Chapter Quesrions #2 Flashcards by Corey Merritt

High humidity during coating application:

Slows the evaporation of the solvent
Can leave moisture on the surface of the coating
May cause amine blush (must be removed prior to top coating)
May effect the gloss or color

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Coatings may be applied by the following methods:

Roller
Brush
Airless spray (including plural component) Brush
Conventional spray
Airless spray (including Air Assisted Airless)
High Volume Low Pressure (HVLP)
High Conventional spray

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High temperatures concerns during coatings application include:

Can cause the solvent to evaporate too fast
Will reduce the pot life
Decrease the viscosity of many two-component materials

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Low temperature concerns during coatings application include:

Slow the curing of chemically curing coatings
Will increase the viscosity of material
Some coatings may use special cure

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One guide for enclosures for coatings projects is:

SSPC Technology Guide No. 12
SSPC Technology Update No. 6 Guide for Containing surface
Preparation Debris Generated During paint removal operations

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Documentation may include:

Detailed written daily report
Inspection logs
Routine reports
Reports for weekly progress 
Daily entries in a project log book
A daily inspection report using standardized forms
Monthly or quarterly reports

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Inspection records show:

Pretreatment Details
Environmental conditions 
Cleaning details 
Materials Details 
Coating applications Details
Materials Details
Results of work and all test

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Good records allow management to:

Evaluate coating performanc
Detect and tag design defects for future work
Determine annual cost data on each coating system
Develop ongoing maintenance program

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Project inspection documentation provides:

Inspection (QC) records
Verification of work performed by the contractor
Management information
Details of non-conforming work

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Goals of a Pre Job Conference include:

Discuss health, safety and environment (HES) Requirements f a Pre Job
Address/ clarify emergency procedures
Review and discuss scope of work (SOW)
Review logistical support
Discuss line communications between parties
Review known critical hazards
Establish list of critical point of contacts (POCS)
Discuss and clarify inspector (s) responsibilities and authority
Clarify the chain of command (Reporting system)
Discuss and clarify inspector (s) responsibilities and authority
Discuss and clarify areas of concern in the project specification
(Omissions, clarifications, testing)
Agree on critical hold points for inspections
Conflict resolution between the inspector and applicator
Change orders

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People may be required to attend a pre-job conference include:

Owner
      Owners contract manager
      Engineer
     Operations personal
     Specifier
     Specifying engineer 
     Purchasing agents    
     Coatings Inspector (s)
     Coatings applicator (Supervision personnel)
     Project safety personnel
     Coating manufacturer (preferably tech, service rep)

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Before the start of the Pre Job Conference the inspector should obtain a copy of, read, and understand the:

Specification
Any standard / procedure referenced in the project specifications
Manufacturer’s product data sheets
Safety requirements of the MSDS

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When using Replica tape common errors include:

Variation in point-to-point profile over the surface being tested
The presence of particles of dirt on either the replica tape or gauge
Gauge Accuracy
The rubbing or burnishing technique

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List the Standards for using the Replica tape:

ASTM D 4417 Method C

NACE SP 0287-2002

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The two types of replica tape are commonly used:

Coarse—for 20 to 64 µm (0.8- to 2.5-mils)

X-Coarse—for 38 to 115 µm (1.5- to 4.5-mils)

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The ISO Comparator grades may be recorded:

Finer-than-Fine Grade 
   Fine Grade 
   Medium Grade 
   Coarse Grade 
   Coarser-than-Coarse Grade

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Depth of surface profile can be evaluated by several methods:

ISO Comparator
Replica tape
Digital Profile Gaug

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Test for soluble salts include:

Bresle Patch
Sleeve Test
Soluble Salt Meters
Conductivity Meters

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If inspection is to be effective with regards to soluble salts, the specification should very clearly state:

Limits to be accepted 
  Specific salts to be limited 
  Test method to be used 
  Frequency of testing 
  Locations in which tests should be administered

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Types of Soluble Salt Contamination include:

Chlorides
Sulfates
Nitrates

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Coatings Product Data Sheets (Paint Specs) provide users with the following:

Surface preparation 
  Storage 
  Mixing and thinning 
  Application procedure 
  DFT requirements

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MSDS contains the following:

Provides workers and emergency personnel with critical information
on composition, handling or working with the substance
Includes information such as melting point, boiling point, flash point,
toxicity, health effects, first aid, reactivity, storage, disposal,
protective equipment, and spill handling procedures.

Provides information regarding the safety issues associated with any
hazardous (or potentially hazardous) material.
Provides instructions for the correct action to take in the event of a
spill, explosion, fire or hazardous exposure.

