Frosio 17A Inspection Work & Equipment

Frosio 17A Inspection work & equipment slide # 1

Use of instruments


Utstyr utlagt

Inspection Equipment


Inspection after application

Climatic conditions (Ventilation, Temperature and humidity) Curing / drying of the film Dry film thickness (DFT) Adhesion Holiday detection (if required)

After application the following must be checked


Wet paint

Steel

ISO 2808 - 97 Method No.1 Wet film measuring comb

Microns250 225 200 175 150 125 100 75 50 25


4932-81

0459-21

ISO 2808Wet film thickness gauge• Measure wet paint film• Here: 25 microns between the teeth


Using “PIG” Universal on a ship’s hull

• PIG = Paint Inspection Gauge

• Destructive test method

• Possible to verify the number of coats applied

• Possible to measure the thickness of each individual coat

Cd-4932-100


PIG Paint Inspection GaugeMainly for laboratory use

4932-100


ISO 2808 - 97 Determination of film thickness

Method No. 6: Magnetic method

• Magnetic induction principle (Method 6 A)

• Permanent magnetic principle (Method 6 B)

• Instruments for magnetic, metallic substrates

• Calibration must be done in accordance with instructions from the manufacturer

• Before testing the paint system must be properly cured.



• High frequency electromagnetic instrument

• For non-magnetic substrates• Calibration in accordance with the

manufacturers instruction

Method No. 7 - Eddy current method


• Electromagnetic instruments• Calibration on a smooth steel surface min. 1,2 mm

thick• For DFT measurement, not less than 25 and

preferably above 50 microns• Number of readings, as a guide:

– 1 reference area: At least 3 readings evenly– 2 reference areas for every square meter for flat plates– 4 reference areas for every length for a web– 2 reference areas every metre length for a flange– 2 reference areas every metre length for a pipe


Method No. 10 - On blast cleaned steel substrates


ISO 2808 - Magnetic and electromagnetic Dry film thickness gauges• Dry film thickness gauge• Calibrate on smooth

surface to zero and to thickness similar to be measured

• Check with your calibration foil frequently

• Plastic material foils wear easily. Replace frequently.

• No internal memory in gauge

Cd-4932-82


ISO 2808 - Magnetic and electromagnetic Dry film thickness gauges• Dry film thickness gauge• Calibrate on smooth




• No internal memory in gauge

Inspection \ Dryfilmthickness1


Tørrfilm målere Elektr. Magn.

Magnetic and Electromagnetic Dry Film Thickness Gauges

• ISO 2808• Dry film thickness gauge• Calibrate on smooth




• Some models have internal memory.


SSPC - PA 2 Measuring DFT on small areas

1. Area of 10 m2: 5 spot measurements

2. Each spot measurement: The average of 3 individual readings made on one small area

3. The average of 5 spot measurements must be within specified range of film thickness

4. Single spot measurements may be as low as 80% of specified minimum film thickness

5. Individual readings included in the spot measurements may be less than 80% of minimum thickness

Procedure


SSPC - PA 2 Number of film thickness measurements

1. 10 m2 5 spots (on each spot: 3 measurements)2. 30 m2 As for case 1 for each 10 m2

3. Up to100 m2 Select 3 areas, each of 10 m2

4. Above 100 m2 The first 100 m2 as for case 3 For each following 100 m2 select randomly one area of 10 m2

Note: If measurements outside the specification for any 10 m2 in case 3 or 4 above are found, then each 10 m2 shall be measured

Case Area Selection of Measurements


Instruments for measuring surface roughness

• Stylus instruments• Elcometer Mod. 123• Testex Press-O-film• Microscope• Comparator

– Rugotest No. 3– ISO 8503 etc.


Clemco

Compartor

Surface Roughness acc. to ISO 8503

• Example of a reference comparator: Clemco

• Surface profile comparator comprising four segments.

• Clemco - grit• Clemco shot also available • Check if the profile is

according to specification and the paint manufacturer’s recommendation


Jan, speil, lykt

Using Inspection Tools: Mirror and Flash light

• Visual inspection• Important tools to be

able to inspect areas difficult to access


1. Air temperature2. % Relative humidity3. Steel temperature4. Dew point

ISO 8502 – 4 Humidity

Guidance on the estimation of the probability of condensation prior to paint application

Steel temperature min. 3 oC above the dew point


Steel temperature

Contact Thermometer• Electronic instrument

for measuring the steel temperature

• Steel temperature must be min. 3oC above the dew point

• Other types of thermometers are also available. E.g. magnetic thermometers


Measuring the Relative Humidity

• ISO 8502 - 4• Photo: Sling hygrometer

for measuring:- Dry temperature- Wet temperature

• Measure the temperature in the vicinity of the work

• Calculate the relative humidity

• Use together with dew point calculator


Dew Point Calculator• ISO 8502 - 4• For calculation of dew

point• To be used together with

surface temperature thermometer and sling hygrometer.

