CORROSION OP : MONDAY

1) DIRECT CURRENT
2) CORROSION OCCURS ONLY AT THE ANODE.
3) ANODE---THAT PART OF A METAL THAT CORRODES; THE ELECTRODE AT WHICH CORROSION (OXIDATION ) OCCURS; A POSITIVELY CHARGED AREA, IT
BECOMES POSITIVELY CHARGED BECAUSE THE ATOM RELEASES 2 ELECTRONS EACH THUS CAUSING AN IMBALANCE BETWEEN PROTONS & ELECTRONS.
CATHODE---THE LESS ACTIVE AREA ON THE ELECTRODE; A NEGATIVELY CHARGED AREA WHERE THERE ARE MORE ELECTRONS NEEDED IN ITS PASSIVE STATE,
THESE ARE ELECTRONS RELEASED AT THE ANODE. AT THE CATHODE, THE ELECTRONS ENTER INTO THE ELECTROLYTE TO PASS BACK TO THE ANODE.
ELECTROLYTE---IS A SUBSTANCE WHICH WILL CONDUCT A CURRENT & BE BROKEN DOWN BY IT (DISSOCIATE INTO IONS). WATER AS THE MOST
ABUNDANT & VERY EFFICIENT ELECTROLYTE.
4) ELECTROLYTE---IS A SUBSTANCE WHICH WILL CONDUCT A CURRENT & BE BROKEN DOWN BY IT
(DISSOCIATE INTO IONS). WATER AS THE MOST ABUNDANT & VERY EFFICIENT ELECTROLYTE.
ELECTROLYTE---IS ANY SOLUTION CAPABLE OF CONDUCTING ELECTRICITY (SEA WATER, HARD WATER & EVEN
MOISTURE ON THE STEEL SUBSTRATE)
5) CORROSION IS GENERALLY DEFINED AS DEGRADATION OF A METAL BY CHEMICAL OR ELECTRO-CHEMICAL MEANS. FROM THIS DEFINITION,
2 MECHANISMS ARE INVOLVED, FIRSTLY AN ELECTRICAL CIRCUIT & SECONDLY A CHEMICAL REACTION.
CORROSION---DETERIORATION OF A MATERIAL USUALLY A METAL BECAUSE OF A REACTION WITH ITS ENVIRONMENT.
6) ELECTRONS FLOW FROM ANODE TO CATHODE IN THE CORROSION CIRCUIT.
7) HYDROGEN GAS IS RELEASED AT THE CATHODE WHEN THE ELECTROLYTE IS WATER.
8) STEEL IS THE MORE NOBLE METAL.
9) ALUMINIUM IS MORE ELECTRONEGATIVE.
10) STEEL WILL CORRODE & NOT THE COPPER
11) 2 MOST COMMON HYGROSCOPIC SALTS:
--- CHLORIDES (PREDOMINANT IN MARINE ENVIRONMENT)
--- SULPHATES (INDUSTRIAL & SOMETIMES IN AGRICULTURAL AREAS)
12) ALUMINIUM ALLOYS, ZINC & MAGNESIUM
13) 25 TO 100 um IS THE THICKNESS OF MILLSCALE.
14) ZINC WILL CORRODE & NOT THE STEEL.
15) ELECTRO-MOTIVE FORCES SERIES & ELECTRO-CHEMICAL SERIES ARE OTHER NAMES FOR GALVANIC LIST.
16) IN A MARINE ENVIRONMENT---CHLORIDE SALTS
17) WUSTITE, MAGNETITE & HAEMATITE.
18) MAGNESIUM WILL CORRODE & NOT THE ZINC.
19) INDUSTRIAL & AGRICULTURAL AREAS---SULPHATE SALTS
20) OSMOTIC BLISTER---ALSO KNOWN AS HYGROSCOPIC BLISTER IS DEFINED AS PINHEAD SIZED WATER FILLED BLISTERS. (SULPHATES & CHLORIDES)
21) ION---IS A CHARGED PARTICLE, WHICH MAYBE AN ATOM OR GROUP OF ATOMS & CAN BE (+) OR (-) CHARGED.
22) POLARISATION---THE PHENOMENON IN W/C WAVES OF LIGHT OR OTHER ELECTROMAGNETIC RADIATION ARE RESTRICTED IN DIRECTION OF VIBRATION.
POLARIZATION---INDUCTION OF POLARITY IN A FERROMAGNETIC SUBSTANCE.
23) ANODE IS POSITIVELY CHARGED.
24) CORROSION CANNOT OCCUR WITHOUT AN ELECTROLYTE, ANODE & CATHODE. IF ANY OF THESE THREE IS MISSING, THEN CORROSION CANNOT OCCUR.
25) PROTON, NEUTRON & ELECTRON ARE SUB-ATOMIC PARTICLES.
26) MILLSCALE---PROMOTES CORROSION AT THE ANODIC BARE STEEL AREAS & THEY ARE FORMED DURING THE ROLLING OPERATION OF STEEL SECTIONS
WHEREIN WHICH OXIDES ARE COMPRESSED THUS PRODUCING MILLSCALE.
MILLSCALE---A THIN, BLUISH BLACK, FLAKY, OXIDE LAYER FORMED ON STEEL BY HOT ROLLING AT TEMPERATURES IN EXCESS OF 580 °C.
 1
27) 6 FACTORS WHICH ACCELERATES CORROSION:
a. TEMPERATURE
b. HYGROSCOPIC SALTS (SULPHATES & CHLORIDES)
c. AEROBIC CONDITIONS (PRESENCE OF OXYGEN)
d. PRESENCE OF METAL SURFACE BACTERIA LIKE SRB (SULPHUR REDUCING BACTERIA) & MEM (METAL EATING MICROBES)
e. ACIDS & ALKALIS
f. BI-METALLIC CORROSION
28) MILLSCALE WHICH IS ELECTRICALLY POSITIVE RELATIVE TO THE IRON OR STEEL, SO IT IS CATHODIC TO THE PARENT METAL AND MILLSCALES PROMOTES
CORROSION AT THE ANODIC BARE STEEL AREAS AND THIS IS THE REASON WHY IT IS VERY IMPORTANT TO REMOVE MILLSCALE FROM STEEL SURFACES
PRIOR TO COATING.
29) UNCOATED STEEL PLATE WILL CORRODE BECAUSE IT IS EXPOSED TO ELECTROLYTE.
30) ALLOYING ELEMENTS ARE UNIFORMLY SPREADED SO CORROSION OCCURS EVENLY ALL OVER THE SURFACE.

CORROSION: NOTES

CORROSION---GENERALLY DEFINED AS DEGRADATION OF A METAL BY CHEMICAL OR ELECTRO-MECHANICAL MEANS. FROM THIS DEFINITION,
2 MECHANISMS ARE INVOLVED, FIRSTLY AN ELECTRICAL CIRCUIT & SECONDLY A CHEMICAL REACTION.
CORROSION---DETERIORATION OF A MATERIAL USUALLY A METAL BECAUSE OF A REACTION WITH ITS ENVIRONMENT.
ADHESION---THE FORCE REQUIRED TO SEPARATE 2 SURFACES IN TOUCH; THE MECHANICAL BONDING OF THE PAINT TO THE SURFACE;
--- THE ATTRACTION OF A COATING TO THE SUBSTRATE.
PASSIVATION---THE OXIDE LAYER ALTHOUGH FAIRLY THIN CAN FORM A PROTECTIVE BARRIER AGAINST CONTINUED ATTACK &SLOW DOWN THE RATE
OF CORROSION ALMOST TO A STANDSTILL; ACT OF MAKING INERT OR UNREACTIVE.

FACTORS CONTRIBUTING TO CORROSION: T H A P A B

1) TEMPERATURE
2) HYGROSCOPIC SALTS (CHLORIDES & SULPHATES)
3) AEROBIC CONDITIONS (PRESENCE OF OXYGEN)
4) PRESENCE OF SOME TYPES OF BACTERIA ON THE METAL SURFACE (FOR EXAMPLE SRB: SULPHUR REDUCING BACTERIA, MEM: METAL EATING MICROBES)
5) ACIDS & ALKALIS
6) BI-METALLIC CORROSION (BI-METALLIC CONTACT)

IRON OXIDES---(FeO) OXIDES OF IRON WHICH WAS FORMED VERY QUICKLY AT TEMPERATURES IN EXCESS OF 580°C
OXIDES COMMON NAMES:
1) WUSTITES
2) MAGNETITE
3) HAEMATITE
ADHESION---THE FORCE REQUIRED TO SEPARATE 2 SURFACES IN TOUCH; THE MECHANICAL BONDING OF THE PAINT TO THE SURFACE;
THE ATTRACTION OF A COATING TO THE SUBSTRATE.
PASSIVATION---THE OXIDE LAYER ALTHOUGH FAIRLY THIN CAN FORM A PROTECTIVE BARRIER AGAINST CONTINUED ATTACK & SLOW DOWN THE RATE
OF CORROSION ALMOST TO A STANDSTILL; ACT OF MAKING INERT OR UNREACTIVE.
NOBLE METAL---IS A METAL WHICH WILL NOT CORRODE.
 2

GALVANIC LIST: NOBILITY OF METALS

MATERIAL (GTSNLAC, TMLMAZM) KNOWN PROPERTIES (AVERAGE VALUES)
GRAPHITE + 0.25V
TITANIUM 0.0
SILVER - 0.10V
NICKEL 200 - 0.15V
LEAD - 0.20V
ADMIRALTY BRASS - 0.30V
COPPER - 0.35V
TIN - 0.35V
MILLSCALE - 0.40V
LOW ALLOY STEEL - 0.70V
MILD STEEL - 0.70V
ALUMINIUM ALLOY - 0.90V
ZINC - 1.00V
MAGNESIUM - 1.60V
3
SURFACE PREPARATION: MONDAY
1) BS 410: USED IN DETERMINING THE SIZE OF COPPER SLAG ABRASIVE
2) BS 410: USED IN DETERMINING THE SIZE OF METALLIC ABRASIVES.
3) COSHH REGULATIONS PROHIBIT THE USE OF SAND FOR BLASTING STEEL.
4) KEY---AN EXPRESSION MEANING THE CROSS SECTION OF A BLASTED AREA AS MEASURED FROM THE TOP OF THE PEAKS TO THE TOP OF THE
TROUGHS.
5) IMPORTANCE OF SURFACE PREPARATION:
a. REMOVES SURFACE CONTAMINANTS
b. IMPROVES ADHESION
c. PROVIDES LONGER LIFE.
6) SLIVERS (LAMINATION)---APPEARS TO BE A LONGITUDINAL CRACK, ONE LIP CURLING BACK & SHOULD BE REFERRED TO ENGINEER FOR
ULTRASONIC CHECK.
7) HACKLE---A SMALL SURFACE LAMINATION W/C STANDS UPRIGHT LIKE A NEEDLE AFTER BLASTING. SIZE @ 13mm
8) SURFACE PROFILE, ANCHOR PATTERN, KEY, PEAK TO TROUGH HEIGHT & AMPLITUDE.
9) TESTEX PROVIDES A PERMANENT RECORD & THE TRACEABILITY REQUIRED FROM QUALITY SYSTEMS. ALSO CALLED "REPLICA TAPE" OR
"CORN PLASTER METHOD".
10) GRADE---RELATES AS TO HOW MUCH CONTAMINANT IS LEFT ON THE SURFACE AFTER PREPARATION.
11) THE TIME SPENT ON THE AREA & THE VELOCITY OF THE PARTICLES.
12) YES
13) "X" COARSE TESTEX @ 37-115ùm OR 1.5-4.5 THOU INCH
14) COARSE TESTEX @ 20-50ùm OR 0.8-2 THOU INCH
15) MOLECULAR INTERFERENCE & MOLECULAR ATTRACTION
16) a. MOLECULAR INTERFERENCE---BECAUSE THE SURFACE IS ROUGH & UNEVEN, THE PAINT WETS & LOCKS INTO THE
PROFILE, ANALOGY VELCRO (PHYSICAL)
b. MOLECULAR ATTRACTION---NEGATIVELY CHARGED PARTICLES ATTRACTED TO POSITIVE AREAS & VICE VERSA
ANALOGY MAGNET (SOMETIMES CALLED IONIC BONDING.) CHEMICAL
17) 1 THOU= 25.4ùm
18) SURFACE PROFILE, ANCHOR PATTERN, KEY, PEAK TO TROUGH HEIGHT & AMPLITUDE.
19) 450 mph
20) ROGUE PEAK---THE MOST COMMON CAUSE OF FLASH RUSTING ON A BLASTED SUBSTRATE.
21) TYPICAL MIXING RATIO OF SHOT TO GRIT: 70-80% SHOT TO 20-30% GRIT
22) A MIX OF SHOT & GRIT RESULTS IN A MORE UNIFORM PROFILE.THE GRIT CUTS THE PROFILE WHILE THE SHOT CONTROLS THE PEAK
HEIGHT THUSREDUCING THE NUMBER OF ROGUE PEAKS.
23) METALLIC SHOT HAS THE EFFECT OF WORK HARDENING THE SUBSTRATE.
24) METHODS OF MEASURING / ASSESSING A PROFILE:
a. NAKED EYE
b. VISUAL AID, NOT EXCEEDING 7x MAGNIFICATION
c. TACTILE
25) BLASTING IN ONE AREA FOR A LONG TIME WHICH CAUSES CONTRACTION OF THE PAINT---MOST COMMON CAUSE OF ROGUE PEAKS.
26) WHEN RECYCLING:
STEEL GRIT CHIPS OFF SMALL SLIVERS ON IMPACT TO PRODUCE SHARP CUTTING SURFACES AND CAN BE RE-USED MANY TIMES
WHEREAS FOR COPPER SLAG ABRASIVES, THEY ARE VERY BRITTLE & SHATTERS INTO SMALL PIECES ON IMPACT & ARE USED ONLY ONCE.
27) REFER TO ENGINEER FOR ULTRASONIC CHECK.
28) 3 MAIN PROFILE ASSESSMENTS:
a. FINE---PROFILES EQUAL TO SEGMENT ONE & UP TO, BUT EXCLUDING SEGMENT TWO.
b. MEDIUM---PROFILES EQUAL TO SEGMENT TWO & UP TO, BUT EXCLUDING SEGMENT THREE.
c. COARSE---PROFILES EQUAL TO SEGMENT THREE & UP TO, BUT EXCLUDING SEGMENT FOUR.
29) FINER THAN FINE & COARSER THAN COARSE.

30) G16 ALSO CALLED "SUPA" 1

SURFACE PREPARATION: NOTES

2 FACTORS IN SURFACE PREPARATION:
1) DEGREE OF CLEANLINESS
2) DEGREE OF ROUGHNESS (SURFACE PROFILE)

SURFACE PREPARATION: D W H F P V W
1) DRY ABRASIVE BLAST CLEANING
2) WATER BLASTING
3) HAND & POWER TOOL CLEANING
4) FLAME CLEANING
5) PICKLING
6) VAPOUR DEGREASING
7) WEATHERING

ABRASIVES (DRY BLAST CLEANING): S C G M M M

1) SAND
2) COPPER SLAG
3) GARNET
4) METALLIC GRIT
5) METALLIC SHOT
6) METALLIC GRIT & SHOT MIXED

SIZING OF ABRASIVES:
1) G-PREFIX---GRIT (AMORPHOUS POINTS & CUTTING EDGES, IRREGULAR PROFILE)
2) S-PREFIX---SHOT (SPHERICAL, SMOOTHER PROFILE)

DIAL GAUGES:
1) SURFACE PROFILE NEEDLE GAUGE (NOT SUITED FOR CURVED AREAS SUCH AS PIPES)
2) DIAL MICROMETER & REPLICA TAPE

PROFILE MEASUREMENT:
1) MEASURING USING GAUGES WITH & WITHOUT REPLICA TAPE
2) ASSESING USING SURFACE COMPARATORS. (COMPARATORS ARE NOT FOR ASSESSING CLEANLINESS)

METRIC MICROMETER FOR TESTEX MEASUREMENT IN MICRONS: IMPERIAL MICROMETER FOR TESTEX MEASUREMENT IN 1000 OF AN INCH:
1 mm = 1000 um 0.01 mm = 10 um / SMALL DIVISION
25.4 um = 0.001inch (1 thou) 0.002 mm = 2 um / SMALL DIVISION
40 thou inch = 1 mm 0.001 inch = 1 thou / SMALL DIVISION
25.4 mm = 1 inch 0.0001 inch = 1/10 thou / SMALL DIVISION
example: MICROMETER READS 80 um example: MICROMETER READS 4.6 thou
80 um or 0.080mm 4.6 thou or 0.0046 inch
--- 50 um or 0.050mm (TESTEX PLASTIC BACKING) --- 2.0 thou or 0.002 inch (TESTEX PLASTIC BACKING)
30 um or 0.030mm (SURFACE AMPLITUDE) 2.6 thou or 0.0026 inch (SURFACE AMPLITUDE)
 2

WHEELABRATORS---ALSO KNOWN AS CENTRIFUGAL BLAST UNITS, A MECHANISED WAY OF PREPARING COMPONENTS FOR COATING. THEY ARE IDEAL FOR
LONG PRODUCTION RUNS ON SIMILAR SECTION COMPONENTS SUCH AS PIPES IN A PIPE COATING MILL OR BRIDGE STEEL WORK.

