Professional Documents
Culture Documents
Q What is a mill scale, and why is it a particular problem with attempting to protect steel?
A When ferrous metal is forged into flat plates, beams and girders. It is worked at temperature often
exceeding 1000C while the metal is in this white hot state it is in contact with the cool air and
rapidly oxidizes the results in the formation of a thin flaky layer called mill scale. Mill scale must
be removed from the surface of the steel before painting take place; mill scale is noble to steel
therefore in close contact with each other steel will corrode.
Q What is the number of the Swedish standard contained within BS 7079 and list the rust and
blasting grades together with their brief titles?
A The Swedish pictorial standard 05-59-00 is contained with B.S. 7079 Preparation of Steel
Substrates Prior to the application of paint and related products.
Q What factor influence how clean and how rough the surface becomes after blast cleaning?
A The cleanliness of the steel surface and its amplitude are governed by the abrasive characteristics
and human factors as follows:
ABRASIVE HUMAN FACTORS
Size Speed
Shape Angle
Density Distance
Hardness Time
Q List all Safety Equipment and clothing required for open site blasting?
A Use of Carbon impregnated hosed to reduce the chance of static shock. (Reinforced)
Use of Deadmans handle for direct operator control
Keep hoses straight as possible to prevent kinks, which may lead to a blow out.
Use of external coupling.
Liquid separator.
Hypodermic needle guage to control the nozzle pressure.
Operator should wear protective clothing, including air fed helmet, boots, gloves, ear defender and
leather apron.
Warning signs at the area, barrier tape
Keep the compressor pressure below 100 PSI
Q Give the three basic ingredients within a solvent carrying paint and list the job each has to do?
A A traditional solvent carrying paint consists of three basic ingredients, these are
Binder- It binds the particles together and holds them in suspension, gives the paint its finish,
makes the coating adhere to the surface, gives flexibility to the paint film, converts the coating to a
solid dry film, give resistance to water, chemical and abrasion.
Pigment Gives colour to the paint, gives opacity to the paint, gives resistance to acids, alkalis
and light.
Solvent Forms the evaporative part of the drying process, thins the paint so it can be applied
easily, washes out brushes and equipments, acts as a degreasing agent if approved.
Q Name four Binders / Solvent combination?
A Binder Solvent
Strongest Epoxy Acetone high power
Chlor. Rubber Xylene
Alkyd Resin White spirit
Weakest Emulsion paint Water low power
Metallic Pigment
May be used to anti corrosive properties or to give metallic finish.
Cathodic Protection
Zinc and Aluminum
Q Name 5 methods of applying paints and compare the advantages and limitation of each method?
A Brush application:
Advantages:
Effective for applying primer as it works paint well into a substrate, which gives optimum
coverage and mixes in any dust particles. Thus achieving optimum adhesion. Do not produce
overspray, less environmental hazard, less wastage and less spotting.
Limitation:
Slow production, may not have uniform thickness, high quality brushes quite expensive.
Roller application:
Advantage:
Quicker than brush for large flat surfaces, with extension poles easy to access at elevated
locations.
Limitation:
Non-uniform paint thickness, paint does not worked in to a surface, some specs not permitting
roller applications.
Conventional Spray:
Advantage:
Suitable for applying thin material, good finish, less operating pressure move safe, less
equipment and maintenance cost, less over spray, quicker than brush.
Limitation:
Less production, gravity fed guns to be operated at upright positions only, high viscous paint
application not possible.
Airless Spray:
Advantage:
Higher production (more quality production), highly viscous paint easily applied, more portable,
uniform coating can be achieved, High DFT.
Limitation:
More wastage & over spray, higher equipment & maintenance cost, high risk of safety due to high
pressure operations.
Sacrificial Coatings:
Sacrificial coating contain pigments, which cathodically protect the iron or steel substrate to which
the paint is adhered, these pigment particles eventually corrode thereby sacrificing themselves to
corrosion. In order to have these properly, the sacrificial pigment must be ignoble to the material
to be coated. Zinc and aluminum are the most common type of pigments employed.
MIO, mica, glass flakes and aluminum flakes are eg of laminar pigments.
Q Define the term Pot Life, shelf life, and induction period?
A Pot Life:
The pot life is the maximum period of time after mixing in which the paint must be used, this can
vary few minutes to few hours.
Shelf life:
The max. Period of time paint in good condition in its container before opening in its container
before opening and recommended by the paint manufacturer.
