Chapter 6 Condition Assessment Flashcards
Which option(s) best describe(s) the primary function(s) of surface preparation?
(Select all that apply)
A. To remove surface contaminants that can promote premature coating failure
B. To provide a clean surface to the specified level of cleanliness
C. To determine the type of coating to apply based on the surface condition
D. To provide an adequate surface profile of the surface for good coating adhesion
✅ A. To remove surface contaminants that can promote premature coating failure
✅ B. To provide a clean surface to the specified level of cleanliness
✅ D. To provide an adequate surface profile of the surface for good coating adhesion
C is incorrect because determining the type of coating to apply is typically a function of the coating specification and engineering requirements, not surface preparation itself. Surface preparation ensures the surface is suitable for coating application.
Which statements are true about performing an initial surface condition assessment?
(Select all that apply)
✅ B. Identifies the type of substrate and its current condition prior to surface preparation
✅ C. Is the first phase of the surface preparation process
✅ D. Identifies any substrate features that may prevent the substrate from reaching the specified level of cleanliness
A is incorrect because the initial surface condition assessment focuses on evaluating the substrate and its condition before preparation. The coating application method is typically determined based on project specifications, coating type, and environmental conditions rather than the initial assessment.
Which type of substrate requires special consideration when selecting abrasives for surface
preparation?
A. Rusted Steel
B. Carbon Steel
C. Stainless Steel
D. Painted Steel
✅ C. Stainless Steel
Explanation:
Stainless steel requires special consideration when selecting abrasives for surface preparation because using the wrong abrasive (such as carbon steel grit) can cause contamination and lead to issues like rust staining or loss of corrosion resistance due to embedded iron particles. Non-metallic or specially designated stainless steel abrasives are typically used to avoid contamination.
Other options:
A. Rusted Steel – Rusted steel does require proper abrasive selection but does not need as strict of a consideration as stainless steel.
B. Carbon Steel – Standard abrasives work well for carbon steel without special precautions.
D. Painted Steel – Coatings may impact abrasive selection, but it does not require as much care as stainless steel.
Which statements apply to visual reference guides?
(Select all that apply)
A. Used to pick the coating process
B. Are used as a supplement to the written standards
C. Are included in standards
D. Used as an aid for determining whether a prepared surface meets or exceeds the project specification
✅ B. Are used as a supplement to the written standards
✅ C. Are included in standards
✅ D. Used as an aid for determining whether a prepared surface meets or exceeds the project specification
Explanation:
B. Visual reference guides complement written standards by providing pictorial representations of cleanliness levels, aiding inspectors in making accurate assessments.
C. Many standards (e.g., SSPC, NACE, ISO) include visual reference guides as part of their documentation.
D. These guides help inspectors determine whether the surface preparation meets the specified level of cleanliness and profile.
A is incorrect because visual reference guides do not determine the coating process; that is specified in project requirements, material data sheets, and engineering decisions.
A surface lamination should be removed by ____________ since no coating system can effectively
protect the surface if left intact.
A. Welding
B. Grinding
C. Sanding
D. Abrasive Blasting
✅ B. Grinding
Explanation:
Surface laminations are defects in the metal that can trap contaminants and lead to premature coating failure if not properly removed.
Grinding is the most effective method for removing laminations because it allows precise material removal while preventing the defect from remaining beneath the coating.
Abrasive blasting (D) is not effective for removing laminations because it only cleans the surface without removing the embedded defect.
Sanding (C) is too light of a method and is not effective for structural defects like laminations.
Welding (A) is not a removal method; it is typically used for repairs, but not for eliminating laminations.
How should rough welds be treated?
A. Used as an aid to determine the coating application method
B. Smoothed with sandpaper
C. Prepared only with solvents
D. Ground smooth (if approved)
✅ D. Ground smooth (if approved)
Explanation:
Rough welds can create issues such as poor coating adhesion, difficulty in achieving proper surface preparation, and increased risk of corrosion due to crevices and sharp edges.
