BS 7079 Part A, ISO 8501, SS 05 59 00

BLASTING STANDARDS
SA 3
BLAST CLEANING TO VISUALLY CLEAN STEEL
WHEN VIEWED WITHOUT MAGNIFICATION, THE SURFACE SHALL
BE FREE FROM VISIBLE OIL, GREASE AND DIRT AND FROM
MILLSCALE, RUST, PAINT COATINGS AND FOREIGN MATTER.
IT SHALL HAVE A UNIFORM METALLIC COLOUR.
 BLASTING STANDARDS

SA 3 BLAST TO RUST GRADE A SUBSTRATE

 Calculations:
PAINT VOLUME
Volume = AREA x WFT
1000
1 litre = 1,000 cc’s
Volume is normally given in litres
 Calculations:
PAINT VOLUME SOLIDS

VS% = DFT
x 100
WFT
 Calculations:
PAINT WET FILM THICKNESS

WFT = DFTx100 OR
WFT = Vol
VS% AREA
INDICES 10 = 10¹ 10,000 = 10⁴
100 = 10² 100,000 = 10⁵
1,000 = 10³ 1,000,000 = 10⁶
1,000 x 1,000 = 10³ x 10³ = 10⁶ = 1,000,000
Just add the indices !
UNITS.
1 KILOMETER = 1,000 METRES
1 METRE = 1,000 MILLIMETRES
1 MILLIMETRE = 1,000 MICRONS(µm)
INFORMATION HANDOUT TO SUPPLIMENT ATC 88, 89 & 90 JUNE 2010
DJR

CONCERNING ABRASIVES

 Naturally Occurring: - Sand, Garnet, Coconut Shells, Walnut Shells, Corn

Cobs.
 Waste Products: - Copper slag, Coal Slag, Boiler Slag, Aluminium Slag,
Nickel Slag.
 Manmade: - Chilled Iron Grit, Steel Grit, Steel Shot, Aluminium Oxide,
Sodium Bicarbonate, Silicon Nitrate, Corundum, Sugar, Glass Beads,
Cut Wire, Dry Ice.

SAND – 98% Silica Specific Gravity 2 Gms/cc Hardness 6.7 moh

(Diamonds are 10 moh)

SLAG – 3% Silica Specific Gravity 2 Gms/cc Hardness 6.7 moh.

GARNET – No free Silica SG 4 Gms/cc Hardness 8.1 moh.

Sand abrasives produce “free silica particles” (approx. 5µm in size) on impact, these
can travel a significant distance in air and can be ingested by participants and non-
participants alike - possibly causing silicosis.
Sand from a marine environment needs washing to remove the chloride content prior
to use as an abrasive – this is not always carried out.
Sand has been banned as an abrasive by the United Nations.

Slag as an abrasive; -
 Is expensive
 Is angular in shape - and is consequently wearing on equipment.
 Can embed itself into a substrate where it is difficult to remove. Should this
occur it will expand at a different rate to the steel (as it has a different
coefficient of expansion to steel) with heat, and cause paint blistering.
 It’s angular profile may cause air entrapment when paint fails to fully whet the
troughs it produces in the substrate. Any trapped air will encourage corrosion
to occur under the paint coat.

Garnet
 Produces no free silica on impact.
 Contains no chlorides or metallic content.
 Can be re-cycled up to six times.
 Can contain 11,000,000 particles to a kilogramme weight ( as opposed to
500,000 of sand)
 Costs less than sand or grit.
 Is denser and harder than sand or grit.
 Produces a profile less prone to rogue peaks and air entrapment.
 It’s sub-rounded shape causes less wear and tear on equipment than grit.

Q.E.D
 SURFACE TESTING
The Copper Sulphate Test

Copper sulphate test

The test is designed to detect mill-scale on the surface and
relies on the potential difference between mill-scale and
steel. When immersed in copper sulphate solution a redox
reaction takes place and copper metal is deposited on the
steel and not on the mill-scale.
Copper Sulfate Test. In test for Mill Scale, copper color
indicates absence of mill scale when steel is swabbed with 5
to 10 percent solution.
 PAINTING INSPECTION
CROSS HATCH CUTTER

TO USE
The coating thickness determines the Cutter size used. The 1mm Cutter is suitable for
coatings under 60 microns, the 2mm cutter is suitable for coatings over 60 microns.
Simple operation, each Cross Hatch Cutter has 6 cutting blades spaced either 1mm or
2mm apart, one cutting pass makes 6 cuts in the coating, a second pass at 90° makes a
square lattice pattern. Apply Adhesive Tape over cut section and within 5 minutes remove
tape. Classify the cut area according to BS 3900 PT E6.
 Calculations:
PAINT DENSITY

D = WEIGHT
VOLUME
 BGas PAINTING INSPECTION
THE DENSITY CUP IS USED TO CHECK FOR ADDITION OF
THINNERS, OR THE CORRECT MIX RATIO OF 2 PACK PAINTS

PART A Mixing Correct

PART B Our Caused By
Mix Should Test Result
(Base) (Catalyst) Ratio Excess Of:
Be
1.35 0.95 6:1 1.29 1.35 A
1.28 0.80 6:1 1.21 1.40 A
1.40 0.79 4:1 1.27 1.20 B
1.19 0.75 5:1 1.11 1.39 A
1.22 0.80 7:1 1.16 1.08 B
1.50 0.82 4:1 1.36 1.16 B
 ELCOMETER 456