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During surface preparation, surface cleanliness should be inspected (as a minimum) the following three (3) times:

Before any surface preparation activities
After surface preparation, before coating begins
Between each application of coating in a multi-coat system

Factors during surface preparation that may effect service life include:

Residues of oil, grease, and soil
Residues of (non-visible) chemical salts
Rust on the surface
Loose or broken mill scale
Rust scale
Anchor pattern
Defects mechanical cleaning equipment
Surface condensation
Old coatings that have poor adhesion/too deteriorated for recoating
Existing coatings that may be incompatible

Common design defects include:

Hard-to-reach or inaccessible areas Rivets, bolts, or other connectors Welds Gaps (particularly skip welds or surfaces close together) Overlapping surfaces (e.g., roof plates in water tanks) Angle iron badly oriented or in complex arrangements Threaded areas Dissimilar metals Sharp edges, particularly on corners or rough cut plate Construction aids

Common fabrication defects include:

Weld Spatter Skip Welds Rough Welds Sharp Corners & Edges

Four (4) Typical SSPC SP1 pre-cleaning methods include:

``` Solvent wipe with cloth or rag Immersion of the substrate in solvent Solvent spray Vapor degreasing Steam cleaning Emulsion cleaning Chemical paint stripping Use of alkaline cleaners ```

One Standard for use with Power Tool Cleaning is:

ISO St2 ISO St3 SSPC SP-3 SSPC SP-11

Four (4) Examples of tools used for Power Tool Cleaning are:

``` Rotary Wire Brushes Impact tools Needle Scaler Rotary Scalers Piston Scalers Grinders and sanders Disc Sanders ```

Abrasive Blasting methods include:

``` Centrifugal blasting Sand-injected water blast Slurry blast Wet abrasive blast Dry Grit Blast Cleaning (Air Blasting) ```

Visual Standards for abrasive blasting include:

SSPC-Vis 1 | ISO 8501-1

SSPC SP 10/NACE 2 SSPC SP 5/NACE 1 SSPC SP 6/NACE 3

limits staining to 5% per each unit area limits staining to 0% per each unit area limits staining to 33% per each unit area

The two (2) types of abrasive blasting nozzles include:

Straight | Venturi

Failure of coatings to cure may be caused by:

Not adding curing agent, wrong curing agent or incorrect amount of it Problem with material from the manufacturer Environmental issues (too cold, hot, or humid) Wrong or contaminated thinner (Solvent)

Some of the problems that can be caused by amine blush are:

``` Surface tackiness or greasiness Incomplete curing Poor adhesion Coating discoloration Poor gloss retention ```

Runs, Sags, and wrinkles may be caused by:

``` Applying the coating too thick Too much or the wrong thinner used Surface too hot to apply the coating Application of coating at the end of its pot life Wrong thixotrope used in manufacturing ```

Chalking

is a powdery, friable layer on the surface of a coating that is most common with epoxy coatings.

Cratering may be caused by:

Air trapped in the coating and forming a bubble which then bursts Air trapped in the coating during mixing if the proper procedures are not followed

Vacules or voids are typically caused by:

Running the mixer too fast

Pinholes are:

Very small holes in a coating typically caused by air or solvent trapped in porous film and escaping.

A common cause of blistering is:

Surface Contamination under the applied coating

Cracking of a coating is noted:

When the crack extends to the substrate

Fine cracks in the surface of a coating that don’t extend through to the substrate

Checking

Adhesion failures may be caused by:

``` Contamination on the surface Wrong surface preparation specified Failure to inspect surface preparation Insufficient surface profile Exceeding the topcoat window Application of incompatible coatings Applying the coat to a glossy surface ```

General types of holiday detectors include:

Low-voltage DC - under 20 mils High-voltage DC - over 20 mils High-voltage AC - do not use ground wire (use a 110v or 220v power supply) emits a spark Nace SP0188 low and high voltage direct current Use 100 volts per mil

Low-voltage (wet-sponge) holiday detectors are powered by batteries

- with output voltages ranging from 5 to 120 V DC - use tap water used for 20 mils or less - may be used on concrete

Describe Low-voltage (wet-sponge) holiday detectors:

Ground cable is attached directly to substrate Sponge saturated with a solution of tap water/wetting agent Maximum rate of 30 cm/s (1 linear ft/s) double stroke Used on coatings up to 500 µm (20 mils) May be used on concrete.

High Voltage DC Holiday detector types include:

DC – Pulsed | DC – Constant Current

The type of High Voltage Holiday detector used for concrete is a:

High Voltage DC Constant Current

What is a Standard?

An established norm or requirement that is written by industry professionals A formal document that establishes uniform engineering or technical criteria, methods, processes and practices

What percentage of NACE Standards relate to coatings:

50%

Alligatoring

When hard coat is applied over a soft extensible coat Or applied to thickly and exposed to sunlight

Failure on weds and edges problems

Edges Coating tends to pull away from the sharp edges Edges should be rounded to at least 2mm radius Welds Spatter should be removed Heat can harden steel

Holiday detection inspection consideration

``` Work environment Type of substrate Specification requirements Type of coating and thickness Standard to be followed ```

Confined space types

Class A - immediate danger to life and health Class B - no immediate danger to life and health Class C - potential hazard not required to modify work or surrounding Class D - documented low hazard