Grinding the weld smooth (if approved by project specifications) helps ensure better coating adhesion and reduces potential failure points.
A (Used as an aid to determine the coating application method) is incorrect because weld condition does not determine the coating application method.
B (Smoothed with sandpaper) is incorrect because sandpaper is not effective for heavy weld spatter or rough welds.
C (Prepared only with solvents) is incorrect because solvents only clean contaminants; they do not smooth rough welds.
You notice a large amount of weld spatter in an area while inspecting a steel surface prior to
coating application. What is the best remedy?
A. Scrub several times with an abrasive pad
B. Use a chipping hammer or grind down with an angle grinder
C. Fill in the area with caulk and then smooth it down
D. Ignore it because it will not affect the coating performance
✅ B. Use a chipping hammer or grind down with an angle grinder
Explanation:
Weld spatter creates adhesion problems for coatings and can lead to premature coating failure due to poor surface preparation and uneven coverage.
The best method to remove weld spatter is mechanical removal, such as using a chipping hammer or an angle grinder to smooth the surface before coating.
A (Scrub several times with an abrasive pad) is ineffective because an abrasive pad will not remove hardened weld spatter.
C (Fill in the area with caulk and then smooth it down) is incorrect because caulk is not a suitable material for coating adhesion in this scenario.
D (Ignore it because it will not affect the coating performance) is incorrect because weld spatter can cause poor adhesion, leading to coating defects and corrosion issues.
Factors during surface preparation that may affect service life include:
- Surface Cleanliness
Presence of contaminants (e.g., oil, grease, salts, dust) can lead to adhesion failure and corrosion under the coating.
Proper degreasing and surface preparation standards (e.g., SSPC, NACE, ISO) must be followed. - Surface Profile (Anchor Pattern)
An insufficient surface profile can cause poor adhesion, leading to premature coating failure.
An excessively rough profile can cause premature coating breakdown and increase material usage. - Environmental Conditions During Preparation
Temperature, humidity, and dew point affect coating adhesion and drying times.
High humidity or condensation can cause flash rusting, leading to coating defects. - Surface Defects
Weld spatter, sharp edges, and laminations must be removed or smoothed to prevent weak points in the coating.
Rough welds should be ground smooth (if approved). - Residual Abrasives and Dust
Leftover abrasive media or dust can cause coating adhesion issues and contamination.
Proper blowing down and vacuuming are required after blasting. - Improper Surface Preparation Method
Different substrates require different prep methods (e.g., stainless steel needs special abrasive considerations).
Using the wrong method (e.g., power tool cleaning instead of abrasive blasting when required) can lead to poor adhesion and early failure. - Compliance with Specification Requirements
If the specified cleanliness level, profile depth, or preparation method is not met, the coating system may not perform as expected.
Failing to address these factors can significantly reduce the service life of the coating and lead to early coating breakdown, corrosion, and costly repairs.
Design Challenges Affecting Surface Preparation and Coating Application:
Riveted and Bolted Connections
Design Challenges Affecting Surface Preparation and Coating Application:
Riveted and Bolted Connections
The large number of rivets and bolts create crevices and shadowed areas, making it difficult to achieve full coating coverage.
These areas can trap contaminants and moisture, leading to premature corrosion.
Complex Geometry and Hard-to-Reach Areas
The structure has multiple angles, tight spaces, and overlapping components, making surface preparation (abrasive blasting or power tool cleaning) difficult.
Ensuring proper coating thickness and adhesion in these areas will be a challenge.
Moving Mechanical Parts
The rotating or moving components near the base can make surface preparation and coating application dangerous and impractical without proper isolation.
These parts also experience high mechanical stress, requiring a wear-resistant coating.
Existing Coating Condition
The current coating appears intact, but if it is failing or contains lead-based paint, special precautions may be needed for removal.