DRY FILM THICKNESS GAUGE

USER GUIDE
1. Switch on gauge ---- Press the button marked with the letter e

2. Press Calibration Key ---- The soft Key to the LHS of the
instrument

3. Choose a shim that is nearest the thickness of the coating eg 250

micron shim

4. Place this shim on to A PLAIN STEEL SURFACE

5. Place the probe from the instrument on to the shim

6. Take a reading then lift probe and adjust either up or down to the
shim thickness

7. Press Set

8. Place the probe on the PLAIN STEEL SURFACE

9. Take a reading then lift probe and PRESS ZERO

10.Press Set

11.Test Readings? Press Yes then OK

12.Take readings AS REQUIRED.

 TWI LTD TRAINING & EXAMINATION SERVICES
BGAS CANDIDATES. ATTENDANCE OF EXAMINATION

DECLARATION

FIRST NAME

FAMILY NAME

FULL HOME ADDRESS

POSTCODE (UK Only)

Date of Birth: Contact telephone No.

Photographs provided: YES / NO

All candidates are required to sign in agreement with the undermentioned statements before any
results are issued.

1. I understand that it is my responsibility to ensure renewal when appropriate and that

reminders are not issued.

2. I accept responsibility for any approval fee in event of non-payment by the sponsor who signed
the application form. I also appreciate that any approval issued will be invalidated if any fees
in respect of the approval remain unpaid after six months.

3. A Results Notice will be forwarded to the sponsor shown on the Application Form.

4. If you wish to make a comment regarding any aspect of the examination you take, please write
it down and pass it to the examiner before you leave.

SIGNED: DATE:

BGAS Attendance Sheet Issue 1 (Revision 2) MAY 2009

 PAINTING INSPECTION
WET FILM MEASUREMENT –
ECCENTRIC WHEEL

TO USE
Hold between thumb & index finger and “roll” through wet paint starting at
the roll at zero.
SPRAYERS SHOULD BE COMPLETING THIS AS THEY SPRAY TO ENSURE THEY HAVE
APPLIED SUFFICIENT PAINT, IF THEY HAVE NOT THEY CAN APPLY MORE AT THAT TIME.
 PAINT TESTING
VISCOSITY, FORD FLOW CUP, NO 4.

TO USE
LEVEL THE STAND & CUP. PLACE ANOTHER CUP UNDER THE FLOW CUP TO
CATCH THE PAINT. FILL THE CUP WITH PAINT ENSURING IT IS FULL WHILST
COVERING THE 4mm HOLE IN THE BOTTOM. RUN A STRAIGHT EDGE OVER THE
LIP OF THE CUP TO ENSURE IT IS FULL. SIMULTANEOUSLY REMOVE FINGER
FROM BOTTOM AND START STOP WATCH. TIME UNTIL 1ST BREAK IN FLOW. THE
TIME RECORDED IS THE VISCOSITY IN SECONDS AT THE TEMPERATURE.
 CORROSION
GALVANIC SERIES.
“Electro-motive force series” or the “Electro-Chemical series”

Cathodic end of the table, will not corrode or slow to corrode.

NOBLE
MATERIAL KNOWN POTENTIAL AV. VALUES
Graphite + 0.25 v
Titanium 0.0 v
Silver - 0.1 v
Nickel 200 - 0.15 v
Lead - 0.2 v
Admiralty Brass - 0.3 v
Copper - 0.35 v
Tin - 0.35 v
Mill Scale - 0.4 v
Low Alloy Steel - 0.7 v
Mild Steel - 0.7 v
Aluminium Alloys - 0.9 v
Zinc - 1.0 v
Magnesium - 1.6 v