FOOTNERS TYPICAL PROCESS: O T R I R

1) OIL & GREASE REMOVAL BY XYLENE (SOLVENT)
2) TOTAL IMMERSION IN A BATH OF SULPHURIC ACID @ 5-10% CONCENTRATION AT A TEMPERATURE OF 65-70 DEGREE CELSIUS FOR 5-25 MINUTES.
3) RINSE IN CLEAN WARM WATER TO REMOVE LAYERS OF SOLUBLE SALTS. IT CAN ONLY BE CALLED FOOTNERS WHEN PICKLED THEN PHOSPHATED /
CHROMATED.
4) IMMERSE IN A BATH OF PHOSPHORIC ACID @ 2% SOLUTION @ 80 DEGREES CELSIUS FOR 2 MINUTES WITH IRON FILING @ 0.5% & AN INHIBITOR
TO PREVENT EMBRITTLEMENT. THUS LEAVING A VERY THIN LAYER OF IRON PHOSPHATE/ CHROMATE WHICH ACTS AS A RUST PREVENTOR FOR A LIMITED TIME.
5) RINSE IN CLEAN WATER & CHECK Ph VALUES.

OPEN BLASTING SYSTEMS OPERATE USING: C P V H N D

1) COMPRESSOR
2) POT CONTAINING THE ABRASIVES
3) VAPOR TRAPS FOR OIL & WATER (KNOCK-OUT POTS)
4) HOSE (USUALLY CARBON IMPREGNATED)
5) NOZZLE
6) DEAD MANS HANDLE FOR OPERATOR SAFETY.

COMPRESSORS ARE RATED BY 2 FACTORS:

1) AIR PRESSURE (MEASURED IN psi)
2) CAPACITY---THE AMOUNT OF AIR IT CAN DELIVER AT THE PRESSURE REQUIRED (FT3/MIN) CFM OR (L/S) LITERS PER SECOND.

SAFETY DURING ABRASIVE BLASTING: H D H R E M C

1) THE HOSE SHOULD BE CARBON IMPREGNATED TO REDUCE THE CHANCE OF THE OPERATOR GETTING ELECTRIC SHOCK FROM STATIC.
2) A DEAD MANS HANDLE SHOULD BE UNDER DIRECT OPERATOR CONTROL FOR HIS OWN SAFETY.
3) HOSES SHOULD BE KEPT AS STRAIGHT & AS SHORT AS POSSIBLE TO AVOID KINKS & BLOW OUTS AND TO MAINTAIN PRESSURE AT THE NOZZLE.
4) USE REINFORCED HOSES AS POSSIBLE
5) USE EXTERNAL BAYONET TYPE COUPLINGS, CONTINUALLY BONDED.
6) MAINTAIN OPERATING PRESSURE AT 100psi
7) CORRECT POSITIVE CLOTHING SHOULD BE WORN BY THE OPERATOR INCLUDING DIRECT AIR FED HELMET WITH ADEQUATE VISORS, LEATHER APRONS &
GLOVES, BOOTS & EAR PROTECTORS.

WATER BLASTING: (2)

---THIS SURFACE PREPARATION METHOD IS MORE ENVIRONMENTALLY FRIENDLY THAN OPEN BLASTING, THIS IS ALSO SPARK FREE. THEY ARE IDEAL FOR
REMOVAL OF SOLUBLE SALTS (SULPHATES, CHLORIDES), LAYERS OF TOXIC MATERIALS LIKE CALCIUM PLUMBATE, RED LEAD & ZINC CHROMATE PRIMERS.
TYPES OF WATER BLASTING:
1) HIGH PRESSURE WATER BLASTING UP TO 30,000psi (WATER JETTING) 60 L/MIN
2) HIGH PRESSURE WATER PLUS ABRASIVE INJECTION---@ 20,000psi OFTEN USED IN DRY DOCKS ON SHIP HULLS TO REMOVE MARINE GROWTH LIKE
BARNACLES.
3) LOW WATER PRESSURE PLUS ABRASIVE INJECTION---@ 100psi WITH WATER AS PROPELLANT RATHER THAN AIR. Ex. SODIUM BICARBONATE CRYSTALS
 WHICH IS EXCELLENT FOR ACIDIC OR GREASY SITUATIONS.
4) AIR BLASTING WITH WATER INJECTION---WATER IS INJECTED WITH OR WITHOUT AN INHIBITOR INTO THE AIR ABRASIVE STREAM, EITHER IMMEDIATELY
AFTER IT EXITS THE NOZZLE OR IMMEDIATELY BEFORE IT ENTERS THE NOZZLE.
5) STEAM CLEANING---IDEAL FOR OILY & GREASY SITUATIONS.

3
HAND & POWER TOOLS CLEANING: (3) N W E G J
---ANY HAND OPERATED OR POWER TOOLS INCLUDING NEEDLE GUNS, WIRE BRUSHES, EMERY CLOTH & GRINDERS TO ACHIEVE THESE STANDARDS.

FLAME CLEANING: (4)

---NOT LIKELY TO BE USED ON OIL & GAS PLANTS BUT IT IS AN APPROVED METHOD OF SURFACE PREPARATION.

PICKLING: (5)
---IS A GENERAL TERM RELATING TO THE CHEMICAL REMOVAL OF OXIDES (RUST) FROM A METAL SUBSTRATE. THE METALS CAN EITHER BE DIPPED
(TOTALLY IMMERSED)IN THE PICKLING FLUID OR SPRAYED WITH IT.

VAPOUR DEGREASING: (6)

---FUMES FROM A SOLVENT BATH CONDENSED ON A COMPONENT SUSPENDED OVER THE BATH & DISSOLVE ANY OIL OR GREASE WHICH THEN DRIPS BACK
INTO THE BATH.

WEATHERING: (7)
---WEATHERING RELIES ON CO-EFFICIENT OF EXPANSION PROPERTIES AS MENTIONED IN FLAME CLEANING. WHEN LEFT IN A STOCK YARD, OPEN TO
TEMPERATURE CHANGES, DAY & NIGHT THE MILLSCALE SHEDS. THIS CAN NOW LEAVE THE STEEL OPEN TO ATMOSPHERIC CORROSION WHICH PRODUCES
SULPHATE SALTS.

PROCEDURES FOR USING REPLICA TAPE: Z R R R

1) ZERO THE DIAL MICROMETER,
2) REMOVE THE BACKING PAPER FROM THE REPLICA TAPE ALONG WITH THE SMALL WHITE DISC & STICK THE REPLICA TAPE TO THE AREA TO BE MEASURED.
3) USING A PEN OR PENCIL END, RUB FIRMLY & EVENLY ALL OVER THE AREA OF THE MYLAR, IT WILL THEN TURN TO GREY, READY FOR THE READING.
4) REMOVE THE REPLICA TAPE, & PLACE THE AREA THAT WAS TESTED BETWEEN THE ANVILS OF THE MICROMETER, FROM THE FINAL READING ON THE GAUGE,
DEDUCT 50um IF USING A METRIC GAUGE OR DEDUCT 2THOU INCH IF USING AN IMPERIAL GAUGE. THE BALANCE FIGURE IS THE "PEAK TO THROUGH
HEIGHT OF THE PROFILE"

PRIMARY PROFILE---THE SURFACE OF THE STEEL PRIOR TO ABRASIVE BLASTING.

SECONDARY PROFILE---THE BLASTED SURFACE,
1 PSI DROP IN PRESSURE---EQUALS TO EFFICIENCY DROP OF 1.5%
1/4 INCH NOZZLE---WILL NEED 103 cfm TO MAINTAIN 100 psi OF PRESSURE
1/2 INCH NOZZLE---NEEDS 413 cfm TO MAINTAIN 100 psi OF PRESSURE
SLURRY---WATER + DETRITUS
LINED TO NOZZLE TO REDUCE WEAR:
a. TUNGSTEN CARBIDE
b. CERAMICS
DIRECTLY RELATED TO THE NOZZLE APERTURE SIZE:
a. AIR CONSUMPTION
b. AIR SPEED

HEAT---REDUCES PAINT VISCOSITY & GIVES BETTER FLOW PROPERTIES.

DRY FILM THICKNESS (DFT)---IS THE UPPER LIMIT FOR THE SIZE OF THE AGGLOMERATES W/C IS ACCEPTABLE IN A PAINT.
AGGLOMERATES---CONSISTS OF PRIMARY PARTICLES CEMENTED TOGETHER FORMING SMALL LUMPS.
MECHANICAL DISPERSION---OFTEN CALLED "GRINDING" W/C IS ONE OF THE MOST IMPORTANT PHASES IN PAINT PRODUCTION, THIS IS WHERE THE
AGGLOMERATES HAVE TO BE DIVIDED INTO PRIMARY PARTICLES OR AT LEAST SMALLER PARTICLES.

4
SURFACE PREPARATION: TUESDAY
1) BS 7079: PREPARATION OF STEEL SUBSTRATES BEFORE APPLICATION OF PAINTS & RELATED PRODUCTS.
2) ABRASIVE CHARACTERISTICS: SIZE OF THE PARTICLES, SHAPE OF THE PARTICLE, HARDNESS OF THE MATERIAL & DENSITY OF THE MATERIAL.
3) BLAST HOSES ARE CARBON IMPREGNATED TO REDUCE THE CHANCE OF THE OPERATOR GETTING ELECTRIC SHOCK FROM STATIC.
4) HYPODERMIC NEEDLE GAUGE---GAUGE USED FOR MEASURING PRESSURE AT THE BLAST NOZZLE.
5) ADVANTAGES OF CENTRIFUGAL BLASTING OVER OPEN BLASTING: (C, E, O, P)
--- QUALITY CAN BE CONTROLLED BY ADJUSTING THE SPEED OF THE FEED ROLLER, THEREFORE IT IS MORE
CONSISTENT.
--- EFFICIENT USE OF ABRASIVES (BECAUSE THE SYSTEM IS TOTALLY ENCLOSED)
--- MORE OPERATOR SAFETY BECAUSE THE OPERATOR IS NOT INVOLVED.
--- THE SYSTEM CAN BE FAR MORE PRODUCTIVE (DEPENDENT ON SUPPLY OF COMPONENTS)
6) YES
7) TO 9)
RUST GRADES:
RUST GRADE "A"---STEEL SURFACE IS LARGELY COVERED WITH ADHERENT MILL SCALE WITH LITTLE IF ANY RUST.
RUST GRADE "B"---STEEL SURFACE WHICH HAS BEGUN TO RUST AND FROM WHICH THE MILLSCALE HAS BEGUN TO FLAKE.
RUST GRADE "C"---STEEL SURFACE ON WHICH THE MILLSCALE HAS RUSTED AWAY OR FROM WHICH IT CAN BE SCRAPED, BUT WITH SLIGHT PITTING, VISIBLE
UNDER NORMAL VISION.
RUST GRADE "D"---STEEL SURFACE ON WHICH THE MILLSCALE HAS RUSTED AWAY & ON WHICH GENERAL PITTING IS VISIBLE UNDER NORMAL VISION.
ABRASIVE BLASTING GRADES:
Sa 1: LIGHT BLAST CLEANING (WHEN VIEWED W/OUT MAGNIFICATION, THE SURFACE SHALL BE FREE FROM VISIBLE OIL GREASE, DIRT, POORLY ADHERING
MILL SCALE, RUST, PAINT COATINGS AND FOREIGN MATTER.
Sa 2: THOROUGH BLAST CLEANING (WHEN VIEWED WITHOUT MAGNIFICATION, THE SURFACE SHALL BE FREE FROM VISIBLE OIL GREASE, DIRT, POORLY
ADHERING MILLSCALE, RUST, PAINT COATING & FOREIGN MATTER. ANY RESIDUAL CONTAMINATION SHALL BE FIRMLY ADHERING.
Sa 2 1/2: VERY THOROUGH BLAST CLEANING (WHEN VIEWED WITHOUT MAGNIFICATION, THE SURFACE SHALL BE FREE FROM VISIBLE OIL GREASE, DIRT,
POORLY ADHERING MILLSCALE, RUST, PAINT COATINGS & FOREIGN MATTER. ANY REMAINING TRACES OF CONTAMINATION SHALL SHOW ONLY AS
SLIGHT STAINS IN THE FORM OF SPOTS OR STRIPES)
Sa 3: BLAST CLEANING TO VISUALLY CLEAN STEEL (WHEN VIEWED W/OUT MAGNIFICATION, THE SURFACE SHALL BE FREE FROM VISIBLE OIL GREASE, DIRT,
POORLY ADHERING MILLSCALE, RUST, PAINT COATINGS & FOREIGN MATTER. IT SHALL HAVE A UNIFORM METALLIC COLOUR.
10) 220mph---TYPICAL SPEED OF ABRASIVES LEAVING A WHEEL ABRATOR.
11) 100 psi---EFFICIENT BLASTING PRESSURE.
12) BURNISHING---AN EXISTING PROFILE THAT WAS REDUCED; A POLISHED, SMOOTH SHINY AREA WHICH DOES NOT PROVIDE GOOD ADHESION.
13) Sa 1
14) 7 IS THE NEUTRAL FIGURE ON THE pH SCALE.
15) pH IS A MEASURE OF ACIDITY OR ALKALINITY OF A SUBSTANCE & IS MEASURED USING pH INDICATOR STRIPS.
16) TO RETARD THE FORMATION OF CORROSION PRODUCTS --- WHY INHIBITORS ADDED TO WATER.
17) LIMITED ACCESS & ENVIRONMENTAL CONSIDERATIONS --- TYPICAL AREAS WHERE NEEDLE GUNS ARE USED.
18) FOOTNERS DUPLEX SYSTEM INVOLVES THE PICKLING PROCESS FOLLOWED BY A PASSIVATION PROCESS USING PHOSPHORIC OR CHROMIC ACID ALONG
WITH A SMALL PERCENTAGE OF IRON FILINGS, WHICH PRODUCES IRON CHROMATE OR IRON PHOSPHATE SALTS WHICH ARE NOT SOLUBLE. THUS FORMING
A RUST INHIBITIVE LAYER WHICH PASSIVATES THE SURFACE & INCREASES THE ADHESION PROPERTIES.---SURFACE PREPARATION PAGE #3 O T R I R
19) ACIDITY AT 7 TO 0 pH VALUE WHILE ALKALINITY AT 7 TO 14 pH VALUE.
20) BOLTS & NUTS (FASTENERS RELYING ON TENSION) --- FLAME CLEANING CANNOT BE DONE ON A STRUCTURE.
21) EXPANSION, DEHYDRATION & HEAT PENETRATION.
22) BS 7079 STATES THAT IT CONTAINS 4 PHOTOGRAPHS SHOWING FLAME CLEANING STANDARDS FROM THE ORIGINAL RUST GRADES A TO D.
23) JASONS HAMMER---A POWER TOOL WHICH TENDS TO LEAVE A VERY COARSE PROFILE WHICH NEEDS TO BE REDUCED BY ABRADING WITH EMERY OR
GRINDING.
24) St2 (THOROUGH HAND & POWER TOOL CLEANING)---WHEN VIEWED WITHOUT MAGNIFICATION, THE SURFACE SHALL BE FREE FROM VISIBLE OIL
 GREASE, DIRT, POORLY ADHERING MILLSCALE, RUST, PAINT COATING & FOREIGN MATTER. 1
St3 (VERY THOROUGH HAND & POWER TOOL CLEANING)---AS FOR St2 BUT THE SURFACE SHALL BE TREATED MUCH MORE THOROUGHLY TO GIVE A
METALLIC SHEEN ARISING FROM THE METALLIC SUBSTRATE. (O, D, PAM, R, P, F)
25) PHOSPHOR BRONZE & BERYLLIUM BRONZE ARE NON-SPARKING ALLOYS.
26) BURNISHING IS AVOIDED BECAUSE IT CREATES A SMOOTH SHINY AREA AND DOES NOT PROVIDE GOOD ADHESION.
27) LACK OF SURFACE PROFILE &TENDS TO LEAVE A VERY COARSE PROFILE WHICH NEEDS TO BE REDUCED BY ABRADING WITH EMERY OR GRINDING &
PRODUCES BURNISHING.--- DISADVANTAGES OF USING NEEDLE GUNS.
28) 4.5 TO 7 pH REQUIREMENT PRIOR TO COATING
29) KNOCK OUT POT---VAPOR TRAPS FOR OIL & WATER.
30) 70% EFFICIENCY --- BLASTING NEEDLE PRESSURE @ 80 PSI.
31) XYLENE IS THE COMMONLY USED SOLVENT FOR DEGREASING.
32) DEAD MANS HANDLE IS THE SAFETY MECHANISM ATTACHED TO THE BLASTING HOSE AND IS UNDER DIRECT OPERATOR CONTROL FOR THEIR OWN SAFETY.
33) CLEANSING OF ABRASIVES IN A WHEEL ABRATOR: (GF, P, C, C, F)
a. THE ABRASIVE IS GRAVITY FEED TO THE CENTER OF THE WHEEL TO THE IMPELLER AT THE SPEED OF 220mph IN A FAN PATTERN IN WHICH THE ABRASIVE
THEN SHATTERS MILL SCALE & CUTS A PROFILE,
b. IT THEN PASSES TO THE FLOOR OF THE UNIT W/C IS AN OPEN GRATING OVER A "V" SHAPED PIT IN WHICH A ROTATING SCREW CARRIES THE SPENT
ABRASIVES INTO A HOPPER,
c. A CONVEYOR SYSTEM THEN CARRIES THE ABRASIVES TO THE TOP OF THE MACHINE, DISPENSES IT TO START A GRAVITY FED PATH BACK TO BE RE-USED.
d. THE ABRASIVE THEN CASCADES OVER THE EDGE OF A TILTED WEIR PLATE IN W/C A CURRENT OF AIR IS DRAWN THROUGH IT. THE AIR WASH SEPARATOR
THEN DRAWS OUT LOW DENSITY MATERIALS SUCH AS RUST,MILLSCALE, FLAKES OF PAINT & FININGS.
e. THE CLEANSED ABRASIVES ARE THEN FED BACK INTO A COMMON HOPPER TO BE RE-USED.
34) MAIN DISADVANTAGE OF HIGH PRESSURE JETTING: IT WILL NOT CUT A PROFILE, IT WILL ONLY CLEAN UP THE ORIGINAL PROFILE ON REWORK AREAS.
35) 5 METHODS OF WET BLASTING:
a. HIGH PRESSURE WATER BLASTING UP TO 30,000 psi
b. HIGH PRESSURE WATER PLUS ABRASIVE INJECTION
c. LOW PRESSURE WATER PLUS ABRASIVE INJECTION
d. STEAM CLEANING
e. AIR BLASTING WITH WATER INJECTION
36) SULPHURIC ACID CONCENTRATION @ 5 TO 10%, THEN TEMPERATURE @ 65°C TO 70°C
37) FOOTNERS DUPLEX SYSTEM INVOLVES THE PICKLING PROCESS FOLLOWED BY A PASSIVATION PROCESS USING PHOSPHORIC OR CHROMIC ACID ALONG
WITH A SMALL PERCENTAGE OF IRON FILINGS, WHICH PRODUCES IRON CHROMATE OR IRON PHOSPHATE SALTS WHICH ARE NOT SOLUBLE. THUS FORMING
A RUST INHIBITIVE LAYER WHICH PASIVATES THE SURFACE & INCREASES THE ADHESION PROPERTIES.
38) 30,000 psi IS THE MAXIMUM PRESSURE FOR WATER JETTING.
39) DISADVANTAGES OF WET BLASTING OVER DRY BLASTING:
a. SUPPLY OF LARGE AMOUNTS OF WATER
b. DISPOSAL OF THE RESULTING SLURRY
40) ADVANTAGES OF WET BLASTING OVER DRY BLASTING:
a. ENVIRONMENTALLY FRIENDLY
b. SPARK FREE
c. IDEAL FOR REMOVAL OF SOLUBLE SALTS (SULPHATES & CHLORIDES)
d. IDEAL FOR REMOVAL OF TOXIC MATERIALS (RED LEAD, CALCIUM PLUMBATE & ZINC CHROMATE PRIMERS)
41) PHOSPATING OR CHROMATING OF STEEL IS DONE TO FORM A RUST INHIBITIVE LAYER W/C PASSIVATES THE SURFACE & INCREASES THE ADHESION
PROPERTIES.
42) ABRADING WITH COARSE EMERY (REMEDY FOR BURNISHED AREAS)
43) YES
44) 4 PHOTOGRAPHS OF BLAST CLEANING STANDARDS: RUST GRADES
RUST GRADE "A"---STEEL SURFACE IS LARGELY COVERED WITH ADHERENT MILL SCALE WITH LITTLE IF ANY RUST.
 RUST GRADE "B"---STEEL SURFACE WHICH HAS BEGUN TO RUST AND FROM WHICH THE MILLSCALE HAS BEGUN TO FLAKE.
RUST GRADE "C"---STEEL SURFACE ON WHICH THE MILLSCALE HAS RUSTED AWAY OR FROM WHICH IT CAN BE SCRAPED, BUT WITH SLIGHT PITTING, VISIBLE