Induction Period:
It is the min. period of time during which the mixed components are left to stand before use. This
is to allow for the certain chemical reaction to take place and for the time allowed for air bubbles
to escape. Induction periods are typically up to 30 minutes.
Q What does a crypto meter measure and two example of crypto meter?
A A crypto meter measures the opacity or hiding power of paint possesses.
Pfund crypto meter
Hiding power charts.
Procedure:
Fix the Abel cup containing the substance for the assessment into a water bath.
Activate the source of ignition every 0 C rise in temperature.
Apply a heat source to the water bath and monitor the air/vapour temperature in the Abel Cup.
The flash point temperature is identified when a blue flame flashes over the substance being
assessed.
Q What is density and how do you assess it? Give two reason for its use?
A Density is weight per unit volume of a substance possess.
Density = mass / volume unit = gm/cc
By using laboratory balance weigh the cup to the nearest decigram with sensitivity of + 0.19
Remove the cover and fill with paint to within 2.5 mm of the brim.
Carefully replace the cover so that air and any excess paint are expelled through the vent.
Wipe off any surplus paint from the cover then reweigh.
Determine the weight of the paint by subtraction.
Divide the weight by 100 if the density in g/cc is required.
Purpose:
To determine whether two pack paints have been mixed in the correct proportions.
This procedure can be used to determine the quantity of any added thinner.
Q What is Viscosity and what equipment is used to measure viscosity of the free flowing paint and
thixotropic paint?
A Viscosity is a measure of a fluids resistance to flow. Viscosity of free flowing paints can be
measured by using a flow cup, there are many types including Ford cup, red wood and Zahn flow
cups.
For thixotropic paints, the viscosity can be measured by a rotation. Viscometer or another type of
Viscometer, which works the paints. (Kerb-stormer viscometer, cone and plate viscometer and
rotathinner)
Q What is specific gravity and how is testing for specific gravity carried out?
A Relative density or specific gravity is the density of any substance compared to the density of
water.
Specific gravity = density of given substance
Density of water
Q Name 3 adhesion tests and describe how one of them is carried out?
A Adhesion is the force that resists the separation of two surfaces in contact.
1. Cross cut test. 2. Cross hatch. 3. Dolly test (pull of adhesion test)
Q Name 4 artificial weathering devices and what are these designed to stimulate?
A Artificial weathering devices are designed to create accelerated weathering to speed up to the
duration of different test to be carried out to determine the coating systems behaviour at specific
condition.
Tropical box to simulate high humidity environment
Salt spray box simulates a marine environment
Water soak test to asses paint systems resistance to water absorption.
Cold check test test for low temperature contraction cracking.
Temp. Cycling to assess film flexibility at alternate hot & cold temperature.
Stylus test:
The stylus test employs a series of trailing needles which pass over the wet painted panel, because
the needles are set at different tensions it can be established when the paint is in tack dry, hard dry
and fully cured.
Q What is WFT? How do you measure it? What are the advantages of using it?
A Wet film thickness is the thickness measured immediately after a coating has been applied. The
wet film thickness may be found by using a comb gauge or an eccentric wheel.
Advantages:
If the WFT is known, any deviation from the specified thickness range can be immediately
rectified.
If the WFT is known, the approximate DFT can be calculated if the volume of solid is known.
DFT = WFT x VS / 100.
Q What is DFT? State the principle of being able to use a banana gauge for taking DFT? State
calibration procedure for a banana gauge?
A DFT is the dry film thickness of the coated surface and is measured in microns.
The banana gauge is only used for measuring the thickness of non-ferromagnetic coating applied
over a ferromagnetic substrate.
Calibration Procedures:
Choose a magnetically insulated shim of known thickness, close to the thickness of the paint you
expect to find.
Place the shim on the same substrate surface finish as the surface finish on which the paint to be
measured is attached. For eg, if the paint is on a basted surface, calibrate the gauge on a uncoated
blasted surface.
Place the magnet on the shim and press firmly on the instrument, wind the scale wheel forward
(away from yourself) until the magnet is definitely attached to the shim/substrate.
Gradually wind the wheel backwards slowly until the magnet detaches itself. At this point, move
the curser on the instrument to the thickness of the shim as shown on the scale wheel. With some
instrument the scale itself may be moved to line up with fixed cursor.
The instrument is now calibrated and may be used to measure the DFT of any non magnetic film
to within a claimed accuracy of + 5% in some cases.