IGNOBLE
Anodic end of the table, will corrode or corrode at a faster rate.
Note and remember the relative positions of:
Mill Scale – Steel – Aluminium - Steel
The above materials are an extract from The Galvanic Series and not the complete list of
materials.
 Glossary of paint terms
ACRYLATED Resin binder produced from the copolymerisation of
RUBBER styrene and acrylic monomers
ACRYLIC A synthetic resin produced by polymerising various acrylic
or acrylate monomers. This resin is used in single pack
coatings which have good colour and gloss retention
ADHESION The force required to separate
AERATION Air bubbles can be formed during stirring, shacking or
application of mainly water based paints which can results
in a bubbles dry film.
AIR DRYING PAINT Paints which dry by absorbing atmospheric oxygen, the
reaction being catalysed by metallic dryers e.g. alkyd paints
AIRLESS Method of application which uses hydraulic pressure to
SPRAYING atomise the paint. Airless spraying is a very fast and
efficient method of application.
A.G.I Above ground installation
ALKYD A synthetic resin made by reacting naturally occurring
dying oils and other chemicals. Alkyds can be modified to
meet varying requirements on speed of drying, adhesion,
flexibility, etc.
ANODE A positively charged area which will corrode
ANTI- Paint that, under intermittent dry and humid conditions,
CONDENSATION minimised the effects of condensation of moisture.
PAINT
ANTI-CORROSIVE A paint formulated to prevent corrosion of steel substrates
PAINT
ARTIFICIAL The testing of coatings in which aging is accelerated by
WEATHERING exposure to a cycle of ultraviolet radiation and moisture.
BARRIER A thick impermeable layer of high electrical resistance
PRINCLIPLE which physically prevents electrolyte coming into contact
with the steel.
BASE Part of a multi component paint (normally 2-pack) – e.g. the
epoxy component of a 2 pack epoxy polymide coating.
Base is normally the larger volume of the two components.
BINDER The constituent of the paint which serves to bind together
the various constituents as well as securing adhesion to the
surface.
BITUMINOUS PAINT Paint formulated with coal tar or bitumen as the resin;
usually single pack with good moisture resistance
BITTY FILM A film containing traces or foreign particles or “bits”, which
project above the surface of the film giving it a rough
appearance.
BLAST CLEANING Use of abrasive materials suck as garnet, copper slag,
steel grit or shot propelled by compressed air to remove
millscale, rust or old paint from steel. This is the most
effective form of surface preparation.
BLEEDING Discolouration of a new applied coating caused by staining
components of previous coatings “bleeding” to the surface.
Usually associated with coatings applied over coal tar or
bitumen or paints containing inferior organic pigments.
BLISTERING Localised delamination of a pint film in the form of blisters
from the underlying surface.
BLOOMING The formation of a thin film on top of a glossy paint film
thereby reducing the gloss and dulling the colour.
BRUSHABILITY The ease with which a coating can be uniformly applied to
the surface using a brush
CATHODE A negatively charged area. Hydrogen gas will be evolved at
this area as a by product of the corrosion reaction.
CHALKING The result of photochemical breakdown of the surface layer
of a binder with consequent release of pigment
CHIPPING Removal of paint and surface contaminants from a
substrate b y means of impact from a mechanical
sharpened tool.
 Glossary of paint terms
CHLORINATED A non-convertible binder used to produce single pack
RUBBER paints, with good resistance to acids, alkalies and humidity
CISSING The partial creeping back or contraction of the wet film into
craters which causes small areas of the substrate to
become visible.
COAL TAR EPOXY A combination of epoxy/curing agent and tar products
which give a very water resistant film.
COBWEBBING The formation of fine filaments of partially dried paint during
spray application making it unacceptable for this type of
application. Normally associated with chlorinated rubber
paints.
CONTRAST RATIO The hiding power of a paint film. Expressed as a ratio of
coverage over white against coverage over black
C.O.S.H.H Control of substances hazardous to health
CONVENTIONAL They are single pack and react usually with atmospheric
PAINT oxygen when drying and curing. Synthetic resins such as
alkyd come into this category
CORROSION The degradation of a material by chemical or
electrochemical means
COVERAGE The spreading rate of a coating
C.P.V.C Critical pigment volume concentration
CROCODILING The formation of wide criss-cross cracks in a paint film
similar to a crocodile hide.
CURING AGENTS Normally the additive component of a two pack coating.
DEW POINT The temperature at which water vapour in the air will
condense
DRY SPRAY A rough, powdery, non-coherent film produced when dry
applied atomised coating dries before reaching the surface.
EH 40 HSE guidance notes containing all known harmful
substances. Updated every year. Any substance which is
contained within the EH40 guidance notes must have
COSHH documentation supplied with it.