UNDER NORMAL VISION. 2

RUST GRADE "D"---STEEL SURFACE ON WHICH THE MILLSCALE HAS RUSTED AWAY & ON WHICH GENERAL PITTING IS VISIBLE UNDER NORMAL VISION.
45) PLATES SHOWN IN BS 7079 PT. A RELATES TO "GRIT BLASTING"
3
PAINT TECHNOLOGY 1 (WEDNESDAY)
1) POWDERS---VIRTUALLY SOLVENT FREE MCL's W/C ARE SOLID AT ROOM TEMPERATURES. THE BASE RESIN & THE CHEMICAL ACTIVATOR, ALONG WITH THE
OTHER CONSTITUENTS REQUIRED TO COMPLETE THE FORMULATION ARE HEATED UP TO THE RESINS' MELTING POINT, MIXED INTO A HOMOGENEOUS LIQUID,
COOLED AND GROUND INTO POWDER FORM.
2) ACETONE (KETONES)---SOLVENT FOR EPOXY RESIN.
3) ADVANTAGES OF CHLORINATED RUBBER PAINTS: H N N V V V
a. COZ' OF THE CHLORINE CONTENT, HIGH RESISTANCE TO MOULD GROWTH.
b. NON-FLAMMABLE AFTER SOLVENT RELEASE.
c. MATERIAL IS NON-TOXIC AND PROVIDES A VERY DURABLE FILM
d. VERY HIGH RESISTANCE TO VAPOUR TRANSMISSION.
e. VERY HIGH RESISTANCE TO CHEMICAL ATTACK (ex. ACIDS & ALKALIS)
f. VERY EASILY MAINTAINED, NO ABRASION REQUIRED, ONLY CLEAN THE SURFACE.
4) DISADVANTAGES OF CHLORINATED RUBBER PAINTS: L L S
a. SOLVENT COMPATIBILITY LIST SHOWS LOW RESISTANCE TO SOLVENTS (ONLY RESISTANT TO ALIPHATICS & WATER)
b. LOW TEMPERATURE TOLERANCE (65°C MAXIMUM)
c. SPRAY APPLICATION OFTEN RESULTS IN "COBWEBS"
5) SOLVENT NAPHTAS (ALIPHATIC HYDROCARBONS)---SOLVENT FOR PHENOLIC RESIN.
6) XYLENE (AROMATIC HYDROCARBONS)---SOLVENT FOR CHLORINATED RUBBER PAINT.
7) NO, AS IT WOULD RESULT IN LIFTING & WRINKLING.
8) TURPENTINE SUBSTITUTE (ALIPHATIC HYDROCARBONS)---SOLVENT FOR ALKYD RESIN
9) ALKYD---A TERM DERIVED FROM ALCOHOL (ACID REACTION) USUALLY ASSOCIATED MORE WITH THE DOMESTIC MARKET, THEY HAVE A LOW RESISTANCE TO
ALKALIS, BRITTLE & NEED MODIFICATION WITH OILS.
10) OPAQUE---EXCELLENT LIGHT SCATTERING PROPERTIES IN ORDER TO GIVE COVERING POWER.
OPAQUE PIGMENTS---ARE INERT PARTICLES WITH EXCELLENT LIGHT SCATTERING PROPERTIES IN ORDER TO GIVE COVERING POWER, OPACITY & COLOUR.
11) VEHICLE---ALSO CALLED "BINDER" & "NON-VOLATILE", IT IS THE MAIN CONSTITUENT OF A PAINT & IS OFTEN REFERRED TO AS A "FILM FORMER"
12) YES, BECAUSE A WEAK SOLVENT OVER A STRONG SOLVENT HAVE NO ILL EFFECT.
13) NO, BECAUSE A STRONG SOLVENT OVER A WEAK SOLVENT IS NOT ADVISED.
14) YES, BECAUSE A WEAK SOLVENT OVER A STRONG SOLVENT HAVE NO ILL EFFECT.
15) NO, BECAUSE A STRONG SOLVENT OVER A WEAK SOLVENT IS NOT ADVISED.
16) YES, BECAUSE A WEAK SOLVENT OVER A STRONG SOLVENT HAVE NO ILL EFFECT.
17) NO, BECAUSE A STRONG SOLVENT OVER A WEAK SOLVENT IS NOT ADVISED.
18) DYE---UNPIGMENTED PAINT
19) NATURAL PROPERTIES OF A RESIN:
a. FAST DRYING
b. BRITTLE
20) NATURAL PROPERTIES OF AN OIL:
a. THE TYPE THAT WILL COMBINE WITH OXYGEN
b. IT MUST BE UNSATURATED.
21) BARRIER---THE MATERIAL FORMS A THICK IMPERMEABLE LAYER OF A HIGH ELECTRICAL RESISTANCE (ex. URETHANE)
22) PASSIVATION---CAUSING A CHEMICAL REACTION BETWEEN THE PAINT CONSTITUENTS & THE SUBSTRATE (ex. RUST INHIBITIVE PRIMERS)
23) CATHODIC PROTECTION---EMPLOYS THE BI-METALLIC PRINCIPLES BY USING A LESS NOBLE METAL AS PIGMENTATION (ex. ZINC RICH PRIMERS)
24) MULTI COMPONENT LIQUIDS (MCL)---ANOTHER NAME FOR SOLVENT FREE TWO PACKS.
 1
CONTINUATION……….

25) 6 PROPERTIES OF A BINDER: V A R R C D A A

a. VISCOSITY (FLOW PROPERTIES)
b. ADHESION TO THE SUBSTRATE FOR THE EXPECTED LIFE OF COATING
c. RESISTANCE TO ABRASION
d. RESISTANCE TO CHEMICAL ATTACK ACCORDING TO ENVIRONMENT
e. COHESIVE STRENGTH (ITS ABILITY TO HOLD TOGETHER AS A FILM)
f. DIALECTRIC STRENGTH
g. ABILITY TO RESIST THE PASSAGE OF WATER
h. ABILITY TO CHANGE FROM A LIQUID AS APPLIED, INTO A SOLID TO PROVIDE THE ABOVE PROPERTIES & OTHERS FOR THE EXPECTED LIFE OF A COATING.
26) NATURAL RESINS USED IN PAINTS: C D C
a. COPALS
b. DAMMARS
c. COUMARONES
27) 5 NATURAL OILS USED IN PAINTS: L T S T S
a. LINSEED OIL
b. TUNG OIL / CHINA WOOD OIL
c. SOYA OIL
d. TALL OIL
e. SAFFLOWER OIL
28) OLEORESINOUS---A MIXTURE OF OIL & RESIN.
29) SILICONES---INORGANIC HIGH TEMPERATURE SERVICE BINDER (@150°C SERVICE TEMPERATURE)
30) 2 PIGMENTS USED FOR HIGH TEMPERATURE SERVICE:
a. CARBON
b. ALUMINIUM