• Use this frequently during pre-treatment, application and drying of the paint.

• Recommendation: Every 6 hours and when weather conditions are changing


Bresle sett

Salt Test Equipment - Bresle Test

• ISO 8502 - 6 (Sampling)

• ISO 8502 - 9 (Conductivity)

• Equipment for sampling and measuring content of water soluble salt on substrate

• Bresle method


How to measure the salt level on a surface

• Water soluble salts will be removed by water jetting

• Here: The substrate is cleaned at a pressure of 2000 bar

• Salt level is measured by the Bresle method

• Dissolve the salt inside the frame of the patch

• Measure the conductivity of the water sample

Pre-treatment: Wj_saltlevel1

For 15 ml sample size, multiply conductivity measured in μS by a factor of 6 to get mg salt per m2


Calculating salt level on the substrate

Formula: (L2 – L1) x 6 = mg salt per m2

L2 = μS after cleaning

L1 = μS before cleaning

Water sample, ml: 10 15 20 50

Constant in formula: 4 6 8 20


ApprovedNot approved

Tape Blast cleaned steel

Assessment of Dust on Steel Surfaces Prepared for Painting. ISO 8502-3



Glove RagMEK

Rubbing 50 x

No Zinc on the Rag:CuredApproved

ASTM D 4752-87 Curing test of Zinc - ethylsilicate with MEK.

A lot of Zinc on Rag:Not curedFurther curing / Reblasting


ASTM D 4752-87MEK curing test of zinc ethyl silicate

• Left: One cured and uncured test plate• Right: Uncured zinc over coated. Result: Delamination

A-40807-2


Glove

Rag

MEK

ASTM D 4752-87 ASTM D 4752-87 Curing test of Zinc – ethyl silicate with MEK. Curing test of Zinc – ethyl silicate with MEK.

Inspection / Zincsilicate_curing1


ASTM D 3359-87 Adhesion testing by knife and adhesive tape

• There are two test methods• The method to select depends on the DFT

Method A: DFT above 125 micronsMethod B: DFT below 125 microns

(Above 125 if wider cuts are used)

Method A: X - cut. Tape testMethod B: Cross - cut. Tape test


ASTM 3359-87. Method B Adhesion testing• < 50 microns = 1 mm apart (11 cuts)• 50 - 125 microns = 2 mm apart (6 cuts)• > 125 microns = Method A

1. Cuts: 20 mm long2. Brush with a soft brush3. Examine4. Cuts: 20 mm long at 90o on the original cuts5. Brush with...6. Tape 75 mm7. Within 90 + 30 sec. remove tape


5B The edges of the cuts are completely smooth; none of the lattice is detached

4B Small flakes of the coating is detached at intersections: 5% of the area is affected

3B Small flakes of the coating are detached along edges and at intersections of cuts. The area affected is 5 to 15% of the lattice.

2B The coating has flaked along the edges and on parts of the squares. The area affected is 15 to 35% of the lattice.

1B The coating has flaked along the edges of cuts in large ribbons and whole squares have detached. The area affected is 35 to 65 % of the lattice.

0B Flaking and detachment worse than Grade 1B.

Classification of adhesion test results. Method B. (Example for six parallel cuts).

5B None4B

3B

2B

1B

0B Greater than 65%


ISO 2409 Cross-cut test Cutting tool

Single bladed knife or

Multi-blade cutting tool with 6 cutting edges spaced 1 mm or 2 mm apart

Spacing of cuts 0 - 60 microns: 1 mm spacing, hard substrates 0 - 60 microns: 2 mm spacing, soft substrates60 - 120 microns: 3 mm spacing, hard/soft substrates121 - 250 microns: 3 mm spacing, hard/soft substrates


Procedure:• Make 6 parallel cuts with defined space in the

coating.• Repeat operation, crossing original cuts at 90o

so that a grid pattern is formed.• Brush with soft brush.• Apply adhesive tape and pull off.• Classify results in accordance with table 1.

ISO 2409 Cross-cut test


ISO 2409Cross cut adhesion test

• Cross cut adhesion test

• Cut vertical and horizontal lines to form a grid

• Apply a strong tape• Pull off the tape• Evaluate according to

the standard

Cd-4932-91


ISO 2409Cross-cut adhesion test

• Left: A good type of cross-cut tool• Right: Evaluation of performed test

0002-001

0002-002


5B The edges of the cuts are completely smooth; none of the lattice is detached

4B Small flakes of the coating is detached at intersections: 5% of the area is affected

3B Small flakes of the coating are detached along edges and at intersections of cuts. The area affected is 5 to 15% of the lattice.