Q Name 3 environmental conditions when would you stop painting? Or When shall coating not be
applied.
A 3 Environmental conditions: Rain, Snow & high wind.
Q Why are the environmental test carried out during a painting project?
A In order to verify the weather conditions are acceptable to the specification to carry out the
painting operation.
Q Explain how environmental test are carried out? What equipment is used to find RH and DP?
Explain its use?
A Environmental conditions like RH and dew point are measured using a hygrometer of which there
are many types. The whirling hygrometer consists of two mercury thermometer set side by side in
a frame which is provided with a handle and spindle so that the frame and thermometer can rotated
quickly about a horizontal axis. The bulb of one thermometer is called Wet bulb thermometer. It
is covered with a closely fitted cylindrical cotton wick, the end of which dips into distilled water
or clean rain water contained in a small cylinder attached to the end of the frame.
The frame is rotated by hand for 30 to 40 seconds as fast as possible so that the bulbs pass through
air at least 4 m/s. This causes the water to evaporate from the wet bulb. The wet bulb cools down
to a constant wet bulb temperature due to the evaporation rate of water from the wet wick.
Always read the wet bulb temperature before dry bulb temperature immediately after the rotation.
Repeat the operation until consecutive readings of each bulb temperature agree to with 0.20C.
If it is 100% RH, the wet bulb will be same temperature, because no evaporation can occur, i.e. the
air is saturated. If wet bulb and dry bulb temperature are the same the current temperature is the
dew point. The R.H and dew point can not be read directly from the apparatus, hygrometer tables
or special slide rules must be used.
Q What does BS 2015 - GLOSSARY OF PAINT TERMS refers to and give three examples?
A Faults, which occur with paints, are described in BS 2015 GLOSSARY OF PAINT TERMS.
These faults are due to three main caused.
1. Fault in the can. (Manufacturing faults)
2. Problem, which occur due to poor preparation.
3. Problem, which occur due incorrect or poor application or interference by weather.
Examples:
Bleeding: The action of a material in penetrating and discoloring a coating applied on top of it.
Blistering: The formation of dome shaped blister in a paint film. They can be dry blisters which
are usually caused by the expansion and contraction of the paint film against the substrate or
Osmotic blister which can be caused by water/solvent entrapment or hygroscopic salts let on a
blast cleaned surface.
Chalking: The breaking down of a paint film to become chalky or powdery usually due to
disintegration of the binder caused by attack from UV light or severe weather condition.
HUE:
The first part signifies HUE or colour and consists of an even number of two numerals and 12
main hues are used and numbered
02 Red Purple 14 Greens
04 Reds 16 Green Blues
06 Yellow Reds 18 Blues
08 Yellow Reds 20 Purple Blues
10 Yellows 22 Violets
12 Yellow Greens 24 Purples
GREYNESS:
The second part signifies greyness, i.e. the apparent amount of difference in greyness between one
colour with other colors. Five grades are used, each defined by a letter.
A - Max. Greyness
B -
C -
D - Min. greyness
E - Pure No greyness
WEIGHT: (Saturation)
Colours of similar hue and greyness may differ in colour brightness or intensity of colour. This
quality termed as saturation, may be defined as the intensity of any particular hue when compared
with a neutral grey of similar lightless of the spectrum colours being the most intense or of highest
saturation.
* The weight is given in pairs of numbers from 01 to 56. Groups of colours within each of the
five greyness ranges are graduated high to low value.
BS 4800 can be used to identify existing colours when maintenance painting and is a method by
which all manufactures can make exactly the same colours.
Q What is the procedure for removing oil, grease form a substrate after preparation has taken place?
A If oil or grease is found on a surface after it has been prepared that area must be swabbed with an
approved solvent followed by a 2% detergent wash, washing with clean water, thorough drying
and reblasting.
Q What is procedure for removing oil, grease from a surface before preparation commences?
A Small areas of oil and grease shall be removed with an approved solvent, where as large areas can
be given to low pressure detergent washing, which must be followed by rinsing with clean water
and thorough drying.
Q What is the procedure for removing algae & mould growth from pipe work?
A Algae and mould grown shall be treated with a biocidal agent and left for 24 hour at least in order
that biocide can kill the spores. It shall then be removed by scrubbing with stiff bristle brushes
and clean water or by use of high-pressure water wash.
Q What must pneumatically and electrically operated power tool equipment be?
A All equipment whether electrically or pneumatically operated shall be earthed. All equipments
shall be non-spark and flame proof.