NOTES:
BASIC PAINT INGREDIENTS:
a. BINDER
b. PIGMENTS & OTHER ADDITIVES
c. SOLVENT
TYPES OF PAINTS:
a) SOLVENT FREE
b) SOLVENT TYPE
c) POWDERS
2
PAINT TECHNOLOGY 2 (WEDNESDAY)
1) ATOMS OR MOLECULES---THE BASIC UNIT OF POLYMERS.
2) POLYMERIZATION---JOINING TOGETHER OF A STRING OR STRUCTURE OF REPEATED UNITS.
3) 3 TYPES OF POLYMERS:
a. LINEAR POLYMERS---ALSO REFERRED TO AS "SOLUTION POLYMERS" WHICH USES LINEAR POLYMER MATERIALS. THE TYPE OF PAINT WHICH DRIES BY
SOLVENT EVAPORATION FOLLOWED BY OXIDATION. (ACRYLICS, VINYLS, CHLORINATED RUBBER, ASPHALT, COAL TAR & CELLULOSIC RESINS)
b. BRANCHED POLYMERS---FORMED BY COMBINING OXYGEN WITH THE DOUBLE BONDS AVAILABLE. (NATURAL OILS, NATURAL RESINS, ISOMERS SUCH
AS ALKYDS & PHENOLICS)
c. CROSS LINKED POLYMERS---ALSO CALLED CHEMICAL CURING WHICH IS A 3 DIMENSIONAL POLYMERISATION PROCESS.(URETHANES)
4) SHORT OIL PAINT---LESS THAN 45% OIL TO RESIN, FASTER DRYING MATERIAL, SUITABLE FOR STEELWORK.
5) LONG OIL PAINT---MORE THAN 60% OIL TO RESIN, SLOWER DRYING PROPERTIES SUITABLE FOR DECORATIVE MATERIALS.
6) OPAQUE PIGMENT---ARE INERT PARTICLES WITH EXCELLENT LIGHT SCATTERING PROPERTIES IN ORDER TO GIVE COVERING POWER.
7) 1/10TH MICRON---SIZE OF PIGMENT PARTICLES.
8) SATURATED OIL---CANNOT BE USED AS A BINDER BECAUSE IT WILL NOT SOLIDIFY BY POLYMERISATION TO FORM A FILM.
UNSATURATED OIL---AS A USABLE PAINT BINDER, THE OIL MUST BE A TYPE THAT WILL COMBINE WITH OXYGEN.
9) UNSATURATED RAPID DRYING OILS---LINSEED OIL & TUNG OIL
10) PIGMENTS---SOLID PARTICLES WITHIN THE VEHICLE.
DYE (UNPIGMENTED PAINT)---DISSOLVED SOLID PARTICLES WITHIN THE VEHICLE.
11) SOURCES OF PIGMENTS: A V M S
a. ANIMAL
b. VEGETABLE
c. MINERAL
d. SYNTHETIC
12) WHITE---COLOUR WITH TITANIUM DIOXIDE USED IN PAINT.
13) TOXIC RUST INHIBITIVE PIGMENTS:
a. RED LEAD
b. CALCIUM PLUMBATE
c. ZINC CHROMATE
14) MINERALS USED AS EXTENDER PIGMENTS: C C T S
a. CLAYS (KAOLIN, CHINA CLAY)
b. CHALK (CALCIUM CARBONATE)
c. TALCUM (MAGNESIUM SILICATE)
d. SLATE FLOUR (ALUMINIUM SILICATE)
15) LAMINAR PIGMENTS: M A G M G
a. MIO (MICACEOUS IRON OXIDE) (SPECULAR HAEMATITE)
b. ALUMINUM FLAKE
c. GLASS FLAKE
d. MICA
e. GRAPHITE
16) PIGMENT IS WAY BELOW THE CPVC:
--- TOO MUCH BINDER TO SOLIDS RATIO WOULD GIVE THE FILM A GOOD GLOSS PROPERTIES BUT POOR COVERING POWER (OPACITY), & WITH A
TENDENCY TO BLISTER (LOW COHESIVE STRENGTH)
17) CPVC (CRITICAL PIGMENT VOLUME CONCENTRATION)--- AS PER BS 2015 CPVC IS THE PARTICULAR VALUE OF THE PIGMENT VOLUME CONCENTRATION
AT WHICH THE VOIDS BETWEEN THE SOLID PARTICLES THAT ARE NORMALLY TOUCHING ARE JUST FILLED WITH THE BINDER & IN THE REGION OF WHICH
CERTAIN PROPERTIES ARE CHANGED MARKEDLY.
18) THIXOTROPIC AGENTS (ANTI-SETTLING AGENTS) LIKE BENTONES & WAXES, HELPS KEEP SOLID PARTICULATE CONSTITUENTS IN DISPERSION WITHIN
THE PAINT.
19) BLACK---COLOR WITH CARBON PIGMENT. 1
20) PROPERTIES THAT A BINDER CONTRIBUTES TO A PAINT FILM: V A R R C D A A
a. VISCOSITY (FLOW PROPERTIES)
b. ADHESION TO THE SUBSTRATE FOR THE EXPECTED LIFE OF COATING.
c. RESISTANCE TO ABRASION
d. RESISTANCE TO CHEMICAL ATTACK
e. COHESIVE STRENGTH (ITS ABILITY TO HOLD TOGETHER AS A FILM)
f. DIALECTRIC STRENGTH
g. ABILITY TO RESIST THE PASSAGE OF WATER
h. ABILITY TO CHANGE FROM A LIQUID INTO A SOLID.
21)
22)
23) PIGMENT WAS ADDED ABOVE THE CPVC:
---THE CPVC IS EXCEEDED & ALL PARTICLES ARE NOT WETTED, THE FILM WOULD BE POROUS, LOW IN COHESIVE STRENGTH & ADHESION.
24) ZINC PHOSPHATE IS THE MOST COMMONLY USED RUST INHIBITIVE PIGMENT.
25) EXTENDERS ARE ADDED IN PAINT FORMULATION BECAUSE THESE MATERIALS PROVIDE SOME OF THE MAIN PROPERTIES EXPECTED OF THE FILM SUCH AS:
a. ADHESION A C F D A L A C
b. COHESION
c. FILM STRENGTH
d. DURABILITY
e. APPLICATION & FLOW
f. LEVELLING
g. AN AID TO INTER-COAT ADHESION
h. CAN REDUCE GLOSS
26) CHROMIUM PIGMENT @ GREENS, YELLOWS & ORANGES COLOURS.
27) PLASTICISERS---BASICALLY GIVES PAINT FLEXIBILITY & REDUCES BRITTLENESS.
28) METALS COMMONLY USED FOR GALVANIC PIGMENTATION:
a. ZINC---FOR GALVANIC PROTECTION
b. ALUMINIUM---FOR SOLAR PROTECTION
29) DRIERS (OXIDANTS)---WHICH ARE HEAVY METAL SALTS RICH IN OXYGEN, ARE ADDED TO OIL BASED PAINTS TO ALLOW THOROUGH DRYING OF THE FILM
EXAMPLES ARE (OCTOIC ACID & NAPHTANIC ACID)
30) THIXOTROPIC---THICKENER OR ANTI SETTLING AGENT WHICH ALLOWS A HIGHER FILM THICKNESS.
31) AGGREGATES (AGGLOMERATES)---CLUSTERED SMALL PIGMENT PARTICLES.
32)
33) PLASTICISERS:
a. ALKYD RESIN
b. SATURATED OIL (CASTOR OIL, COCONUT OIL, PALM OIL)
34) SOLUTION---A LIQUID IN WHICH A SUBSTANCE IS DISSOLVED. Ex.(SALT & WATER, SUGAR & WATER, A BINDER & SOLVENT)
35) EXAMPLES OF SOLUTION: SALT & WATER, SUGAR & WATER, A BINDER & SOLVENT)
36) DISPERSION---SUSPENSION OF ONE COMPONENT IN ANOTHER.
37) 2 TYPES OF DISPERSION:
a. SUSPENSION---WHEN FINE PARTICULATE SOLIDS ARE DISPERSED WITHIN A LIQUID.
b. EMULSION---IS A LIQUID DISPERSED IN ANOTHER LIQUID WHEN THERE IS NO SOLUBILITY.
38) CONVERTIBLE
39) INDUCTION PERIOD ("STAND TIME"OR "LEAD TIME")---LENGTH OF TIME AFTER MIXING WHICH THE PAINT SHOULD STAND BEFORE USE.
40) SOLUTION POLYMERS---PAINTS EMPLOYING THIS DRYING MECHANISM ARE LINEAR POLYMER MATERIALS.
41) NON-CONVERTIBLE (REVERSIBLE)---STRONG SOLVENTS WHEN RE-APPLIED ONTO THE PAINTS, EASILY PENETRATE BETWEEN THE POLYMERS & SPLIT THE
 SECONDARY BOND, ALLOWING THE POLYMER TO GO BACK INTO SOLUTION. (CHLORINATED RUBBER, VINYLS, ACRYLICS, CELLULOSIC MATLS., LACQUERS)
42) CONVERTIBLE (NON-REVERSIBLE)---OXYGEN HAS REACTED WITH THE BINDER & IT HAS CHANGED THE CHEMICAL STRUCTURE OF THE BINDER & CANNOT

BE REMOVED. (ALKYDS, PHENOLICS, NATURAL OILS & RESINS) 2

43) 4 DRYING MECHANISMS: S O C C
a. SOLVENT EVAPORATION---SOLUTION POLYMERS DISSOLVE IN THE SOLVENT & AS PAINT IS APPLIED THE SOLVENT EVAPORATES AWAY ALLOWING
FULLY FORMED LINEAR POLYMERS TO COME OUT OF SOLUTION & FORM A FILM ON A SUBSTRATE.
b. OXIDATION---FORMS A FILM BY OXIDATIVE CROSS LINKING (POLYMERISATION) USING ATMOSPHERIC OXYGEN
c. CHEMICAL CURING---MATERIALS ARE CONVERTIBLE OR NON-REVERSIBLE.
d. COALESCENCE---TO PHYSICALLY JOIN TOGETHER.
44) REVERSIBLE (NON-CONVERTIBLE)---THE TYPE OF POLYMERISATION THAT OCCURS IN A COATING WHICH DRIES BY SOLVENT EVAPORATION.
45) FINENESS OF GRIND---AGGREGATE SIZE
46) SOLUTION POLYMERS---THE TYPE OF PAINT WHICH DRIES BY SOLVENT EVAPORATION FOLLOWED BY OXIDATION.
47) LINEAR POLYMERS---THE TYPE OF POLYMERS THAT FORMS DURING OXIDATION.
48) AIR DRYING---THE TERM APPLIES TO PAINT DRYING AT AMBIENT TEMPERATURES.
49) COALESCENCE---MEANS TO PHYSICALLY JOIN TOGETHER.
50) POT LIFE---IS THE PERIOD OF TIME AFTER MIXING IN WHICH THE PAINT MUST BE USED, AS FOR INDUSTRIAL PAINTS @ 6 TO 8 HOURS.
51) 3 CURING AGENTS USED IN EPOXIES (TWO-PACK MATERIALS CURING AGENTS):
a. AMIDES---USUALLY 7 DAYS TO FULL CROSS LINKING @ 20°C
b. AMINES---USUALLY 3 DAYS TO FULL CROSS LINKING @ 20°C
c. ISOCYANATES---FOR PIPELINE USE AT 16 HOURS TO FULL CURE (FOR LOW TEMPERATURE APPLICATION @ -10°C BEING TYPICAL)
52) PAINT---CONSISTS OF SOLID PARTICLES SUSPENDED IN THE VEHICLE WHERE THERE IS NO SOLUBILITY, SO A PAINT IS A DISPERSION.
PAINT---IS A MATERIAL WHICH WILL CHANGE THE TEXTURE, COLOR OR APPEARANCE OF A SURFACE & GIVES SOME FORM OF PROTECTION TO THE
UNDERLYING SURFACE.
53) EXOTHERMIC REACTION---GIVING OFF HEAT, THE CONTAINER WILL WARM UP.
54) INDUCTION PERIOD---IS THE LENGTH OF TIME AFTER MIXING WHICH THE PAINT SHOULD STAND BEFORE USE.
55) THERMOSETTING---MEANS THE MATERIAL WILL CURE WITH THE APPLICATION OF HEAT, THEREFORE THEY ARE CONVERTIBLE OR NON-REVERSIBLE.
ex. EPOXY & URETHANE
THERMOPLASTIC---MATERIALS SOFTEN WITH THE APPLICATION OF HEAT ARE LINEAR POLYMERS, THEREFORE THEY ARE NON-CONVERTIBLE OR
REVERSIBLE. ex. POLYETHYLENE & POLYPROPYLENE
56) TWO-PACK OR MULTI COMPONENT LIQUID---THE TYPE OF POLYMERISATION THAT OCCURS WITH A CHEMICALLY CURING PAINT.
57) INDUCTION PERIOD---ALSO CALLED STAND TIME OR LEAD TIME.
58)
59) REVERSIBLE or NON-CONVERTIBLE BINDERS: C V A L C
a. CHLORINATED RUBBER
b. VINYLS
c. ACRYLICS
d. LACQUERS
e. CELLULOSIC MATERIALS
60) EPOXY POWDERS ARE THERMOSETTING MATERIALS.
61) PERMEABLE COATING---COATINGS THAT ALLOW SOME PASSAGE OF WATER VAPOR, OXYGEN & OTHER VAPORS THROUGH THE CURED COATING FILM.
62) CROSS LINKING (CHEMICAL CURING)---A 3 DIMENSIONAL POLYMERISATION PROCESSWHICH OCCURS RAPIDLY USING ONLY COMPONENTS PROVIDED
IN THE CANS. ex. AMIDES, AMINES, ISOCYANATES
63) ENDOTHERMIC REACTION---TAKING IN HEAT, THE CONTAINER WILL COOL FORMING CONDENSATION.
EXOTHERMIC REACTION---GIVING OFF HEAT, THE CONTAINER WILL WARM UP.
64) STOVING---PAINTS CURE AT TEMPERATURES IN EXCESS OF 65°C
65) 20 TO 30 MINUTES---TYPICAL INDUCTION PERIOD FOR CHLORINATED RUBBER PAINT.
66) PAINT DRIERS (HEAVY METAL SALTS RICH IN OXYGEN):
 a. OCTOIC ACID
b. NAPHTANIC ACID
67) BENTONITE & WAX---THEY HELP KEEP SOLID PARTICULATE CONSTITUENTS IN DISPERSION WITHIN THE PAINT.
68) PLASTICISER MATERIALS:

a. ALKYD RESIN 3
b. SATURATED OIL (CASTOR OIL, COCONUT OIL, PALM OIL)
69) SOLUTION POLYMERS---TYPE OF PAINTS WHICH USES ANTI-OXIDANTS.
70) A SINGLE PACK, EPOXY ESTER PAINT DRIES BY:
a. IF A SOLVENT IS PRESENT, THE SOLVENT EVAPORATES AWAY, ALLOWING OXIDATION TO BEGIN
b. OXYGEN THEN COMBINES WITH THE UNSATURATED BONDS ON THE FATTY ACID ESTERS, PROGRESSIVELY LINKING THEM TOGETHER TO FORM THE FILM.
71) DEW POINT TEMPERATURE---THIS IS THE TEMPERATURE AT WHICH WATER VAPOR IN THE AIR WILL CONDENSE.
72) RELATIVE HUMIDITY---THE AMOUNT OF WATER VAPOR IN THE AIR EXPRESSED AS A PERCENTAGE OF THE AMOUNT OF WATER VAPOR WHICH COULD BE
IN THE AIR AT THAT SAME TEMPERATURE.
73) WET BULB SHOULD BE READ FIRST AFTER ROTATION STOPS BECAUSE THE ASPIRATION RATE SLOWS, THE WB TEMPERATURE WILL SLOWLY START TO RISE
TOWARDS THAT OF THE DRY BULB TEMPERATURE. WATER ON THE WET BULB USES HEAT ENERGY FROM THE AIR TO CHANGE INTO WATER VAPOR SO THE
WET BULB WILL GIVE A LOWER TEMPERATURE READING THAN THE DRY BULB.
74) 4 m/s---THE SPEED AT WHICH THERMOMETER BULBS PASS THROUGH THE AIR
75) SCREW LID---IS USED WHEN WETTING THE WICK ON A WHIRLING HYGROMETER.
76) WHIRLING HYGROMETER---ALSO CALLED "ASPIRATED HYGROMETER" OR "SLING PSYCHROMETER" WIDELY USED BY COATING INSPECTORS TO
DETERMINE WET & DRY BULB TEMPERATURE READINGS FROM WHICH USING CALCULATORS OR HYGROMETRIC TABLES, RELATIVE HUMIDITIES &
DEW POINTS CAN BE CALCULATED.
77) THE AIR'S CAPACITY TO HOLD WATER DECREASES WHEN THE AIR TEMPERATURE RISES.
78) STANDARD CRITERION FOR ACCEPTANCE PRIOR TO CALCULATIONS ON A WHIRLING HYGROMETER:
---ON TWO CONSECUTIVE SPINS, THE READINGS SHOULD BE WITHIN 0.2°C, WET BULB TO WET BULB & DRY BULB TO DRY BULB.
79) STEEL TEMPERATURE MEASUREMENT:
a. MAGNETIC GAUGE (LIMPET GAUGE)
b. DIGITAL THERMOMETER
c. THERMOCOUPLE (TOUCH PYROMETER)
80) NO, IT'S NOT POSSIBLE FOR WB TEMPERATURE TO BE HIGHER THAN THE DB TEMPERATURE.

NOTES NOTES NOTES NOTES NOTES NOTES NOTES NOTES

PAINT CONSTITUENTS & BASIC TECHNOLOGY:

POTASSIUM FERRICYANIDE TEST (POTASSIUM HEXA-CYANOFERRATE TEST)---TEST TO DETECT SOLUBLE IRON SALTS.
a) WHATMAN #3 LABORATORY FILTER PAPERS ARE SOAKED IN A 5 TO 10% SOLUTION OF POTASSIUM FERRICYANIDE & DISTILLED WATER & LEFT TO DRY.
THE RESULT IS A LIME GREEN PAPER FRINGED WITH AN ORANGE BRIM.

b) THE AREA OF BLAST TO BE TESTED IS SPRAYED WITH A FINE MIST OF DISTILLED WATER & LEFT FOR A FEW SECONDS TO ALLOW THE SALTS IF PRESENT, TO
DISSOLVE & FORM A SOLUTION.
c) A POTASSIUM FERRICYANIDE TEST PAPER IS THEN APPLIED TO THE AREA & BY CAPILLARY ACTION DRAWS UP THE SOLUTION LIKE BLOTTING PAPER.
d) IF THERE ARE ANY DISSOLVED SALTS THEY REACT WITH THE POTASSIUM FERRICYANIDE TO FORM POTASSIUM FERRICYANIDE, THE FERROCYANIDE IS
PRUSSIAN BLUE & SHOWS AS BLUE SPOTS ON A LIME GREEN BACKGROUND.
SILVER NITRATE TEST--- TEST TO DETECT SOLUBLE CHLORIDE SALTS
a) A SOLUTION OF SILVER NITRATE, 2% WITH DISTILLED WATER IS MADE & THE WHATMAN PAPERS CUT INTO STRIPS
b) THE STRIPS ARE THEN SOAKED IN THE SOLUTION & PRESSED ONTO THE AREA UNDER TEST FOR ABOUT 20 SECONDS THEN WASHED IN DISTILLED WATER.
c) THE REACTION BETWEEN SILVER NITRATE & ANY CHLORIDE SALTS PRESENT PRODUCES SILVER CHLORIDE, WHICH REMAINS ON THE STRIP AFTER
WASHING.
d) IF THE STRIP IS THEN DIPPED INTO PHOTOGRAPHIC DEVELOPER, THE CHLORIDES SHOW UP AS BLACK / BROWN.
4

