Explain the steps involved in final

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

Help ensure quality surface preparation

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

• Poor surface preparation

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

• Knowledge of industry standards

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

• Quality Control (QC) is observation and test intended

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

Form courtesy of SSPC

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

• Not responsible for QC or QA

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

CONDITION OF THE SUBSTRATE:

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

• Relative Humidity (RH)

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

DO A TEST TO DETERMINE WHETHER MOISTURE

• ASTM D4263 — Plastic Sheet Method (Qualitative)

• ASTM F1869 — Calcium Chloride Method (Quantitative)

• ASTM F2170 — Standard Test Method for determining

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

Maximum amount allowed:

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

Surface preparation is the most important factor

Surface conditions affecting coating life:

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

• Establish a project-specific surface

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

• Measurement of surface roughness

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

ELCOMETER MODEL 224

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

Stylus tip reaches into

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

TESTEX PRESS-O-FILM REPLICA TAPE

Method will pick up surface debris and read

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

*Visual profile replicas

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

• Chlorides and sulfates from:

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

• Verify product data and SDS (most current)

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

• Witness mixing and thinning procedures

© 2020 The Sherwin-Williams Company sherwin-williams.com/protective

MEASUREMENT OF WET FILM THICKNESS