2B The coating has flaked along the edges and on parts of the squares. The area affected is 15 to 35% of the lattice.

1B The coating has flaked along the edges of cuts in large ribbons and whole squares have detached. The area affected is 35 to 65 % of the lattice.

0B Flaking and detachment worse than Grade 1B.

Classification of Adhesion Test Results. (Example for six parallel cuts).5B None4B

3B

2B

1B

0B Greater than 65%


ISO 2409Classification of Cross-cut test

Classi-fication

Description Appearance of surface Six parallel cuts

0 Completely smooth: none of the squares detached1 Small flakes at the Intersections. Area affected 5 %

2 Flaked along the edges and/or at theIntersections. Area affected: 5-15%

3Flaked along the edges, wholly in large ribbons, and/or partly or wholly on different parts of the squares. Area affected: 15-35%

4Flaked along the edges in large ribbons and/orsome squares have detached partly or wholly. Area affected: 35-65%

5 Any degree of flaking that cannot even be classified by 4.


ISO 2409Cross cut adhesion test• Cross cut adhesion

test• Cut vertical and

horizontal lines to form a grid

• Apply a strong tape• Pull off the tape• Evaluate according to

the standard

Inspection / Adhesion_crosscut1


Instruments:• Elcometer Adhesion Tester• Saeberg Adhesion Tester (pneumatic)• Hate Adhesion Tester (hydraulic)• PAT• Other

ISO 4624Pull-off test for adhesion

Failure:Adhesion failure: Between coats or between or substrate and 1st coatCohesion failure: Inside a coat


ISO 4624Pull-off test for adhesion

Procedure:• Test dollies glued onto the coating• Adhesive: Cyano-acrylate or solvent free epoxy• Remove adhesive and coating around the dollies• Pull off test-dollies vertical to the surface• Read adhesion value and report the type of fracture

Fractures:• Adhesion failure - fracture between coats or substrate and 1.

coat• Cohesion failure - fracture within a coat


ISO 4624Pull-off dollies glued to the structure

• Pull off adhesion test

• Dollies are glued to the structure with a strong glue

• Prior to pull-off: Cut around the dolly, through the paint film and down to the substrate material

Cd-4932-102


ISO 4624Pull-off testing of paint on a structure

• Pull off adhesion test.• Destructive test method• Here, connecting of the

device for pulling off the dollies

• Read and note the value• Several types of

instruments are available

Cd-4932-101


ISO 4624Area after pull-off testing

• Pull off adhesion test• The adhesiveadhesive failure -

fracture between coats - or between coating and substrate must be evaluated

• Note adhesion failure, %• The cohesivecohesive failure -

fracture within the coating- must be evaluated.

• Note cohesion failure, %• Also: Note glue failure, %

Cd-4932-103


ISO 4624Pull-off dollies glued to the structure• Pull off adhesion test• Dollies are glued to the

structure with a strong glue

• Prior to pull-off: Cut around the dolly, through the paint film and down to the substrate material

• Record the pull-off value

• Evaluate the failureInspection / Adhesion_pulloff1


ASTM G 62 - 85 Method A Pinhole detection. Low voltage.

• Low voltage: < 75 V DC• To detect pinholes, voids or metal particles to

be in the range of 25-250 microns.• Effective for paint films up to a DFT of 500

microns if a wetting agent is used in the water.• This is a non-destructive test.


ASTM G-62-85, method ALow voltage holiday detector

• Photo: Low voltage pinhole detector

• Detecting pinholes, voids or metal particles in paint film up to 250 microns

• Non destructive test method

• Will only detect defects down to bare metal

• The sponge must be wetted

• Do not use excessive water

Cd-4932-92


ASTM G-62-85, method ALow voltage pinhole detector

• Photo: Low voltage pinhole detector

• Detecting pinholes, voids or metal particles in paint film up to 250 microns




• Do not use excessive water

0002-004


ASTM G-62-85, method ALow voltage pinhole detector• Detecting pinholes,

voids or metal particles in paint film up to 250 microns




• Do not use excessive water Inspection / Pore_detection1


ASTM G 62 Method B Holiday detection. High voltage.

High voltage: 900 - 20.000 V

Used to detect pinholes, voids andareas with thin paint films

This is a destructive test.


ASTM G-62-85, method B High voltage holiday detector

• Destructive test method for detecting pinholes, voids and thin spots in paint film

• Adjust voltage according to the film thickness or the paint manufacturers recommendation

• Gives a light or signal when pinhole or weak point is detected

Cd-4932-93


• 0002-005

ASTM G-62-85, method BHigh voltage holiday detector

• Destructive test method for detecting pinholes, voids and thin spots in paint film

• Adjust voltage according to the film thickness or the paint manufacturers recommendation

• Gives a light or signal when pinhole or weak point is detected


ASTM G 62 Method B Holiday detection. High voltage.• High voltage: 900 - 20.000

V

• Used to detect pinholes, voids and

• areas with thin paint films

• This is a destructive test.