OTHER TESTS FOR PRESENCE OF SALTS:

a) MERKOQUANT
b) BRESTLE SAMPLE PATCH
c) SALT CONTAMINATION METERS (mg/m2)
SA3 BLASTING WITH ACIDIC COPPER SULPHATE SOLUTION---TEST TO DETECT THE PRESENCE OF MILLSCALE ON A SUBSTRATE.
a) BLASTED STEEL IS DARK GREY IN COLOR, WHILE MILLSCALE IS DARK BLUE, THE SURFACE IS SPRAYED WITH A FINE MIST OF ACIDIC COPPER SULPHATE
SOLUTION, THE SOLUTION IONISES & TINTS THE STEEL COPPER COLOR & BLACKENS THE MILLSCALE, REBLAST & RETEST THEN FOLLOWS.
SELF ADHESIVE TAPE APPLICATION ON THE SURFACE---TEST TO DETECT THE PRESENCE OF DUST ON A SUBSTRATE.
a) SELF ADHESIVE TAPE IS STUCK ONTO THE SURFACE & SNATCHED OFF, THE DUST / FININGS STICKS TO THE TAPE.
b) BY STICKING THE TAPE ONTO WHITE PAPER, THE DUST CAN EASILY BE SEEN.
SPRINKLING WITH TALC OR POWDERED CHALK---TEST TO DETECT THE PRESENCE OF MOISTURE ON A SUBSTRATE.
a) SPRINKLE WITH TALC OR POWDERED CHALK & LIGHTLY BLOW AWAY, THE POWDER WILL STICK TO AREAS WHERE MOISTURE IS.
SOLVENT APPLICATION ON THE SUSPECT AREA---TEST TO DETECT THE PRESENCE OF OIL & GREASE
a) OTHER THAN ULTRA VIOLET LIGHT, OIL & GREASE CAN BE DETECTED BY DROPPING SOLVENT ONTO THE SUSPECT AREA & ABSORBING THE SOLUTION
ON WHATMAN OR BLOTTING PAPER. THE SOLVENT WILL EVAPORATE & OIL AND GREASE WILL GIVE A DARKER APPEARANCE.
BINDERS ("VEHICLE" OR "NON-VOLATILE")---MAIN CONSTITUENT OF A PAINT OFTEN REFERRED TO AS "FILM FORMER".
TYPES OF BINDERS: A A A C C E E E N N P P S S V
a) ACRYLIC f) EMULSIONS k) PHENOLIC RESINS
b) ALKYD g) EPOXIES l) POLYURETHANES
c) ASHPALTIC BITUMENS h) ETHYL & METHYL SILICATES m) SILICONES
d) CELLULOSE RESINS i) NATURAL OILS n) STYRENE
e) CHLORINATED RUBBER j) NATURAL RESINS o) VINYL
RUST INHIBITIVE PIGMENTS---ADDED INTO PRIMERS TO PROTECT THE STEEL SUBSTRATE BY PASSIVATION.
a) RED LEAD
b) CALCIUM PLUMBATE
c) ZINC CHROMATE
d) ZINC PHOSPHATE (MOST COMMONLY USED)
e) COAL TAR
f) BARIUM METABORATE

g) ZINC PHOSPHOSILICATE 5
OPAQUE PIGMENTS---ARE INERT PARTICLES WITH EXCELLENT LIGHT SCATTERING PROPERTIES IN ORDER TO GIVE COVERING POWER, OPACITY & COLOR.
a. CARBON-----BLACK
b. COMPOUNDS OF COBALT-----BLUE
c. COMPOUNDS OF CHROMIUM-----GREEN, YELLOW, ORANGE
d. COMPOUNDS OF IRON-----BROWN, RED, YELLOW
e. COMPUNDS OF CALCIUM-----RED, YELLOW
f. TITANIUM OXIDE-----WHITE
EXTENDER PIGMENTS---KNOWN AS "EXTENDERS" OR "FILLERS", THESE MATERIALS PROVIDE SOME OF THE MAIN PROPERTIES EXPECTED OF THE FILM SUCH AS:
ADHESION, COHESION,FILM STRENGTH & DURABILITY. THEY ALSO HAVE A ROLE IN APPLICATION & FLOW, LEVELLING, MECHANICAL PROPERTIES OF THE
FILM, AN AID TO INTER-COAT ADHESION & CAN REDUCE GLOSS.
a. CLAYS (KAOLIN, CHINA CLAY)
b. CHALK (CLACIUM CARBONATE)
c. TALCUM (MAGNESIUM SILICATE)
d. SLATE FLOUR (ALUMINIUM SILICATE)
PIGMENT BELOW CPVC---TOO MUCH BINDER TO SOLIDS RATIO, WOULD GIVE A FILM OF GOOD GLOSS PROPERTIES BUT POOR COVERING POWER (OPACITY)
AND WITH A TENDENCY TO BLISTER (LOW COHESIVE STRENGTH)
PIGMENT NEAR CPVC---A FILM WITH LOWER GLOSS PROPERTIES BUT GREATER COHESIVE STRENGTH & JUST ENOUGH RESIN TO ENCAPSULATE EACH PARTICLE,
GIVING GOOD RESISTANCE TO WATER PERMEATION.
PIGMENT ABOVE CPVC---THE CPVC IS EXCEEDED & ALL PARTICLES ARE NOT WETTED, THE FILM WOULD BE POROUS, LOW IN COHESIVE STRENGTH AND
ADHESION.
SOLVENTS---ADDED TO PAINTS TO REDUCE THE VISCOSITY & EASE APPLICATION PROPERTIES.
4 PROPERTIES OF A SOLVENT: S E F T
a) SOLVENT STRENGTH---STRONG SOLVENT FOR STRONG BINDERS, WEAK SOLVENT FOR WEAK BINDERS.
b) EVAPORATION RATE---GOVERNS AT WHAT POINT THE POLYMERISATION STARTS.
c) FLASH POINT---THE MINIMUM TEMPERATURE OF THE SOLVENT AT WHICH THE VAPORS GIVEN OFF ARE FLAMMABLE IF A SOURCE OF IGNITION IS
INTRODUCED.
d) TOXICITY---SOLVENTS ARE HAZARDOUS TO HEALTH.
PAINT ADDITIVES---VIZ, BINDER, SOLVENT, PIGMENT & EXTENDERS.
4 TYPES OF ADDITIVES: A P D A
a) ANTI SETTLING AGENTS---AN AID TO SHELF LIFE, A THIXOTROPE (BENTONES & WAXES) & A THICKENER WHICH ALLOWS A HIGHER FILM THICKNESS.
Ex. JELLY PAINTS
b) PLASTICISERS---GIVES PAINT FLEXIBILITY & REDUCES BRITTLENESS. (ALKYD RESIN, SATURATED OILS: CASTOR OIL, COCONUT OIL, PALM OIL),
CHEMICALS ADDED ESPECIALLY TO RUBBERS & RESINS TO IMPART FLEXIBILITY.
c) DRIERS (OXIDANTS)---USED IN OXIDISING OILS & RESINS. COMMON SALTS (OCTOATES OR NAPHTHANATES OF COBALT), MANGANESE & ZIRCONIUM
(COBALT NAPHTHANATE), HEAVY METAL SALTS (OCTOIC ACID & NAPHTANIC ACID)
d) ANTI SKINNING (ANTI-OXIDANTS)---ADDED TO OXIDISING PAINTS TO RETARD THE FORMATION OF A SKIN ON THE SURFACE OF THE PAINT.
(METHYL ETHYL KETOXIME)
SOLUTIONS & DISPERSIONS:
SOLVENT---A LIQUID WHICH WILL DISSOLVE ANOTHER MATERIAL, LIQUID OR SOLID.
SOLUTION---THE RESULTING LIQUID.
DISPERSION---PAINTS WHICH HAS NO SOLUBILITY.
SUSPENSION---WHEN FINE PARTICULATE SOLIDS ARE DISPERSED WITHIN A LIQUID, THE VEHICLE.
EMULSION---A LIQUID DISPERSED IN ANOTHER LIQUID WHEN THERE IS NO SOLUBILITY.

DRYING & CURING OF PAINT FILMS:

DRYING & CURING TEMPERATURES:
a) AIR DRYING---REFERS TO NORMAL AMBIENT TEMPERATURES.
b) FORCED DRYING---WHEN HEAT IS NEEDED TO EFFECT A CURE OR ACCELERATE THE REACTION (65°C)
c) STOVING---TEMPERATURES ABOVE 65°C ARE USED USING OVENS OR INFRA-RED. 6

4 DRYING MECHANISMS:
a) SOLVENT EVAPORATION---REVERSIBLE OR NONCONVERTIBLE (ACRYLICS, VINYLS, CHLORINATED RUBBER, ASPHALT, COAL TAR & CELLULOSIC RESINS)
b) OXIDATION---CONVERTIBLE OR NON-REVERSIBLE (NATURAL OILS & RESINS, ALKYDS, PHENOLICS)
c) CHEMICAL CURING---WITH INDUCTION PERIOD
d) COALESCENCE---TO PHYSICALLY JOIN TOGETHER.

PAINT SYSTEMS:
PRIMER---NORMALLY LOW VOLUME SOLID MATERIALS, WETS OUT THE SUBSTRATE & PROVIDES EXCELLENT ADHESION AND A KEY FOR ANY SUBSEQUENT LAYER.
PRIMERS FOR NON-FERROUS SUBSTRATES:
a) WASH OR MORDANT PRIMERS
b) PVB ETCH PRIMERS
MID-COATS---ARE MAINLY BARRIER COATS, APPLIED OVER THE PRIMERS TO PREVENT FURTHER WATER PASSING INTO THE FILM & LEACHING OUT THE
INHIBITIVE PIGMENTATION WITHOUT WHICH THERE WOULD BE NO PASSIVATION.
FINISHING COATS---MAINLY AESTHETIC (COLOR & APPEARANCE), TO HAVE A GLOSS FINISH, THE SURFACE MUST BE PERFECTLY SMOOTH AND THIS ALSO HELPS
IN THE REMOVAL OF DUST & DIRT AND NATURAL DRAINAGE OF WATER.
MOISTURE TOLERANT SYSTEMS---SINGLE PACK MOISTURE CURING POLYURETHANES ARE MATERIALS WHICH USE MOISTURE FROM THE ATMOSPHERE TO CURE.
POWDER COATING MATERIALS---ARE SOLVENT FREE MATERIALS WHICH ARE SOLID AT ROOM TEMPERATURE.
THERMOSETTING---THE MATERIAL WILL CURE WITH THE APPLICATION OF HEAT, THEREFORE THEY ARE CONVERTIBLE OR NON-REVERSIBLE.
(EPOXY & URETHANE)
THERMOPLASTIC---MATERIALS SOFTEN WITH THE APPLICATION OF HEAT (LINEAR POLYMER) REVERSIBLE OR NON-CONVERTIBLE
(POLYETHYLENE & POLYPROPYLENE)
SACRIFICIAL COATINGS---CLASSIFICATION OF MATERIALS WHICH SACRIFICES ITSELF TO PROTECT THE UNDERLYING SUBSTRATE. (ZINC & ALUMINIUM)
INORGANIC BINDERS (ETHYL OR METHYL SILICATES) WHICH ARE ZINC PIGMENTED FOR HIGH TEMPERATURE SERVICE WHICH NEEDS "SEALERS" SUCH AS
ALUMINIUM OR CARBON PIGMENTED SILICONES.

WATER BORNE COATINGS:

WATER BORNE COATINGS---PAINT ALTERNATIVES IN THE FORM OF SOLVENT FREE, HIGH VOLUME SOLIDS & WATER BORNE.
BINDER TYPES MODIFIED TO USE WATER:
a) ACRYLICS
b) ALKYDS
c) POLYESTERS
d) POLYURETHANE
e) VINYLS
f) EPOXIES
g) SILICONES

PAINT MANUFACTURE:
3 MAIN STAGES OF PAINT MANUFACTURE:
a) PREMIXING---PIGMENT, BINDER & SOLVENT ARE MIXED IN PROPORTIONS SUITABLE TO GIVE A CONSISTENCY OF PREMIX OR MILL BASE, SUITABLE FOR THE
MACHINERY TO BE USED IN THE NEXT PART OF THE OPERATION.
b) DISPERSION or GRINDING or MILLING---THE ACTUAL DISPERSION OR GRINDING OR MILLING OF THE PASTE FROM THE ABOVE.
c) LETDOWN PROCESS---THE REMAINING AMOUNTS OF BINDER/ SOLVENT & ANY ADDITIVES ARE FINALLY & THOROUGHLY MIXED PRIOR TO QUALITY CHECKS
AND CANNING.
DIRECT CHARGE DISPERSING MILLS:
a) BALL MILL e) SAND MILL
b) ATTRITOR MILL f) COLLOID MILL
c) HIGH SPEED DISPENSER g) TRIPLE ROLL MILLS
d) KADY & SILVERSON MILLS h) SINGLE ROLL MILLS 7