ELECTROLYTE A substance which will conduct a current and be broken

down by it.
EMULSION PAINTS A collection designation for water based paints where the
resins are emulsified, e.g. latex paints consisting of
polyvinyl acetate, poly-acrylates etc. In all emulsion paints,
the solvent/ thinning agent is water and the paints dry as
soon as the water evaporates so that the emulsified
droplets of resin join together and form a solid film.
EPOXY A resin based on polymerised bisphenol a containing
epoxiede groups.
ETCH PRIMER A paint containing an acid which gives an etching effect for
use on aluminium and zinc coated steel to improve the
adhesion of the subsequent layer of paint. Etch primers
must only be applied to bare metals in a very low film
thickness
FEATHERING The abrasive smoothing of the firm edge of a film of paint to
ensure that patch repairs etc. Adhere well to the existing
coating.
FILIFORM A type of corrosion proceeding under a coat of paint,
CORROSION varnish or related product, in the form of threads and
generally starts from bare edges and local damage to the
paint coating.
FILLER A product is used for filling cracks or voids in a substrate.
FILM THICKNESS The thickness of a continuous layer of paint applied to the
substrate
FLASH POINT The lowest temperature at which the vapours given off from
a solvent will ignite given an external source of ignition
FLOTATION Separation of one pigment which appear to “float” to the
surface which results in streaks in the surface of the film
 Glossary of paint terms
GRINNING The effect observed when a paint has insufficient opacity to
THROUGH obscure the underlying coating or substrate
HARD SETTLING The accumulation of solids on the bottom of the container
of paint which are very difficult to reincorporate
HARDNER A cross-linking agent used to cure a resin or paint system
H.A.S.A.W.A Health and safety of work act
HIGH BUILD Paints which can be applied at a high film thickness,
PAINTS normally over 100um dry film thickness
HOLIDAYS Defects characterised by an applied paint having areas of
insufficient thickness even to the point where parts of the
surface may be uncoated
HYGROSCOPIC Salt which has a high affinity for water and will dissolve
SALT within it. Cause osmotic blistering in paint films
INDUCTION The time after mixing when the paint has to be left in order
PERIOD for chemical cross linking to begin. 20-30 mins.
INTUMESCENT A paint that when heated by a flame swells to form
PAINT insulating char. This insulates the substrate from the
surrounding heat and provides extra time for evacuation of
a building, prior to structural failure of the steel.
JET FIRE A fire scenario normally associated with hydrocarbon fuels
which has a flame projecting from a small orifice with the
fuel under pressure. Very severe fire as there is both
temperature and erosive effects of the flames.
LACQUER A fast drying clear coating which dries only by the
evaporation of solvent
LATEX A suspension of resinous particles in an essentially
aqueous medium
LIVERING Early stage of gelling that is characterised by the thickening
of a paint caused by a chemical reaction between basic
pigments and acidic constituents of the binder
M.E.L Maximum exposure limit (to an airborne substance)
MIST COAT A very thin coat of paint usually applied to reduce bubbling
of a coating over a porous substrate, sometimes called a
sealer coat.
MIXING RATIO The ratio, in which components in a multi pack paint, must
be mixed prior to application.
MUDCRACKING Visible cracking in thick films of paint caused by shrinkage
tension during drying, especially observed with zinc
silicates
NON- Describes a paint which dries by solvent evaporation only,
CONVERTIBLE e.g. chlorinated rubber, vinyls etc.
O.E.L Occupational exposure limit
O.E.S Occupational exposure standard
OLEO-RESINOUS Generally refers to resins composed of vegetable drying
oils in conjunction with hard resins, which dry by reaction
with atmospheric oxygen.
OPACITY The ability of a paint film when applied at a given thickness
to obliterate the substrate or previous coating from view
ORANGE PEEL The dimpled appearance of a sprayed film caused by it’s
failure to flow out to a level surface
OVERSPRAY Sprayed paint which misses the surface to be coated
PEELING Loss of adhesion resulting in detachment and curling of the
paint film from either the previous coating or the substrate
pH Potential hydrogen
PICKLING The treatment for the removal of surface contaminants from
steel by immersion in an acid solution
PIGMENTS Powders which give paint its required anticorrosive or
coloured properties
PINHOLES Small holes in through a dry film which form during
application and drying of paint
 Glossary of paint terms
POLYESTER PAINT A coating using synthetic resin resulting from the
condensation polymerisation of various polyacids and
polyols
POLYMERISATION The joining together of a string or structure of repeated
units
POLYURETHANE A synthetic resin containing hydroxide groups cured with an
isocyanate hardener (through single pack moisture cured
polyurethanes are available) when an aliphatic isocyanate
is used good gloss and colour retention result
POT LIFE Time after opening and mixing when the paint remains in a
usable condition. 6 -8 hours.
PRESSURE POT A pressure vessel containing paint and fitted with a
compressed air supply to force paint to a spray gun.
PRIMER Paint intended for protection of metals against corrosion or
for preparing a surface for subsequent topcoats
R.A.Q Required air quantity
RELATIVE The amount of water vapour in the air expressed at a
HUMIDITY percentage of the amount of water vapour which could be
in the air at that same temperature.
RESIN That constituent of the paint which serves to bind together
the various constituents as well as securing adhesion to the
surface.
RUNS Paint film defects in the form of sagging paint in narrow
ribbons flowing downwards on vertical surfaces, usually
caused by applying the coating above the recommended
film thickness or over thinning
RUST GRADE A Tightly adherent blue/black millscale over entire steel
substrate will no signs of corrosion.
RUST GRADE B Millscale which has begun to flake and can be scraped off,
exposed steel has begun to corrode.
RUST GRADE C Millscale has flaked off steel, if there is any millscale
remaining it can be brushed off. Heavy corrosion evident
and some slight pitting maybe visible.
RUST GRADE D No millscale. Heavy corrosion and heavy general pitting.
Sa 1 Light blast cleaning
Sa 2 Thorough blast cleaning
Sa 2.5 Very thorough blast cleaning
Sa 3 Blast cleaning to visually clean steel
SAGGING Excessive flow of paint on vertical surfaces causing
imperfections with thick lower edges in the paint film, not as
excessive as runs
SAPONIFICATION A coating defect cause by the reaction of the binder with
the substrate or attack of the film by an alkali resulting in a
soapy film
SEALER Paint used to seal the substrate or previous coats and
prevent interaction between the subsequent coats applied
SHEEN Gloss level between 10-30% when measured on an 850
head
SHOP PRIMER Rust preventing paint, for short term exposure, to be
applied to abrasive shot blasted steel. Intended to protect
the blast cleaned surface against corrosion during the
construction period only
SILICONE RESINS Based on polymers containing silicon, carbon and
hydrogen
SKINNING The formation of a tough, skin like covering on liquid paints
and varnishes when exposed to oxygen.
SOLVENT FREE Coatings (normally two components) which contain no
COATINGS solvent.