Q What type of sheeting may or may not be used for protection against spillage & spotting?
A Sheeting of a non-flammable nature must be employed to protect areas against spillage & spotting.
Tarpaulins must not be used.
Q What is BS 7079?
A Preparation of steel substrates before application of paints and related products.
Q Paint Faults?
A Bleeding:
Discoloration of newly painted surface due to inter penetration of substances by natural
movements
Rust Blooming:
First stage of corrosion process
Blistering:
Formation of done shaped blisters or projection in paints in the dry film of a coating material by
local loss of adhesion and lifting of the film from the underlying surface.
Chalking:
The formation of friable (easily give away) powdery coating, on the painted surface caused by
disintegration of the binder medium due to ultra violet or moister.
Checking:
Cracking that compress fine cracks which do not penetrate the topcoat and are distributed over the
surface giving the resemblance of a small pattern.
Cissing:
Due to contamination, the wet paint tries to slope backwards from small areas of the surface
leaving no coating.
Cratering:
The formation of small bowl shaped depression in the film of a coating material.
Crazing:
Cracking that resembles checking but the cracks are deeper and broader.
Cracking:
Generally the splitting of a dry paint or varnish film usually as a result of ageing.
Dry Spray:
The production of a rough or slightly bitty film from sprayed coating material where the particle
are insufficiently fluid to flow together to form a uniform coating.
Flaking:
Lifting of the coating material from the substrate in the form of flakes or scales.
Flocculation:
The development of loosely coherent solid aggregates in a pigment vehicle dispersion. Which
will not mix back even after re-stirring.
Grinning:
The showing through of the substrate due to the inadequate opacity (hiding power) of a paint film
which has applied to it.
Holidays:
Missed or poorly coated areas on a painted surface.
Chemical Curing:
A part from the oxidation, paint is cured due to the presents of a catalyst in the paint when they
mix together.
Lifting:
Failure caused by the swelling of a dry film of paint or varnish when another coat is applied over
it. It may be due to stronger solvent, when new coat is applied over the old one.
Orange Peel:
The uniform pock marked appearance in particular of a sprayed film resembles the peel of an
orange due to the failure of the film to flow out to a level surface.
Osmotic blister:
Formation of dome shaped blister, which can be caused by water entrapment solvent entrapment,
or hygroscopic salts left on a blast-cleaned surface.
Pin holing:
The formation of minute holes down through a paint coating caused by escaping air bubbles.
Saponification:
The formation of soapy layer by the reaction between a fatty acid ester and an alkali.
Wrinkling:
The development of wrinkles in a film a coating material during drying mainly due to the initial
formation of a surface skin.
Compliant Coating:
A coating which complies with the environmental protection act of 1990.
Dew Point:
The temperature at which condensation would form on a substrate.
Relative Humidity:
The amount of water vapour in the air expressed as a percentage.
Induction period:
The length of time paint is required to stand after mixing and before application. This time allows
air bubbles to escape and chemical reaction to take place and is specified by the paint
manufacturer.
Pot life:
The length of time that paints remains in an applicable condition according to the manufacturers
instruction.
T wash:
An etch primer for zinc metal surfaces. Blue in color it turns black upon drying if it has been
applied successfully.
Masking out:
Cover out items which are not to be prepared and painted.
Oxidation:
After the painting, when the surface is coming in to contact with the oxygen the binder
polymerized and form a strong layer.
Q What is impressed current and what problem can arise from its incorrect use?
A Impressed current is a type of Cathodic protection system e.g. Used for large areas of pipes. If the
impressed current exceeds the corrosion & current, hydrogen gas bubbles are evolved from the
metal substrate i.e. at the interface between the material and the coating. This is a significant
problem when curing defects are present due to a stripping action caused by the hydrogen bubbles
leads coating disbondment is known as cathodic disbondment.
Disadvantage
It is difficult to over coat
Poor UV resistant, chalk in sunlight
Temp Dependent.
Epoxy is not cured by oxidizing. Cured by chemical reaction between two components.
Q What additional information you should when maintenance painting a pipeline without removing
the existing coating?
A The following additional information to be recorded are:
Nature of the existing system must be established to decide the type of preparation to be carried
out.
Amount of surface contamination.
Extent of paint breaks down.
Extent of corrosion
Compatibility of the existing system with the new system. If not compatible select the appropriate
Tie-coat.
In service environmental condition.