VISCOSITY---A FLUID'S RESISTANCE TO FLOW, IT IS A VERY IMPORTANT PROPERTY OF THE PAINT, IT AFFECTS THE MANUFACTURING PROCESS & APPLICATION
AND LEVELLING PROPERTIES.
POLYMER---A CHEMICAL COMPOUND OR A MIXTURE OF COMPOUNDS FORMED BY POLYMERIZATION.
PRIMER---THE FIRST COAT OF A PAINTING SYSTEM THAT HELPS BIND SUBSEQUENT COATS TO THE SUBSTRATE & WHICH MAY INHIBIT ITS DETERIORATION.
VEHICLE---THE TOTAL SUM OF THE CONSTITUENTS OF THE LIQUID PHASE OF THE PAINT.
SUBSTRATE---THE SURFACE TO WHICH A COAT OF PAINT OR VARNISH IS APPLIED.
BINDER---THE NON-VOLATILE PART OF A MEDIUM.
THIXATROPIC---THE PROPERTY OF A PAINT WHEREBY THE CONSISTENCY IS REDUCED ON BRUSHING OR STIRRING BY LOWERING THE VISCOSITY.
WET FILM THICKNESS (WFT)---THE THICKNES OF A COATING IMMEDIATELY AFTER APPLICATION BEFORE ANY SOLVENT HAS EVAPORATED.
DRY FILM THICKNESS (DFT)---THE THICKNESS OF A COATING AFTER ALL THE SOLVENT HAS EVAPORATED & THE COATING HAS CURED.
HARDENER---A CROSS LINKING AGENT USED TO CURE A RESIN OR A PAINT SYSTEM.
INHIBITOR---A MATERIAL USED IN SMALL PROPORTION TO SLOW A CHEMICAL REACTION.
LITMUS---A CHEMICAL THAT TURNS RED IN ACID SOLUTION & BLUE IN ALKALINE SOLUTION AND IS USED AS AN ACID BASE INDICATOR.
OXIDATION---COMBINATION OF COATING MOLECULES WITH ATMOSPHERIC OXYGEN.
CATHODIC PROTECTION---CORROSION PREVENTION BY SACRIFICIAL ANODES OR IMPRESSED CURRENT.
COATINGS---PAINT SURFACE BARRIERS; SURFACE COVERING.
BASIC PAINT INGREDIENTS: B P S
a. BINDER
b. PIGMENTS & OTHER ADDITIVES
c. SOLVENT
8
PAINT TESTING (THURSDAY)
1) VISCOSITY---A FLUIDS RESISTANCE TO FLOW
2) HIGH VISCOSITY---ONE WHICH HAS A HIGH RESISTANCE TO FLOW, IT WILL NOT RUN EASILY.
3) ONE CENTI-POISE---THE VISCOSITY OF WATER. (1 POISE = 1DYNE-SEC/ cm2)
4) DYNAMIC VISCOSITY UNITS: N-SEC/m2 (SI UNITS) & POISE (CGS UNITS)
5) TYPES OF FLOW CUPS (FLOW VISCOMETERS): Z F &F I D
a. ZAHN & FRIKMAR---USED FOR HOT FLUIDS
b. FORD, ISO, DIN---FOR AMBIENT TEMPERATURE MATERIALS. (FORD CUP BEING THE MOST WIDELY USED FOR INDUSTRIAL PAINTS.)
6) SI UNITS (N-SEC/m2) IS USED FOR VISCOSITY MEASUREMENT FOR A FLOW CUP.
7) FORD FLOW CUP #4---"4" RELATES TO THE 4mm HOLE SIZE IN THE VISCOMETER.
8) TYPES OF ROTATIONAL VISCOMETERS: R P K
a. ROTOTHINNER---MEASURES DYNAMIC VISCOSITY (ELECTRIC MOTOR DRIVEN)
b. PILLAR DRILL
c. KREBS STORMER VISCOMETER---MEASURES KINEMATIC VISCOSITY (FALLING WEIGHTS)
9) REASON FOR PERFORMING A VISCOSITY TEST ON SITE---TO ENSURE THAT THE EQUIPMENT & PAINT TEMPERATURES ARE BOTH @ 20°C ±0.5°C
AN INCREASE OR DECREASE IN TEMPERATURE CAN HAVE A SEVERE EFFECT ON A FLUID'S VISCOSITY. A HIGH TEMPERATURE WOULD REDUCE THE VISCOSITY.
10) FLOW CUP CANNOT BE USED ON THIXOTROPIC PAINTS.
11) IMPORTANCE OF TEMPERATURE WHEN DOING VISCOSITY TESTS---AN INCREASE OR DECREASE IN TEMPERATURE CAN HAVE A SEVERE EFFECT ON A FLUID'S
VISCOSITY. A HIGH TEMPERATURE WOULD REDUCE THE VISCOSITY.
12) DIFFERENCE BETWEEN A ROTOTHINNER & KREBS STORMER
a. ROTOTHINNER---MEASURES DYNAMIC VISCOSITY (ELECTRIC MOTOR DRIVEN)
b. KREBS STORMER VISCOMETER---MEASURES KINEMATIC VISCOSITY (FALLING WEIGHTS)
13) PROCEDURES IN USING A FORD FLOW CUP : E L P P P U ST
a. ENSURE THAT THE EQUIPMENT & PAINT TEMPERATURE ARE @ 20°C ±0.5°C
b. LEVEL OFF THE EQUIPMENT USING THE BUBBLE LEVEL & ADJUSTABLE SCREW LEGS
c. PUT THE LID TO ONE SIDE WHEN LEVELLING IS COMPLETE.
d. PLACE A SUITABLY SIZED RECEPTACLE UNDER THE ORIFICE (GREATER THAN 100cc)
e. PLACE A FINGER OVER THE NOZZLE ORIFICE & FILL WITH THE PAINT TO BE TESTED, UP TO THE BRIM, LEAVING A CONVEX MENISCUS.
f. USING A RULER, QUICKLY SCRAPE EXCESS MATERIAL INTO THE OVERFLOW RIM ON THE TOP OF THE CUP.
g. SIMULTANEOUSLY START A STOPWATCH & REMOVE THE FINGER FROM THE NOZZLE.
h. THE PAINT WILL RUN FROM THE ORIFICE IN A CONTINUAL STREAM. WHEN IT DRIPS, STOP THE WATCH. THE TIME IN SECONDS IS RECORDED AS THE
VISCOSITY AT THE MEASURED TEMPERATURE.
14) HEGMAN GRIND GAUGE---ALSO CALLED FINENESS OF GRIND GAUGE, IT IS USED TO MEASURE THE DEGREE OF DISPERSION OF A PAINT.
15) A HIGH FLASH POINT MATERIAL IS SAFER THAN A LOW FLASH POINT MATERIAL.
16) HEGMAN GRIND GAUGE---ALSO CALLED FINENESS OF GRIND GAUGE, IT IS USED TO MEASURE THE DEGREE OF DISPERSION OF A PAINT. 2 B O A
a. 2 GROOVES TAPERED FROM (ZERO) 0um ALONG THE LENGTH OF THE GAUGE TO 100um DEEP, PAINT IS ADDED TO THE DEEPEST POINT OF THE SCALE &
DRAWN ALONG TO TOTALLY FILL THE GROOVE USING A SPECIALLY PROFILED SCRAPER BAR.
b. BS 3900 REQUIRES THAT WITHIN 3 SECONDS OF THIS OPERATION, THE SCALE SHOULD BE PLACED SO THAT THE EYE LOOKS ALMOST PARALLEL ALONG
THE GROOVE
c. OBSERVE A POINT ALONG THE GROOVE WHERE WITHIN A 3mm BAND, 5 TO 10 AGGREGATES BREAK THROUGH THE SURFACE OF THE PAINT. THIS STATED
ANGLE IS THE POINT WHERE THE SURFACE WILL CHANGE FROM GLOSS AT THE DEEP END, TO MATT AT THE SHALLOW END.
d. ALONG THE GROOVE AT SOME POINT, THE AGGREGATES WILL REST ALONG THE BOTTOM & PROTRUDE THROUGH THE SURFACE GIVING A RESULT.
17) VOLATILE OR NON-VOLATILE TEST (BS 3900 PART B2): S P P T
a. SELECT A CLEAN, THOROUGHLY DRY GLASS STIRRING ROD & WATCHGLASS, & WEIGH ON A SENSITIVE BALANCE TO THE NEAREST MILLIGRAM
b. PLACE ONTO THE WATCHGLASS APPROXIMATELY 2 GRAMS OF PAINT AND WEIGH AGAIN
c. PLACE THE WATCHGLASS WITH PAINT INTO A HOT AIR OVEN, NO NAKED FLAME , REPEATEDLY STIR TO DRIVE AWAY THE VOLATILE CONTENT
d. TAKE A FINAL WEIGHT OF THE GLASS, ROD & DRY PAINT & SIMPLE CALCULATIONS WILL GIVE VOLATILE OR NON-VOLATILE RATIO BY WEIGHT.
 1

18) ABEL CUP---USED TO DETERMINE THE FLASH POINT OF A SOLVENT

a. ADD SOLVENT TO THE ABEL CUP, REPLACE LID WITH THERMOMETER & AGITATOR IN PLACE
b. CLAMP THE ABEL CUP ONTO A RETORT & LOWER INTO A WATER BATH
c. GENTLY HEAT THE WARM BATH, WHICH WILL IN TURN, HEAT THE SOLVENT UNDER TEST
d. EVERY 1/2 °C RISE IN TEMPERATURE, IT ACTIVATES THE HIGH FREQUENCY SPARK
e. FLASH POINT TEMPERATURE IS REACHED WHEN A BLUE FLAME FLASHES OVER THE SOLVENT, AN ORANGE FLAME SIGNIFIES THAT THE FLASH POINT
TEMPERATURE IS EXCEEDED & THE TEST SHOULD BE REDONE.
19) BLUE FLAME---INDICATES THE FLASH POINT
20) DENSITY = WEIGHT / VOLUME
21) SPECIFIC GRAVITY OR RELATIVE DENSITY = DENSITY OF "X" / DENSITY OF WATER
22) RELATIVE DENSITY (SPECIFIC GRAVITY)---A MEASURE OF THE AMOUNT OF MOISTURE IN THE AIR COMPARED TO SATURATION LEVEL & MAY AFFECT THE
COATING APPLICATION.
23) OTHER NAMES FOR DENSITY CUP:
a. RELATIVE DENSITY CUP
b. SPECIFIC GRAVITY CUP
c. WEIGHT PER LITER CUP
d. WEIGHT PER GALLON CUP
e. PYKNOMETER
24) STOKE---KINEMATIC VISCOSITY UNIT
25) TABER ROTARY ABRASER---TEST FOR A MATERIAL'S RESISTANCE TO ABRASION.
26) CYLINDRICAL MANDRELS (VARIOUS DIAMETERS)---EQUIPMENT USED TO DETERMINE FLEXIBILITY, THE FLEXIBILITY OF A COATING IS EXPRESSED AS THE
SMALLEST DIAMETER MANDREL OVER WHICH THE PAINT WILL NOT CRACK WHEN BENT.
27) TUBULAR IMPACT TESTERS---EQUIPMENT USED TO MEASURE IMPACT RESISTANCE.
28) KOENIG ALBERT---EQUIPMENT USED TO TEST THE HARDNESS OF A FILM. (OTHERS: BUCHHOLZ INDENTOR & SWARD HARDNESS ROCKER)
29) DENSITY CUP---USED FOR MEASURING DENSITY OF PAINT.
30) ACCELERATED TEST BOXES: H S W T P
a. HUMIDITY CABINETS
b. SALT SPRAY CABINETS
c. WATER SOAK TESTS
d.TEMPERATURE CYCLING
e. PROHESION TESTING
31) TROPICAL BOX---FOR TESTING TROPICAL CONDITIONS (FOR ACCELERATED TESTING PURPOSES)
32) PAINT WILL HAVE A LOWER DENSITY THAN WATER.
33) DENSITY WOULD BE LOWERED IF SOLVENT IS ADDED TO PAINT.
34) 100cc IS THE CAPACITY OF THE DENSITY CUP.
35) SPECIFIC GRAVITY IS DENSITY OF "X" OVER THE DENSITY OF WATER, WHILE DENSITY IS MASS OVER VOLUME
36) WATER SOAK TESTS---USED TO TEST FOR WATER ABSORPTION BY WEIGHING BEFORE & AFTER SUBMERSION.
37) TEMPERATURE CYCLING---USED TO DETERMINE THE MAXIMUM & MINIMUM TEMPERATURE TO WHICH A PAINT CAN BE SET SO AS TO AVOID CRACKING DUE
TO CONSTANT EXPANSION & CONTRACTION.
38) MINIMUM & MAXIMUM TEMPERATURE SETTING IS OBTAINED FROM A COLD CHECK TEST SO AS TO AVOID PAINT CRACKING DUE TO THE CONSTANT
EXPANSION & CONTRACTION OF THE PAINT DUE TO TEMPERATURE CHANGES.
39) DRYING & CURING TESTS: B B M M P G T
a. BALLOTINI TEST g. THUMBNAIL TEST
b. BECK KOLLER STYLUS TEST (BK DRYING TIME RECORDER)
c. MECHANICAL THUMB TEST
 d. MECHANICAL SCRATCH TEST
e. PENCIL SCRATCH TEST

f. GOLD LEAF TEST 2

40) SOLVENT EVAPORATION TIME---RECORDED AS THE DRYING TIME IN A BK TEST.

41) METHODS OF DETERMINING OPACITY: P T B
a. PFUND CRYPTOMETERS ( 2 TYPES BELOW…..)
b. TROUGH TYPE CRYPTOMETERS
c. BLACK & WHITE FUSED PLATES
42) PIGMENT CONCENTRATION & REFRACTIVE INDEX---AFFECTS THE OPACITY OF A PAINT FILM.
43) PFUND CRYPTOMETER---USED TO DETERMINE THE WET FILM OPACITY
44) PIG GAUGE (PAINT INSPECTORS GAUGE)---A DESTRUCTIVE GAUGE USED TO MEASURE A COATING INCLUDING M.I.O. WHICH IS MAGNETIC.
45) WET PAINT FILM THICKNESS ARE NEEDED SO THAT MEASUREMENT OF WFT CAN MEET THE SPECIFICATION REQUIREMENTS OF THE DFT & HOPEFULLY
ELIMINATE MAJOR RECTIFICATIONS.
46) TWO METHODS OF MEASURING WET FILM THICKNESS: E C
a. ECCENTRIC WHEEL
b. COMB GAUGES
47) WET FILM THICKNESS READINGS ARE IMMEDIATELY TAKEN AFTER APPLICATION IN ORDER TO OBTAIN TRUE READINGS.
48) FROM INFORMATIONS GIVEN ON THE MATERIALS DATA SHEET & CALCULATED DENSITY OF THE SOLVENT, A PAINT INSPECTOR CAN DETERMINE IF A
TWO PACK PAINT WAS MIXED IN THE CORRECT PROPORTIONS USING A DENSITY CUP.
49) BANANA GAUGE (MAGNETIC COATING THICKNESS GAUGE)---MEASURES NON-FERROMAGNETIC COATINGS OVER FERROMAGNETIC SUBSTRATES & CAN
EVEN BE USED UNDER WATER.
50) NO, EDDY CURRENT GAUGE CANNOT BE USED ON FERROMAGNETIC SUBSTRATES.
51) MAGNETIC HORSESHOE GAUGE---USED FOR MEASURING HOT SURFACES (METAL SPRAY) & IN HAZARDOUS AREAS & CAN ONLY BE USED ON
FERROMAGNETIC SUBSTRATES.
52) BAR APPLICATOR---A TYPE OF OPACITY TEST
53) GLOSS METER---USED TO MEASURE REFLECTIVITY OR GLOSS
54) HOW A GLOSS METER WORKS: A LIGHT SOURCE DIRECTS A BEAM OF LIGHT ONTO THE SURFACE UNDER TEST & A PHOTO ELECTRIC CELL COLLECTS THE
REFLECTED LIGHT AND QUANTIFIES IT AND CONVERTS IT DIGITALLY INTO A PERCENTAGE OF THE INCIDENT LIGHT.
55) FACTORS GOVERNING THE DEGREE OF GLOSS: P D P R S
a. PVC
b. DEGREE OF DISPERSION
c. PARTICLE SIZE
d. RESIN TYPE
e. SOLVENT TYPE
56) THE DEGREE OF GRIND IN A PRIMER/ MID COAT WOULD BE LARGER (EXTENDER HAVE 40um PARTICLE SIZE TO AID WITH COHESION & INTER COAT
ADHESION.
57) IN A GLOSS PAINT---THE AGGREGATES WITHIN THE PAINT SHOULD BE SUBSTANTIALLY BELOW THE DIMENSION OF THE FILM THICKNESS.
58) MEASURING GLOSS ON A GLASS PANEL: A HIGH PERCENTAGE OF REFLECTION WILL BE GLOSS (ON A PERFECTLY SMOOTH SURFACE, IT WOULD GIVE
ALMOST 100%), A LOW PERCENTAGE READING WOULD BE MATT.
59) ON A GLOSS METER READING OF 25%, IT SIGNIFIES THAT THERE IS A LOW PERCENTAGE OF REFLECTION, IT IS MATT.
60) AGGREGATE OF LARGER SIZE THAN THE DRY FILM THICKNESS (NOMINAL THICKNESS) WOULD PROTRUDE & DEFLECT LIGHT.
61) THREE COMMON TESTS FOR DETERMINING THE ADHESION OF A PAINT FILM:
a. V CUT TEST
b. CROSS HATCH TEST
c. DOLLY TEST
62) DOLLY TEST---CLASSED AS A QUANTITATIVE TEST.
63) ADHESION FAULTS:
a. PRIMER TO SUBSTRATE FAILURE
b. INTERCOAT ADHESION (BETWEEN FILMS)
c. COHESIVE FAILURE (WITHIN A PAINT FILM)