Inspection / Holiday_detection1


ISO 12944 General standard for corrosion protection:

Part 1 General introduction.Part 2 Classification of environments.Part 3 Design considerations.Part 4 Types of surface and surface preparation.Part 5 Protective paint systems.Part 6 Laboratory performance test methods.Part 7 Execution and supervision of paint work.Part 8 Development of specifications for new work

and maintenance.

Paints and varnishes - Corrosion protection of steel structures by protective paints systems.


ISO 8504 - 1General principles

Selection of methods


ISO 8504 Surface preparation methods:

Part 1: General principles. Part 2: Abrasive blast-cleaning.Part 3: Hand- and power-tool

cleaning.


• Methods• Effectiveness• Fields of

application

ISO 8504 - 2Abrasive blast-cleaning


• Methods• Equipment to be used• Procedure to be followed

ISO 8504 - 3Hand and Power-tool Cleaning


Steel

Rag soaked with solvent

No reaction:Chemically curing

Paint dissolves:Physically drying

Using solvents to determinegeneric type of paint

2 coat paintLifting/Wrinkling:Oxidatively curing


Use a rag soaked with solvent

No reaction:Chemically curing

Paint dissolves:Physically drying

Using solvents to determinegeneric type of paint

Lifting/Wrinkling:Oxidatively curing

Inspection / Determine_generic1


Standards relating to mechanical propertiesProperty Standard / Test method

Adhesion (Cross cut) ISO 2409, DIN 53251, BS 3900-E6, ASTM 3359Adhesion (Pull-off) ISO 4624, ASTM 4541, BS 3900 - E10Adhesion (Shear strength)

ASTM D 1002 (Specified for Chartek)

Hardness ISO 2815 (Buchholz - methode)Hardness ISO 1522 (Kønig - pendel)Hardness BarcholElasticiy ISO 1520 (Cupping test)Flexibility ISO 6860 ASTM D 522

BS 3900 - E11 (Conical mandrel)Impact resistance ISO/TR 6272 - 79E ASTM D 2794 - 84

DIN 55669 BS 3900 - E3


Testing and evaluation.marine atmosphere (1 of 2)

Test method Standards CommentsPhysical testingAdhesionAdhesionFlexibilityElasticityHardnessImpact resistanceGlossAbrasion resistance

ISO 2409ISO 4624ISO 1510ISO 1520ISO 2815ISO 6272ISO 2813ASTM D 4060

Before and after exposureBefore and after exposureBefore and after exposureBefore and after exposure

Exposure conditions:SaltsprayProhesion testUV-cabinetCondensation chamberHumidity chamberWeatheringResistance to liquids

ISO 7253 or ASTM B 117

ASTM G 53ISO 6270BS 3900ISO 2810ISO 2812 Oil, petroleum , etc.


Test method Standards Comments

Evaluation of paint films BlisteringRustCrackingFlakingChalkingScribe

ISO 4628/2ISO 4628/3ISO 4628/4ISO 4628/5ISO 4628/6ASTM D 1654

Evaluation of the liquid paint

Appearance in tin

Application properties

ISO 2431

ISO 2884

“Flow time”

Viscosity

Testing and evaluation.marine atmosphere (2 of 2)


Abrasion resistance• Weigh the painted

sample• Install it in the apparatus

and run 1000 cycles• Measure the weight loss

Testing paints \ Abrasion resistance1


Flexibility test• Use a thin test panel• Measure the paint film

thickness• Carry out the impact test

on the rear side of the test panel

• Determine the highest level of impact load before any crack or defect in the paint film occurs

Testing paints \ Flexibility_test1


Impact test• Use a thick test panel• Measure the paint film

thickness• Carry out the impact test

on the painted side of the test panel

• Determine the highest level of impact load before any crack or defect in the paint film occurs

Testing paints \ Impact_test1


Reference area should:

• be representative to the remaining area coated with the same system.

• be available for inspection at any time.• be marked thoroughly to indicate

"ref.area"• not be overcoated


Controlled application

• Inspection of:» steelwork» cleaning» surface preparation (blastcleaning)» painting» curing» completed system


Number of reference areasSize of structure(painted area)

m2

Recommended maximumNumber of reference areas

Recommended maximum percentage of reference area relative to total area of structure

Recommended maximum total area of reference areas

m2

< 2000 3 0,6 122000 to 5000 5 0,5 255000 to 10000 7 0,5 5010000 to 25000 7 0,3 7525000 to 50000 9 0,2 100

>50000 9 0,2 200

Documents

Frosio 17A Inspection Work & Equipment