SPOT PRIMING The priming of small areas of a previously painted surface

where the substrate has been exposed.
 Glossary of paint terms
2
SPREADING RATE The coverage of a material normally expressed at m /litre
St 2 Thorough hand and power tool cleaning
St 3 Very thorough hand and power tool cleaning
SUBSTRATE The surface to which a coat of paint is applied
TEXTURED PAINT A coating which by action of application or by incorporation
of aggregates has a rough surface to the paint film
THINNER Any volatile liquid used for reducing the viscosity of
coatings; may consist of a simple solvent, a diluent, or a
mixture of solvents and diluents
THIXOTROPIC Paints that have a semi-solid or gel consistency when
PAINTS undisturbed in the tin, but flow readily when stirred or
shaken or when put under the brush or roller. Thixotropic
paints permit the applications of thick coats without
sagging.
TIE COAT A coat of paint applied to a previous coat to improve the
adhesion of subsequent coats or to prevent other surface
defects e.g. bubbling of a subsequent coating.
TOUCH DRY The stage of curing when the coating no longer feels sticky
when lightly touched
TWO PACK Paints based on binders which cure by the chemical
reaction between two components
VINYL A synthetic thermoplastic resin used to make single pack
paints which dry by solvent evaporation
VINYL ESTERS Resins produced from a polymerised vinyl monomer where
the double bonds are at the ends of the monomer chain.
These react completely on polymerisation, giving a
chemically resistant structure. Because cured vinyl ester
resins contain only thermal cross linking, the entire length
of the molecular chain is available to elongate under stress
and thus absorb mechanical or thermal shocks. The end
result is a tough chemical resistant material especially
when pigmented with glass flake.
VOLUME SOLIDS Percentage of the total volume of the paint made up of non
volatiles
WASH PRIMER A paint containing phosphoric acid which gives an etching
effect for use on aluminium or galvanised steel to improve
the adhesion of the subsequent layer of paint.
WATTER The spotting of bleaching effect caused by the interaction
SPOTTING of water with the paint film surface during drying
ZINC PHOSPHATE A phosphate pigment with corrosion inhibiting properties

ZINC RICH PAINTS Paints containing large proportions of metallic zinc in the
dry film, giving extremely efficient anticorrosive properties
due to the cathodic protection effect of the zinc
ZINC SILICATE Zinc paints based on either a water soluble of solvent
PAINT based silicate binder giving very protection against
corrosion
 BS 7079 Part A, ISO 8501, SS 05 59 00
HAND & POWER TOOL CLEANING
ST 2
THOROUGH HAND & POWER TOOL CLEANING
WHEN VIEWED WITHOUT MAGNIFICATION THE SURFACE SHALL BE
FREE FROM VISIBLE OIL, GREASE AND DIRT AND FROM POORLY
ADHERING MILLSCALE, RUST, PAINT COATING AND FOREIGN
MATTER.
HAND & POWER TOOL CLEANING STANDARDS

ST 2 TO RUST GRADE B SUBSTRATE

 ATC 89 Painting Inspection Grade 1 HANDOUT

Offshore use of High pressure wet

blasting Equipment
When high pressure water jetting is specified for use on an offshore
installation the following safety measures apply:-

 Motive power must be pneumatic or hydraulic only.

 Blast cleaning equipment must incorporate a water storage tank which
can be continually agitated.
 Equipment must display evidence of current certification.
 The equipment must include an inline flow meter to monitor the amount
of water transferred and a means of flushing out the water tanks.
 The amount of water used should be between 1 and 3 litres / minute.
 All adjacent areas must be securely masked off to prevent the ingress
of water or abrasives onto those areas, and to contain the waste by-
products generated by the technique.
 There must be an appropriate communication device between the plant
operator and the person doing the cleaning.
 Before cleaning begins the substrate must be degreased using an
approved method.
 It is good practise to have two work areas independent of the platform
and each other so that one can be painted as the other is being
cleaned.
 National Grid PLC do not allow the use of inhibitors during wet blast
cleaning - so a slight discolouration is acceptable.
 Following cleaning the substrate must be washed down with potable
water prior to be painted – this to remove any extraneous matter that
could affect the paint system.
 If using moisture sensitive coatings the surfaces must then be dried
firstly with sponges and then with clean dry air.
 The inspector must then inspect all surfaces for compliance with the
specification (BS EN 7079) before the coating is applied.
 The lances used must be over 1 metre long.
 Appropriate P.P.E must be worn by the operatives.
 The equipment must have a pressure cut out facility and be severrly
earthed.
 An approved pressure tast must have been carried out on the hoses
and their couplings.
 Examples of sensitive include:.
o Valve spindles, glass, machinery cables, stainless steel
pipework, control panels, gratings, exposed fixings etc.
 How to use a Banana gauge
The banana gauge works on the principle of magnetic resistance,
by means of a small magnet and a tensioned spring. It can
therefore only be used on Ferrous substrates. Calibration is
vitally important in order to gain accurate Dry Film Thickness
readings (DFT). The calibration should ideally be carried out on
a blasted surface with a profile similar to that of the painted
substrate.
The calibration process is detailed below:
 The banana gauge is placed firmly on the blasted steel
surface, with the magnet end placed directly on a thin
plastic “shim” of a known thickness, which is measured in
microns. (Older shims have measurements in thousandths
of an inch).
 The tensioning wheel is then pushed slowly forward until
it can go no further. (The magnet can be clearly heard to
make contact with the surface)
 The gauge wheel is then (very slowly and carefully)
reversed; until such time that the magnet lifts from the
substrate. The gauge can then be read, giving a reading of
the DFT.