64) 3% SODIUM CHLORIDE (COMMON SALT)---THE CHEMICAL SOLUTION USED TO CONDUCT A CATHODIC DISBONDMENT TEST.
65) HYDROGEN GAS EVOLVES FROM THE CATHODE WHICH CAUSES DISBONDMENT.
66) F.B.E. MAXIMUM @ 5mm AFTER 28 DAYS---CRITERION USED IN ASSESSING A CATHODIC DISBONDMENT TEST PANEL.
67) 2 METHODS OF APPLYING CATHODIC PROTECTION: S I
a. SACRIFICIAL ANODES SYSTEMS (GALVANIC ANODE SYSTEM)---WORKS ON THE PRINCIPLE OF BIMETALLIC CORROSION.
b. IMPRESSED CURRENT SYSTEM---USED TO PROTECT LONG LENGTHS OF PIPELINE FROM ONE INSTALLATION AT A DISTANCE OF APPROXIMATELY 10 MILES.
68) HALF-CELL REFERENCE ELECTRODE---USED IN MEASURING THE PIPE TO EARTH POTENTIAL OF A PIPELINE.
COPPER / COPPER SULPHATE HALF CELL ELECTRODE---THE MOST COMMONLY USED HALF-CELL ELECTRODE.
69) NO, IT'S NOT ADVISABLE TO REFILL A PIPE TRENCH WITH A CARBONACEOUS BACKFILL.
70) YES, CATHODIC PROTECTION SYSTEM ELIMINATES CORROSION.
71) YES, EXTERNAL SURFACE OF A TANK CAN BE PROTECTED WITH THE PRESENCE OF ELECTROLYTE.
72) YES, A CRUDE OIL TANK CAN BE FULLY PROTECTED INTERNALLY IF THE TANK IS HOLDING AN ELECTROLYTIC MEDIUM, BUT ONLY UP TO THE LEVEL OF
MEDIUM, NOT ABOVE THE MEDIUM.
73) DFT's BELOW OR EQUAL THAN 300um---USE 9V VOLTAGE SETTING (HOLIDAY/ PINHOLE DETECTION)
74) DFT's @ 300-500um---USE 90V VOLTAGE SETTING (HOLIDAY/ PINHOLE DETECTION)
75) DETERGENT LIQUID---THE LIQUID ADDED TO WATER WHEN USING A WET SPONGE PINHOLE DETECTOR TO ALLOW IMMEDIATE WATER PENETRATION.
HIGH VOLTAGE HOLIDAY DETECTOR---USED FOR COATING THICKNESS ABOVE 500um.(PINHOLE DETECTION)
WET SPONGE PINHOLE DETECTOR---USED FOR COATING THICKNESS LESS THAN 500um
76) DETERGENT LIQUID---THE LIQUID ADDED TO WATER WHEN USING A WET SPONGE PINHOLE DETECTOR TO ALLOW IMMEDIATE WATER PENETRATION.
77) NO, IT IS NOT ADVISABLE TO DO WET SPONGE DETECTION ON GALVANISING.
78) WORKING UPWARDS ON A VERTICAL SURFACE WITH A WET SPONGE---UPON CONTACT WITH A PINHOLE, THE DETERGENT ALLOWS IMMEDIATE
PENETRATION OF THE WATER & WHEN A HIGH PITCHED BLEEP SOUNDS, IT INDICATES THE PRESENCE OF A PINHOLE.
79) WET SPONGE DETECTOR WORKS ON ALTERNATING CURRENT.
80) HIGH VOLTAGE HOLIDAY DETECTOR---USED FOR COATING THICKNESS ABOVE 500um. (PINHOLE DETECTION)
4
8
REVISION QUESTIONS GENERAL (FRIDAY)
1) TWO CATEGORIES OF PAINT MILL:
a. DIRECT CHARGE DISPERSING MILLS
b. INDIRECT CHARGE DISPERSING MILLS
2) THE GRINDING OF AGGREGATES & AGGLOMERATES DOWN TO A SUITABLE SIZE FOR THE PAINT TYPE BEING PROCESSED AND TO ASSURE THAT ALL THE BASIC
INGREDIENTS (BINDER, PIGMENTS & ADDITIVES, SOLVENT) ARE THOROUGHLY MIXED, THIS IS THE MAIN REASON FOR PROCESSING PAINT IN A MILL.
3) HOW A BALL MILL WORKS: M H S T
a. MILL BASE IS ADDED TO THE DRUM UNTIL THE BALLS ARE COVERED, ABOUT 50% CAPACITY OF THE DRUM
b. D' HATCH IS THEN SEALED OFF & THE DRUM STARTS ROTATING AT A SPEED, THEN THE BALLS CASCADE DOWN & DO NOT STICK ON THE DRUM
c. SHEAR FORCES ARE APPLIED TO THE MILL BASE AS THE BALLS CASCADES BETWEEN THE BALLS AND VESSEL WALLS.
d. TYPICAL DISPERSION TIME WOULD BE OVERNIGHT.
4) HOW A N ATTRITOR MILL WORKS: (VERTICAL VERSION OF THE BALL MILL)
a. THE BALLS ARE DRIVEN BY PADDLES,
b. THE MILL BASE IS CONTINUALLY CIRCULATED BY PUMP FROM BOTTOM TO TOP & GIVES ADEQUATE DISPERSION IN LESS TIME.
5) STEEL BALLS---FOR DARKER COLOURS (IN A BALL MILL)
PORCELAIN---FOR LIGHTER COLOURS. (IN A BALL MILL)
6) BEAD MILL---OTHER NAMES ARE "SAND MILL" OR "PEARL MILL"
7) HOW A COLLOID MILL WORKS: (HIGH SPEED STONE MILLS)
a. USES STONE GRINDING DISCS CONTAINING CARBORUNDUM, THE TOP STONE IS STATIONARY & THE LOWER STONE IS ROTATING @ 3600 rpm.
b. GRAVITY FED LOW VISCOSITY SLURRY ENTERS THE CENTER OF THE STATIC TOP STONE AND IS PASSED BETWEEN THE TWO STONES BY CENTRIFUGAL
FORCE WHERE IT IS SUBJECTED TO EXTREME TURBULENCE & SHEAR FORCES TO AFFECT THE DISPERSION.
8) MATERIALS DATA SHEET INFORMATION:
a. MANUFACTURER'S DESCRIPTION k. THEORETICAL SPREADING RATE u. IDENTITY OF PLANT
b. RECOMMENDED USAGE l. APPLICATION METHOD v. TIME OF APPLICATION
c. SERVICE TEMPERATURE m. INDICATED DFT w. POT LIFE
d. CERTIFICATES / APPROVALS n. INDICATED WFT
e. COLOURS / SHADE NUMBERS o. SAFETY
f. FLASH POINT p. ISSUANCE DATE
g. SPECIFIC GRAVITY q. PRODUCT REFERENCE NUMBERS
h. CURING PERIIOD r. EXPIRATION DATE
i. FINISH s. BATCH NUMBERS
j. % VOLUME SOLIDS t. REFERENCE # OF THINNERS
9) HALOGENATED HYDROCARBON---ETCHANT
10) ROTATIONAL VISCOMETERS---USED FOR DETERMINING THE VISCOSITY OF A HIGH VISCOSITY PAINT.
11) CATHODIC PROTECTION---IS THE SECONDARY LINE OF DEFENCE AGAINST CORROSION, THE PRIMARY DEFENCE BEING THE COATING. USING LESS NOBLE
METALS AS PIGMENTATION WHICH SACRIFICES ITSELF TO PROTECT THE UNDERLYING SUBSTRATE.
12) PRIMER---THE 1ST COAT OF A PAINTING SYSTEM, IT CONSISTS OF LOW VOLUME SOLID MATERIALS WHICH WETS OUT THE SUBSTRATE AND PROVIDES
EXCELLENT ADHESION AND IT IS THE KEY FOR ANY SUBSEQUENT LAYER.
13) WASH OR MORDANT PRIMER ALONG WITH PVB ETCH PRIMERS ARE FOR NON-FERROUS SUBSTRATES.
14) HIGH SPEED FULL CROSS LINKING / HIGH SPEED CURING---THE ADVANTAGE OF ELECTROSTATIC APPLICATION METHODS.
15) EXPENSIVE TYPE OF BRUSH FILLING---
16) SOLVENT ENTRAPMENT---THE MAIN REASON FOR COHESIVE FAILURE. (2ND CAUSE: INCORRECT RATIO MIX OF A TWO-PACK---FOR TWO PACKS)
17) A VERY STRONG BINDER IS REQUIRED FOR ZINC RICH PAINT IN ORDER TO HOLD TOGETHER THE HIGH CONCENTRATION OF ZINC PARTICLES.
18) ETCH PRIMERS ARE NOT SPRAY APPLIED BECAUSE OF THE ACID CONTENT WITHIN THESE PRIMERS.
19) OVERSPRAY---ALSO REFERRED TO AS SPOTTING.
 1

20) METHODS OF DETERMINING DRY FILM THICKNESS: T C D N

a. TEST PANELS
b. CALCULATIONS
c. DESTRUCTIVE TEST GAUGES
d. NON-DESTRUCTIVE TEST GAUGES
21) PSYCHROMETER (WHIRLING HYGROMETER, ASPIRATED HYGROMETER)---WIDELY USED BY COATING INSPECTORS TO DETERMINE WET & DRY BULB
TEMPERATURE READINGS FROM WHICH RELATIVE HUMIDITY & DEW POINT TEMPERATURE CAN BE CALCULATED USING HYGROMETRIC TABLES &
CALCULATOR.
22) COLOUR OF GALVANISED SURFACE AFTER T-WASH APPLICATION---
23) HOW SOON CAN A T-WASHED SUBSTRATE BE COATED?---
24) TWO OTHER CONSTITUENTS OF FBE POWDER PAINT---
25) AIRLESS SPRAY---AIR IS NOT USED FOR ATOMISATION, AIR IS PRESSURISED BY MEANS OF A PUMP OPERATED BY COMPRESSED AIR.
CONVENTIONAL SPRAY:
a. SUCTION FEED---THE PAINT CONTAINER IS UNDERNEATH THE GUN, ABOUT 1L CAPACITY & THE PAINT IS DRAWN UP BY VENTURI PRINCIPLE TO D' GUN.
b. GRAVITY FEED---THE PAINT CONTAINER IS ABOVE THE GUN & PAINT FEEDS TO THE GUN BY GRAVITY.
c. REMOTE PRESSURE POT---HAS A MUCH BIGGER CAPACITY & MUCH BIGGER AREAS CAN BE PAINTED B4 REFILLING IS REQUIRED.
26) ADVANTAGES OF BRUSH APPLICATION:
a. ENVIRONMENTALLY FRIENDLY
b. RESULTS IN LESS WASTE MATERIAL
c. NO SPOTTING OR OVERSPRAY DAMAGE TO ADJACENT AREAS
27) THE NOBILITY OF A METALLIC PIGMENT IS CONSIDERED WHEN SELECTING A SACRIFICIAL PAINT.
28) SHERADISING---ALL COMPONENTS ARE CLEANED AND TUMBLED IN THE POWDERED ZINC, D' IMPACT FUSES THE ZINC ONTO THE COMPONENTS & IN
EFFECT, COLD WELDS THE POWDER ONTO THE METAL.
29) CONVENTIONAL SPRAY:
a. SUCTION FEED---THE PAINT CONTAINER IS UNDERNEATH THE GUN, ABOUT 1L CAPACITY & THE PAINT IS DRAWN UP BY VENTURI PRINCIPLE TO D' GUN.
b. GRAVITY FEED---THE PAINT CONTAINER IS ABOVE THE GUN & PAINT FEEDS TO THE GUN BY GRAVITY.
c. REMOTE PRESSURE POT---HAS A MUCH BIGGER CAPACITY & MUCH BIGGER AREAS CAN BE PAINTED B4 REFILLING IS REQUIRED.
30) CALORISING---COATING WITH ALUMINIUM (COMPONENTS ARE DIPPED INTO MOLTEN ALUMINIUM)
31) A SEALER IS APPLIED TO ALUMINIUM METAL SPRAY TO GIVE AN EXTENDED MAJOR MAINTENANCE FREE LIFE TO AN ANTI-CORROSION SYSTEM.
32) SKIPPED OR MISSED AREAS---AS PER BS 2015
33) THREE PROPERTIES OF COLOUR:
a. HUE---REFERS TO THE BASIC COLOR RED, YELLOW, GREEN & BLUE
b. BRIGHTNESS---SOMETIMES CALLED LIGHTNESS
c. SATURATION---HOW VIVID COLOR APPEARS.
34) HOT SPRAYING---WHEN PAINT IS HEATED, IT REDUCES VISCOSITY (FLOWS EASIER) AND THE CURE OR DRYING STARTS QUICKER. IT IS THEREFORE EASIER
TO APPLY , WETS OUT BETTER & REDUCES THE NEED FOR SOLVENT ADDITION.
35) ON AN AIRLESS SPRAY TIP, BLOCKAGES CAN BE CLEARED BY TURNING THE TIP THROUGH 180° TRIGGERING TO GROUND OR A CONTAINER TO CLEAR
THE BLOCKAGE, THEN REVERSE THE TIP AGAIN TO ITS ORIGINAL POSITION.
36) APPROXIMATELY 25mm IN FRONT OF THE APERTURE, TWO AIR CHANNELS FROM LUGS ON THE CAP, DIAMETRICALLY OPPOSED, BLOW AIR TO CONVERGE
AT THE PAINT STREAM, AT THIS CONVERGEANCE THE PAINT IS ATOMISED INTO VERY MINUTE DROPLETS & CONDUCTED TO THE WORKPIECE.
37) IN USING AIRLESS SPRAYS, ATOMISATION OCCURS BY FORCING THE PAINT AT EXTREMELY HIGH PRESSURE, USUALLY 2000 TO 2500 psi THROUGH A
VERY SMALL APERTURE, 12-23thou DIAMETER, INTO A VOLUME OF AIR OFFERING A RESISTANCE TO THE PAINT FLOW. AS THE AIR & PAINT MEET,
THE PAINT ATOMISES.
38) DIP COATING---A COMPONENT IS DIPPED INTO PAINT AND HUNG TO DRY.
39) ROPINESS---PRONOUNCED BRUSH MARKS THAT HAVE NOT FLOWED OUT BECAUSE OF THE POOR LEVELLING PROPERTIES OF THE COATING MATERIAL.
40) EFFLORESCENCE---A WHITE CRYSTALLINE FORMATION ON BRICKS, MORTAR, PLASTER. USUALLY FORMS UNDER PAINT FILMS ON THE ABOVE SUBSTRATES
& IS NOT A PAINT DEFECT. THIS IS CAUSED BY SOLUBLE SALTS CRYSTALLISING ON THE SURFACE.

41) WAYS OF MELTING ALUMINIUM:

a. POWDER SYSTEM
b. ELECTRIC ARC SYSTEM
c. WIRE & PISTOL SYSTEM---WIDELY USED FOR SITE APPLICATION OF METAL SPRAY
42) FLOCCULATION---THE DEVELOPMENT OF LOOSELY COHESIVE PIGMENT AGGLOMERATES IN A COATING MATERIAL.
43) BITTINESS---THE PRECENCE OF PARTICLES OF GEL, FLOCCULATED MATERIAL OR FOREIGN MATTER IN A COATING MATERIAL OR PROJECTING FROM THE
SURFACE OF THE FILM
SEEDY---DENOTES THE PRESENCE OF BITS THAT HAVE DEVELOPED IN A COATING MATERIAL DURING STORAGE.
PEPPERY---SOMETIMES USED WHEN THE BITS ARE SMALL & UNIFORMLY DISTRIBUTED.
44) TIE COAT---
45) FIVE DEPRESSIONS OF THE BELLOWS ARE NEEDED FOR THE DRAGER TEST ( TOXICITY OF THE AIR; CONCENTRATION OF XYLENE)
46) HAZARD SIGNS FOR TOXIC AND VERY TOXIC, HARMFUL & CORROSIVE---REFER TO PAGE 104 OF THE BGAS REVIEWER.
47) SAPONIFICATION---DECOMPOSITION OF THE MEDIUM OF A FILM BY ALKALI & MOISTURE IN THE SUBSTRATE.
SAPONIFICATION---THE FORMATION OF A SOAP BY THE REACTION OF A FATTY ACID ESTER AND AN ALKALI.
48) TOXICITY---MEASURED IN PARTS PER MILLION (PPM)
49) POLYURETHANE OR A HIGH SOLID EPOXY---MATERIALS USED ON A DAMP SURFACE
50) PADDING---MAINLY D.I.Y. PADS OF MOHAIR OR FOAM ARE USED TO APPLY PAINT.
51) EXTREMELY HIGH PRESSURE---USUALLY 2000 TO 2500psi THROUGH A VERY SMALL APERTURE, 12 TO 23 THOU DIAMETER (ATOMISATION)
52) LIFTING---THE SOFTENING, SWELLING OR SEPARATION FROM THE SUBSTRATE OF A DRY COAT AS A RESULT OF THE APPLICATION OF A SUBSEQUENT COAT.
53) CISSING---THE FORMATION OF SMALL AREAS OF THE WET FILM OF A COATING MATERIAL WHERE THE COATING MATERIAL HAS RECEDED LEAVING
HOLIDAYS IN THE FILM.
54) O.E.L.---OCCUPATIONAL EXPOSURE LIMIT
O.E.S.---OCCUPATIONS EXPOSURE STANDARD
M.E.L.---MAXIMUM EXPOSURE LIMIT
L.E.L.---LOWER EXPLOSIVE LIMIT
R.A.Q.---
U.E.L.---
55) POTASSIUM HEXACYANOFERRATE---USED TO DETECT THE PRESENCE OF SOLUBLE IRON SALTS IN A METAL SUBSTRATE.
56) 100um---AVERAGE THICKNESS OF GALVANISING
57) CHALKING---THE FORMATION OF A FRIABLE, POWDERY LAYER ON THE SURFACE OF THE FILM OF A COATING MATERIAL CAUSED BY DISINTEGRATION
OF THE BINDING MEDIUM DUE TO DISRUPTIVE FACTORS DURING WEATHERING.
BLOOMING---A DEPOSIT RESEMBLING THE BLOOM ON A GRAPE THAT SOMETIMES FORMS ON THE GLOSS FILM OF A COATING CAUSING LOSS OF GLOSS
AND DULLING OF COLOUR.
58) INTER-COAT ADHESIVE FAILURE:
a. SURFACE CONTAMINATION
b. LACK OF ADEQUATE SURFACE PREPARATION, OIL, GREASE, DIRT, DUST
c. LACK OF OBSERVANCE OF RECOMMENDED OVER-COATING LIMITS
e. EXPANSION / CONTRACTION DIFFERENCES BETWEEN MATERIALS.
59) DETERMINING THE QUALITY OF ADDED THINNERS IN THIXOTROPIC PAINT:
a. WHEN THIXOTROPIC PAINTS ARE STIRRED, IT CHANGES TO NORMAL LIQUID CONSISTENCY, WHEN LEFT, THEY SLOWLY REVERT TO THIXOTROPIC
CONSISTENCY.
60) MANUFACTURERS ARE DEVELOPING SOLVENT FREE, POWDRES & WATERBORNE TYPES OF PAINT SO AS TO LESSEN SOLVENT EMISSIONS INTO THE
ATMOSPHERE (ENVIRONMENTAL CONCERN)
61) GRINNING---THE SHOWING THROUGH OF THE SUBSTRATE DUE TO THE INADEQUATE HIDING POWER OF THE COATING MATERIAL.
62) BLEEDING---THE PROCESS OF DIFFUSION OF A SOLUBLE COLOURED SUBSTANCE FROM, INTO OR THROUGH A COATING MATERIAL FROM BENEATH THUS,
PROVIDING AN UNDESIRABLE STAINING OR DISCOLOURATION.