Surface contaminants like dirt, grease, or old coatings may require extensive cleaning before application.
Environmental Exposure
This structure is exposed to weather, moisture, and possibly road salts, which accelerate corrosion.
Surface preparation must meet strict standards (e.g., SSPC-SP 10 / NACE No. 2 for near-white metal blast cleaning) to ensure coating longevity.
Recommendations:
Use abrasive blasting to remove old coatings and corrosion in difficult areas.
Stripe coat rivets, bolts, and edges to ensure full protection.
Select a high-performance corrosion-resistant coating system suitable for outdoor exposure.
Isolate moving parts and ensure proper safety procedures during surface preparation and application.
If the surface profile is too low, what effect can it have on the coating?
A. The coating will perform as intended
B. Achieving complete coverage of the surface may be difficult
C. The surface profile does not affect the adherence of the coating
D. The coating may not adhere properly
The correct answers are:
✅ B. Achieving complete coverage of the surface may be difficult
✅ D. The coating may not adhere properly
Explanation:
If the surface profile is too low, the coating may not achieve proper mechanical adhesion, leading to poor bonding and premature failure.
B. A low profile can result in an uneven spread of the coating, leading to areas with insufficient coverage, which can cause weak spots and corrosion.
D. Without an adequate profile, the coating may peel, blister, or delaminate over time.
A is incorrect because the coating will not perform as intended if adhesion is compromised.
C is incorrect because the surface profile is critical for coating adherence, especially for high-build coatings.
Proper surface preparation, including achieving the specified profile depth, ensures optimal coating performance and longevity.
During surface preparation, surface cleanliness should be inspected (as a minimum) the
following three (3) times:
During surface preparation, surface cleanliness should be inspected at a minimum during the following three (3) critical stages:
✅ Before surface preparation
To assess the initial condition of the substrate, including contaminants such as oil, grease, salts, rust, and old coatings.
Ensures that solvent cleaning (SSPC-SP 1) or other pre-cleaning methods are performed if necessary before further preparation.
✅ After surface preparation but before coating application
To verify that the surface has been cleaned to the specified standard (e.g., SSPC-SP 10 / NACE No. 2 for near-white metal blast cleaning).
Ensures the removal of dust, abrasive residues, and contaminants before coating.
✅ Between coating applications
Before applying additional coats, the surface must be checked for cleanliness, dust, and contaminants that could interfere with adhesion.
Any flash rusting, oxidation, or contamination must be addressed before proceeding with subsequent coatings.
Why is this important?
Ensuring proper cleanliness at these three stages prevents premature coating failure and ensures the long-term performance of the protective system.
Failure to inspect at these key points can lead to poor adhesion, premature rusting, and coating defects.
Which Visual Reference Guide is used to determine the initial condition of steel prior to
abrasive blasting?
A. SSPC - VIS 3
B. SSPC - VIS 5/NACE VIS 9
C. SSPC - VIS 1
D. SSPC - VIS 4/NACE VIS 7
The correct answer is:
✅ C. SSPC - VIS 1
Explanation:
SSPC-VIS 1 is the visual reference guide used to assess the initial condition of steel before abrasive blasting.
It provides pictorial standards to compare the amount of rust, mill scale, and contaminants present on the surface before preparation.
This guide is commonly used in conjunction with SSPC surface preparation standards to evaluate cleanliness levels.
Why not the other options?
A. SSPC - VIS 3 → Used for evaluating power tool and hand tool cleaned surfaces (not for initial steel conditions).
B. SSPC - VIS 5 / NACE VIS 9 → Used for water jetting cleanliness assessment, not for dry abrasive blasting.
D. SSPC - VIS 4 / NACE VIS 7 → Used for assessing water blasting and water cleaning, not for dry abrasive blasting.
Conclusion:
If you need to determine the initial condition of steel prior to abrasive blasting, SSPC-VIS 1 is the correct visual reference guide.