Should the reading differ from the known thickness of the shim,
the gauge should be rotated back to the zero point, and the scale
should be adjusted by holding the black wheel in position, and
simultaneously moving the thin steel calibration strip up or
down according to requirements. If the initial reading is less
than the shim thickness, the scale would have to be moved up.
Alternately, a reading greater than that of the shim would
require the scale to be moved down.
The calibration process should then be repeated as many times
as is required, until the correct thickness reading of the relevant
shim is achieved.
 BGAS PAINTING INSPECTOR
HOW TO USE A DEWPOINT CALCULATOR

1) Take the Wet Bulb reading (W.B) from the

Whirling Hygrometer e.g. 10° C
2) Take the Dry Bulb reading (D.B) from the
Whirling Hygrometer e.g. 15° C
3) Align the W.B. reading (10° C) on the outer
(RED) scale with the D.B. reading (15° C) on
the next inner (BLACK) scale.
4) Do not move the scales any further.
5) Look down to the next (BLACK) W.B scale
and observe the 10° C point.
6) Look immediately up to the (RED) DEW
POINT scale (within the elliptical window)
and read off the DEW POINT temperature in
°C. (5.5°C)
7) Go to the (RED) DEW POINT scale at the
bottom of the calculator.
8) Set 5.5° C on the D.P scale against 15° C on
the (BLACK) Dry Bulb scale immediately
above it. (To do this you will have to rotate
the slide!)
9) Without moving it any further, look up to the
Relative Humidity scale ( in the small window
above)
10) Observe the line pointing to the Relative
Humidity (55%)
 PAINTING INSPECTOR
HOW TO USE A DIGITAL THICKNESS
METER
 PRESS THE “ON” BUTTON

 OBSERVE THE “CAL” SYMBOL IN THE BOTTOM LEFT

HAND CORNER OF THE SCREEN.

 PRESS THE KEY BELOW THIS SYMBOL (LISTEN FOR 3

BLIPS)

 OBSERVE THE “CALIBRATION STEP 1” SCREEN WITH

THE SYMBOL IN THE BOTTOM L.H. CORNER.

 CHOOSE THE NEAREST PLASTIC SHIM TO YOUR

REQUIRED COATING/PAINT FILM THICKNESS AND
PLACE IT ONTO A “PLAIN” STEEL SURFACE.

 PLACE THE PROBE ONTO THE SHIM AND OBSERVE THE

READING.

 TOGGLE UP↑ OR DOWN ↓ (AS REQUIRED) TO ADJUST

READING TO SHIM SIZE USING THE APPROPRIATE KEY.

 PRESS “SET” KEY TO LOG READING INTO M/C (3 MORE

BLIPS)

 OBSERVE “CALIBRATION STEP 2” SCREEN WITH

SYMBOL IN BOTTOM L.H.CORNER

 ZERO THE PROBE BY PLACING ONTO A “SMOOTH”

STEEL SURFACE (NO SHIM THIS TIME)

 OBSERVE READING – PRESS “ZERO” KEY THEN THE

“SET” KEY.

 SCREEN NOW SAYS “TEST READINGS” PRESS “NO” AND

NOW PROCEED TO MEASURE YOUR FILM THICKNESS.
 PAINTING INSPECTION
ADHESION TESTING
HYDRAULIC ADHESION TEST EQUIPMENT (HATE)

TO USE
This is a much quicker test with a higher degree of accuracy than the mechanical. The HATE use Cyano-
acrylic impact adhesives and can usually be done approximately two hours after dolly/adhesive application,
the dolly’s are mild steel and reusable because they are heated up to destroy the adhesive after use. Big
downside for this test is initial cost and usually high maintenance.
 IMPORTANT PIGMENT.
MICACEOUS IRON OXIDE
Micaceous hematite, Natural lamellar hematite, Specular iron oxide, Micaceous iron oxide,
Natural specular hematite ore – is MAGNETIC and has an effect on DFT readings taken with
Magnetic Dry Film thickness gauges.

Moisture ingress path to substrate

indicated by arrows

Micaceous Iron Oxide comes from a variety of places, is processed to remove

impurities and then by drying, grinding and sieving is refined to produce a grey
material with a metallic sheen and a lamellar structure. It is this lamellar
structure combined with exactly the right particle size distribution which enables
it to be used as a pigment in paints.

MIO is a naturally occurring lamellar (plate like) form of ferrous oxide, Fe 203
 MECHANICAL CLEANING TOOLS.

Top : Chisel Gun Bottom: Needle Gun

Caution: Both lead to very high surface profile.
 PAINT CALCULATIONS - GUIDANCE

D.F.T = Dry Film Thickness (measured in Microns μm)

W.F.T = Wet Film Thickness (measured in Microns μm)

Area = (Area of a circle =  (3.142) x r2 - units mm2)

(Area of a rectangle/square = length x width)
(Area of a cylinder-tank = (2xr²) + ( x D x H)
(this is for tank top + bottom + sides)

Volume = Area (length x width) x h (height) – units mm³

VS. = Volume Solids (Usually expressed as a %)

Equations Reminder

1) WFT = Vol 6 = 12
Area 2

2) Area = Vol 2 = 12
WFT 6

3) Vol. = WFT x Area 12 = 2 x 6

1000

4) WFT = 100 x DFT

VS

5) DFT = VS x WFT
100

6) VS% = DFT x 100

WFT x 1
 SURFACE PREPARATION.
BLASTING POTS - MACHINES
EXHAUST
T

RECCOVA
VALVE PART
OF DEAD MAN
SYSTEM

Blasting Pots and Machines come in many varieties and sizes.