63) DUTIES OF A PAINTING INSPECTOR:

a. AS PER BS 4778 PT.1, INTERNATIONAL TERMS DEFINES INSPECTION AS MEASURING, EXAMINING, TESTING, GAUGING ONE OR MORE CHARACTERISTICS
OF A PRODUCT OR SERVICE AND COMPARING THESE WITH SPECIFIED REQUIREMENTS TO DETERMINE CONFORMITY.
b. AN INSPECTOR SHOULD KEEP ADEQUATE & ACCURATE RECORDS OF ALL STAGES OF THE WORK BEING CARRIED OUT, MATERIALS USED,
AMBIENT CONDITIONS ETC.
c. SUBMIT DAILY PAINTING INSPECTION REPORT WHICH SHOULD CONTAIN ALL INFORMATION REQUESTED.
64) CONTRACT DOCUMENTS 2B VERIFIED BY THE COATING INSPECTOR: J D P Q P S B W R
a. JOB SPECIFICATION
b. DATA SHEETS FOR THE PAINTS / COATINGS
c. PROCEDURES
d. QUALITY PLANS
e. PLANT DRAWINGS
f. SITE PLANS
g. BRITISH STANDARDS
h. WASTE MANAGEMENT (DUTY CARE OF DOCUMENT)
i. RELEVANT LOCAL REGULATIONS
65) DAILY REPORT SHEET INFORMATION:
a. DETAILS ABOUT THE CONTRACT & THE CONTRACTOR
b. AMBIENT CONDITIONS APPLICABLE DURING THE WORK PERIOD NEAR THE TASK LOCATION
c. SURFACE PREPARATION ACTIVITIES SHALL INCLUDE:
--- METHOD USED --- PROFILE ACHIEVED
--- ORIGINAL SUBSTRATE CONDITION --- IDENTITY OF PLANT
--- ABRASIVE TYPE --- TIME OF START & COMPLETION
--- DEGREE OF CLEANLINESS ACHIEVED
d. FOR MATERIALS:
--- MANUFACTURER --- REFERENCE NUMBER OF THINNERS
--- PRODUCT REFERENCE NUMBER --- WFT & RESULTING DFT
--- EXPIRY DATE --- TIME OF APPLICATION
--- BATCH NUMBER --- IDENTITY OF PLANT
--- COLOUR
66) CURTAINS, SAGS, RUNS, TEARS ARE A RESULT OF EXCESS QUANTITIES OF PAINT AT IRREGULARITIES IN THE SURFACE.
67) BINDER TYPER MODIFIED TO USE WATER:
a. ALKYDS e. VINYLS
b. ACRYLICS f. EPOXIES
c. POLYESTERS g. SILICONES
d. POLYURETHANES

68) STRIPE COAT---A METHOD USED AT THE DISCRETION OF THE ENGINEER AND IS NOT SUITABLE ON INTERNAL CORNERS, WELDS, TOES, BOLTS, RIVETS,
& PLATE OVERLAPS.
69) 4.5 LITERS = 4500 cm3
70) PAINT DATA SHEET INFORMATION:
--- MANUFACTURER --- REFERENCE NUMBER OF THINNERS
 --- PRODUCT REFERENCE NUMBER --- WFT & RESULTING DFT
--- EXPIRY DATE --- TIME OF APPLICATION
--- BATCH NUMBER --- IDENTITY OF PLANT
--- COLOUR

IRREGULARITIES, NON-CONFORMANCE, DEVIATION FROM SPECIFICATIONS:

a. SUBSTITUTING APPROVED PRODUCTS WITH UNAPPROVED PRODUCTS
b. SUBSTITUTING NEW MATERIALS WITH OUT OF DATE MATERIALS
c. USING SOLVENTS OTHER THAN THOSE APPROVED BY THE MANUFACTURER
d. NOT OBSERVING INDUCTION TIMES WHEN SPECIFIED
e. USING UNTRAINED PERSONNEL
f. RE-USING EXPENDABLE ABRASIVES
g. NOT OBSERVING RECOMMENDED OVER-COATING TIMES
h. CONTINUING WITH THE NEXT STAGE OF OPERATIONS WITHOUT INSPECTION OF THE SUBSTRATE & APPROVAL
i. PAINTING/ COATING OVER AREAS OF INADEQUATE SURFACE PREPARATION
j. WORKING IN CONDITIONS OUTSIDE OF SPECIFIED REQUIREMENTS
5
8
REVIEW QUESTIONS PA-10 SPECIFIC:
1) SPECIFIED COURSE OF ACTION FOR GRIT INCLUSIONS---RE-BLAST & RE-COAT
2) LONG TERM PROTECTION---PROTECTION TYPICALLY LASTING 15 YEARS.
GALVANISING---REFERS TO LONG TERM PROTECTION. (THE COATING OF COMPONENTS WITH ZINC IN WHICH METAL COMPONENTS ARE CHEMICALLY
CLEANED WITH ACID, WASHED & FLUXED THEN TOTALLY IMMERSED IN A VESSEL CONTAINING MOLTEN ZINC AT 450°C, AVERAGE THICKNESS AT
APPROXIMATELY 100um.
3)FULLY WEATHERED GALVANISING---A GALVANIZED STEEL SURFACE ON WHICH A COHESIVE OXIDE LAYER HAS FORMED BY NATURAL WEATHERING.
THE SURFACE IS NORMALLY DULL & LACKING IN METALLIC SHEEN.
NEW GALVANIZING---A GALVANISED STEEL SURFACE ON WHICH A COHESIVE OXIDE LAYER HAS NOT YET FORMED. (BRIGHT UNWEATHERED ZINC SURFACE)
4) SPECIFIC PAINTING APPLICATIONS (SPAS)---CRITERION FOR DETERMINING WHICH PAINT SYSTEM SHOULD BE USED.
5) TOTAL DFT OF THE COMPLIANT EPOXY SYSTEM @ 265um
a. 75um---HIGH BUILD EPOXY ALUMINIUM PRIMER
b. 75um---EPOXY MIO
c. 75um---HIGH BUILD EPOXY UNDERCOAT
d. 40um---EPOXY OR POLYESTER ACRYLIC FINISH
6) TOTAL DFT OF WATER BORNE SYSTEM @ 225um
a. 50um---PRIMER
b. 75um---MIO
c. 50um---UNDERCOAT
d. 50um---FINISH COAT
7) APPROVAL BY THE ENGINEER---LADDERS & OTHER MEANS OF ACCESS CAN BE REMOVED.
8) TWO MATERIALS USED ON DAMP SURFACES:
a. MOISTURE CURING POLYURETHANES
b. HIGH SOLIDS MULTI-COMPONENT EPOXY PAINTS
9) SOLVENT BASED PRIMER IS RECOMMENDED AFTER REMOVAL OF NON-DRYING PAINT.
10) NON FERROUS SUBSTRATES ARE PAINTED FOR AESTHETICS ONLY: P G F M S C
a. PRE-PAINTED CLADDING (PLASTISOL CLADDING)
b. GLASS REINFORCED PLASTICS
c. FUSION BONDED EPOXY
d. MULTI COMPONENT LIQUIDS
e. STAINLESS STEEL
f. CONCRETE
11) NON FERROUS SUBSTRATES ARE PAINTED FOR ANTI-CORROSION PURPOSES: N W P A
a. NEW GALVANIZED SURFACES
b. WEATHERED GALVANIZED SURFACES
c. PREVIOUSLY PAINTED GALVANIZED SURFACES
d. ALUMINIUM SURFACES
12) T-WASH PRIMER OR ETCH PRIMER SHOULD BE USED WHEN SURFACE PREPARATIONS LIKE SWEEP ABRASIVE BLAST & HAND ABRADING ARE IMPRACTICAL.
13) COATS OF PRIMER FOR SURFACES AT 100-149°C:
a. DFT OF 100um FOR URETHANE
b. DFT OF 250um FOR EPOXY COATING
14) ORDER OF COATING SYSTEMS FOR SURFACES AT 150-340°C:
a. MASK AREAS
b. REMOVE SURFACE CONTAMINATION
c. BLAST CLEAN (SA3 & 75um MAX. PROFILE)
d. --- THERMALLY SPRAYED ALUMINIUM or
--- INORGANIC ZINC SILICATE or
 --- POLYSILOXANE INORGANIC COATING

15) CONTRACTORS MAY BE REQUIRED TO PREPARE & PAINT TEST AREAS TO DEMONSTRATE THAT A CORRECT QUALITY OF SURFACE PREPARATION WITH A
SATISFACTORY FILM THICKNESS & FINISH TO THE PAINT FILM IS OBTAINED.
16) TYPICAL ITEMS TO BE MASKED OFF PRIOR TO BLASTING & PAINTING:
a. FIRE PROTECTION EQUIPMENT
b. WELD END PREPARATIONS
c. ATMOSPHERE SENSING HEADS
d. VENTS ON CONTROL EQUIPMENT
e. FLAME TRAPS
f. LUBRICATION POINTS
g. NAMEPLATES
17) THIN GAUGE ALUMINIUM WOULD NOT BE SWEEP BLASTED.
18) 3 PAINT SYSTEMS FOR USE ON ALUMINIUM:
a. THERMALLY SPRAYED ALUMINIUM SYSTEM
b. INORGANIC ZINC SILICATE SYSTEM
c. POLYSILOXANE INORGANIC SYSTEM
19) OPERATION CHART FOR NEW PAINTING SPECIFICATIONS: M R W C P M U F
a. MASK OFF, REMOVE ALL DEPOSITS, WIRE BRUSH, CLEAN AREAS, APPLY PRIMER, APPLY M.I.O., APPLY UNDERCOAT, APPLY FINISH
OPERATION CHART FOR MAINTENANCE PAINTING SPECIFICATIONS: M R W C SP SM U F F
a. MASK OFF, REMOVE ALL DEPOSITS, WIRE BRUSH, CLEAN AREAS, APPLY PRIMER, APPLY M.I.O., APPLY UNDERCOAT, APPLY FINISH, FULL COAT OF M.I.O.
20)
21) PERMIT TO WORK IS REQUIRED FOR ALL SITE WORKS AT ALL TIMES.
22) ETCH PRIMER OR T-WASH PRIMER IS SPECIFIED FOR NON-WEATHERED GALVANIZING.
23)
24) FLAME CLEANING IS NOT ALLOWED AS PER PA-10
25)
26) HOT DUTY SERVICE (TEMPERATURE RANGE):
a. 100-149°C
b. 150-340C
a. 340°C ABOVE
27) PA 10 COVERAGE:
a. BELOW GROUND
b. OFFSHORE INSTALLATIONS
c. INTERNAL COATINGS OF PIPES
d. STOVE ENAMEL COATINGS
28) 100mm IS THE SPECIFIED OVERLAPS ON REPAIRED AREAS.
29)
30) ALGAE & MOLD GROWTH REMOVAL:
a. THEY ARE TREATED WITH BIOCIDAL AGENT & LEFT FOR 24 HOURS.
b. IT IS THE REMOVED BY SCRUBBING WITH STIFF BRISTLE BRUSHES AND CLEAN WATER OR BY HIGH PRESSURE WASHING
31) B4 SURFACE PREPARATION, ALL CONTAMINANTS INCLUDING OIL & GREASE & WATER SOLUBLE SALTS ON THE WORKING SURFACES MUST BE REMOVED BY
WASHING WITH AN APPROPRIATE SOLVENT.
32)
33) CASE OF EXPENDABLE ABRASIVE---PRECAUTION 2B TAKEN WHEN BLAST CLEANING ON AN AGI
34) STIRRING PAINT IS NOT PERMISSIBLE IN PREPARING PAINTS.
35) SURFACE PREPARATION METHOD FOR NEW GALVANIZING:
a. SWEEP ABRASIVE BLAST
 b. HAND ABRADING

c. T-WASH PRIMER 2

36) WHERE THERMALLY SPRAYED ALUMINIUM & INORGANIC ZINC SILICATE PRIMERS ARE USED, A HIGH TEMPERATURE SEALER IS USED.
37) OPERATIONS CHART FOR PREPARATIONS FOR PAINT BREAKDOWN:
a. MASK AREAS
b. MECHANICALLY WIRE BRUSHES & FEATHER (St 3 MINIMUM)
c. CLEAN ALL SURFACES
d. APPLY PRIMER
e. APPLY M.I.O.
38) MARKINGS OF PAINT CONTAINERS:
a. MANUFACTURER'S NAME f. EXPIRY DATE
b. TRANSCODE IDENTIFICATION CODE PA9 g. APPLICATION GRADE (BRUSH OR SPRAY)
c. DESCRIPTION OF THE PRODUCT h. BATCH IDENTIFICATION CODE
d. COLOR CODE ( AS SPECIFIED BY TRANSCO) i. IDENTIFICATION OF PARTS & MIXING RATIO BY VOLUME FOR MULTI-PACK MATERIALS ONLY
e. SPECIAL STORAGE REQUIREMENTS j. ANY MARKINGS REQUIRED BY CURRENT LEGISLATION
39)
40) FIRST COAT OF A GALVANIZED SUBSTRATE---WATER BORNE ACRYLIC PAINT SYSTEMS DO NOT REQUIRE A SEPARATE PRIMER AS THE M.I.O. FULFILLS
THIS FUNCTION.
41) PA 9---PAINT SYSTEMS (PROPERTIES & PERFORMANCE REQUIREMENTS)
42) CONSIDERATIONS WHEN SELECTING A PAINT SYSTEM:
a. THE MOST APPROPRIATE COST EFFECTIVE METHODS OF SURFACE PREPARATION
b. THE MOST APPROPRIATE COST EFFECTIVE PAINT SYSTEMS TO GIVE THE REQUIRED SERVICE LIFE.
43) COATS APPLIED AT WORKS:
a. STRIPE COATING OR a. PRIMER
b. SPOT PRIMING OR b. M.I.O.
44) CRITERION AS TO PAINTING CAN OR CANNOT TAKE PLACE:
a. PAINT IS APPLIED WHEN THE RELATIVE HUMIDITY IN THE WORK ZONE IS LESS THAN 90%
b. WHEN THE AIR & METAL TEMPERATURES ARE AT LEAST 3°C ABOVE THE DEW POINT
c. AMBIENT & SUBSTRATE TEMPERATURES SHOULD NOT BE BELOW THE MINIMUM APPLICATION TEMP. FOR THE PAINT
45) ETCHING CHEMICAL REACTION HAPPENS WHEN T-WASH PRIMER IS APPLIED TO A NEWLY GALVANIZED SUBSTRATE.
46) 2 MATERIALS USED ON DAMP SURFACES:
a. MOISTURE CURING POLYURETHANES
b. HIGH SOLIDS MULTI-COMPONENT EPOXY PAINTS
47) 4 HOURS---IS THE MAXIMUM TIME LAPSE FROM SURFACE PREPARATION TO COATING
48) ALUMINIUM---THE MOST COMMON PIGMENT USED IN HIGH TEMPERATURE PAINTS
49) MUD CRACKING WILL RESULT DUE TO THICK APPLICATION OF ZINC SILICATE
50) ROLLER APPLICATION IS NOT ALLOWED FOR CORROSION PROTECTION COATING
 3

NOTES: PA 10 SPECIFIC
SPA1---NEW & MAINTENANCE PAINTING FOR LONG TERM PROTECTION OF INSTALLATIONS & COMPONENTS
--- APPLIES TO THE PAINTING AT WORKS OR SITE OF NEW INSTALLATIONS AND COMPONENTS & TO SITE MAINTENANCE PAINTING OF CARBON STEEL SURFACES
OPERATING BELOW 100°C.
4
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