3 points to remember:
A) Blast cleaning is dangerous, so don’t get too close it !
B) Grit exits the nozzles (Venturi) at 450 mph or 720 kph !
C) When the blaster releases the dead man handle the pot will
exhaust the air inside very quickly, it is noisy and always
contains particles of grit !!!!!

SAFETY – SAFETY – SAFETY - SAFETY

 Critical Pigment Volume Concentration (CPVC)
High
CPVC

Gloss

Blistering

Permeability
Low
Low CPVC High
Pigment Pigment
 MECHANICAL CLEANING TOOLS.
POWER BRUSHES

Power brushes come in many varieties and sizes.

2 points to remember:
A) If over used they BURNISH the substrate, which means they
polish it.
B) Needles always come out of the brushes at high speed due
to use and centrifugal force and they are very dangerous.

SAFETY – SAFETY – SAFETY - SAFETY

 BS 7079 Part A
ISO 8501, SS 05 59 00

RUST GRADES
RUST GRADE A
STEEL SURFACE LARGELY COVERED WITH
ADHERENT MILLSCALE WITH LITTLE IF ANY RUST.
 BS 7079 Part A
ISO 8501, SS 05 59 00

RUST GRADES
RUST GRADE B
STEEL SURFACE, WHICH HAS BEGUN TO RUST
AND FROM WHICH MILLSCALE HAS BEGUN TO
FLAKE.
 BS 7079 Part A
ISO 8501, SS 05 59 00

RUST GRADES
RUST GRADE C
STEEL SURFACE, ON WHICH THE MILLSCALE HAS
RUSTED AWAY OR FROM WHICH IT CAN BE
SCRAPPED, BUT WITH SLIGHT PITTING VISIBLE
UNDER NORMAL VISION.
 BS 7079 Part A
ISO 8501, SS 05 59 00

RUST GRADES
RUST GRADE D
STEEL SURFACE, ON WHICH THE MILLSCALE HAS
RUSTED AWAY AND ON WHICH GENERAL PITTING
IS VISIBLE UNDER NORMAL VISION.
SPA1 OPERATION CHART FOR MAINTENANCE PAINTING REF TO PREVIOUS
PAGE AND FOR COATINGS WITH LIMITED DAMAGE

MASK OUT

REMOVE
CONTAIMINANTS OIL,
GREASE ETC

PREPARE EXISTING SYSTEM

BY PROVIDING A KEY IF
REQUIRED
(SEE SPA1b)

SUFACE PREPARATION OF EXPOSED

SUBSTRATE OR WHERE PAINT IS TO BE
FEATHER EDGES
REMOVED
(BLAST CLEANING OR WIRE BRUSHING
AS SPECIFIED)

CLEAN ALL SURFACES IMMEDIDATELY PRIOR TO

PAINTING

SPOT PRIME OVERLAP EXISTING

COATING BY AT LEAST
100mm

SPOT WITH MIO

OVERLAP PRIMER EDGE

APPLY U/C

OVERALL OR TO AREAS
SPOT PAINTED AS
SPECIFIED
APPLY FINISH

NB The Engineer will normally specify the areas to be painted, the method of preparation and
the paint system to be applied. The number of coats required will be dictated by the breakdown
of the existing system and its required life. The minimum DFT will comply with the previous
page.
SPA1 OPERATION CHART FOR PAINTING OF UNCOATED OR UNSUITABLY
COATED SURFACES AT WORKS OR SITE AND APPLICATION OF PAINT TO
PREPARED SURFACES

MASK OUT

REMOVE MAX 7 DAYS

CONTAIMINANTS OIL, ALLOWED BETWEEN
GREASE ETC COATS

BLAST CLEAN SA2½

MAX PROFILE 75µm

ON SITE SYSTEM CLEAN SURFACES ON SITE SYSTEM

(IMMEDIATELY PRIOR TO
COMPLIANT PAINTING) WATER-BORNE ACRYLIC
SOLVENT BASED

HIGH BUILD AT WORKS PRIMER 50µm MIN

EPOXY
ALUMINIUM
75µm MIN HIGH SOLIDS
SOLVENT
MIO 75µm MIN
BASED EPOXY
EPOXY MIO PRIMER 75µm
75µm MIN MIN

U/C 50µm MIN

EPOXY MIO
HIGH BUILD 75µm MIN
EPOXY U/C
75µm MIN FINISH COAT
50µm MIN
COMPLETION
ON SITE
EPOXY (GOOD
WITHIN 3
STRENGTH BUT MONTHS TOTAL SYSTEM
CAN “CHALK”) OR
DFT 225µm MIN
POLYESTER
OR
ACRYLIC FINISH
40µm MIN DFT 250µm MIN
IF PRIMED AND
ST
1 MID APPLIED
AT WORKS
TOTAL SYSTEM
DFT 265µm MIN

NB Other compliant systems may be put forward as a variant

provided they comply with PA9 and provide equivalent long
term performance to the above systems.
Primer, in all cases, is to be applied within 4 hours of metal
preparation.
Stripe coating to welds and edges before primer is applied in
order to assist the achievement of DFT minimums.
 SPA3 OPERATION CHART 100°C TO 149°C
HEAT RESISTANT ALUMINIUM PIGMENTED EPOXY OR
URETHANE PRIMER

MASK OUT

REMOVE CONTAMINATION
OIL, GREASE, ETC

BLAST CLEAN
SA2½ 75µm MAX

CLEAN AREAS IMMEDIATELY

PRIOR TO PAINTING

APPLY PRIMER WITHIN 4 100µm URETHANE

HOURS PRIMER
DFT DEPENDS ON PRIMER 140µm EPOXY
USED (HEAT RESISTANT AL
PIGMENT EPOXY)

FURTHER COATS TO BUILD

100µm URETHANE
250µm EPOXY
 SPA3 OPERATION CHART 150 °C TO 340°C TSA IZS
OR POLYSILOXANE SYSTEM

MASK OUT

REMOVE CONTAMINATION,
OIL, GREASE ETC

BLAST CLEAN
SA3 75µm MAX

CLEAN SURFACES
IMMEDIATELY PRIOR TO
PAINTING

ALTERNATIVE PREFERRED SYSTEM ALTERNATIVE

IZS TSA POLYSILOXANE

TO MANUFACTURERS (LONG SERVICE LIFE) INORGANIC COATING
INSTRUCTIONS TO MANUFACTURERS
INSTRUCTIONS

COSTLY BUT WAY TO

GO IN FUTURE
125mm/COAT
 SPA3 OPERATION CHART ABOVE 340 OC TSA IZS
OR POLYSILOXANE SYSTEM

MASK OUT

REMOVE CONTAMINATION,
OIL, GREASE ETC

BLAST CLEAN
SA3 75µm MAX

CLEAN SURFACES
IMMEDIATELY PRIOR TO
PAINTING

ALTERNATIVE PREFERRED SYSTEM ALTERNATIVE

IZS PREFERRED SYSTEM TSA POLYSILOXANE

SEALER (LONG SERVICE LIFE) INORGANIC COATING
HEAT TO CURE ALSI SEALER NB
ALL TO HEAT TO CURE NO SEALER IS
MANUFACTURERS 80°F (30 – 31°C) REQUIRED
RECOMMENDATIONS FIRE UP PLANT GENTLEY
AL SICONE SEALER

SOFT FINISH SEALER METALLIC

“TOUCHING" IMPROVES PARTS ARE
MARKS IT APPEARANCE POROUS
AND GIVES A NEEDS SEALING
LONGER LIFE
 SPA4 OPERATION CHART FOR DAMP FERROUS SURFACES

MOISTURE CURING POLYURETHANES OR HIGH SOLIDS

MULTI-COMPONENT EXPOXY PAINTS

REMOVE SURFACE CONTAMINATION

SWAB WITH GREASE REMOVING SOLVENTS
WASH WITH 2% DETERGENT SOLUTION

BLAST CLEAN SA 2½
75µm MAX

WHY?
BECAUSE
WASH WITH CLEAN WATER AIR BLAST
SOME
(TO REMOVE GRIT AND DUST) (LIMITED USE)
ABRASIVES
“STICK” WHEN
BLASTING
PRIME
REMOVE DROPLETS AND STANDING IMMEDIATELY
WATER FOLLOWING
DRY WITH (SURFACE SHALL NOT BE WET)
LINT-FREE DRYING
SWABS

BUT SOME RUST

BLOOMING MAY BE
ALLOWED

MOISTURE CURING HIGH SOLIDS MULTI-

POLYURETHANES TO COMPONENT EPOXY PAINT
MANUFACTURERS TO MANUFACTURERS
INSTRUCTIONS INSTRUCTIONS
(BY BRUSH) (BY BRUSH)
 SPECIFIC PAINT APPLICATION
S.P.A.6a PREPARATION OF NON FERROUS SURFACES

SURFACE PREFERRED OPTION FIRST OPTION COMMENTS

New Galvanizing Sweep Blast Hand Abrade An etch primer

(creates profile) (smaller areas) (T.Wash) developed by
British Rail.
Phosphoric acid + 57%
water
Blue dries black
Brush applied
Weathered Galvanizing Stiff Bristle Brushing Weathering provides its
own key.
Previously painted Sweep Blast Hand Abrade
Galvanizing

Aluminium Sweep Blast Hand Abrade For thin gauge

aluminium etch primer
used prior to
intermediate and finish
coats. Not to be blast
cleaned. Chlorinated
hydrocarbon solvent
shall not be used.
Stainless Steel Sweep Blast Only aluminium used
as blasting medium.
Pre-painted cladding Sweep Blast Hand Abrade
plastisol or equivalent

Glass reinforced Sweep Blast Hand Abrade

plastics

Fusion bonded epoxy Sweep Blast Hand Abrade

Multi component liquid Sweep Blast Hand Abrade

Concrete To manufacturers Surface abrasion may

(Exterior Surfaces) instructions not be required for new
concrete. Old paint, if
required should be
removed with
scrabblers.
 SPECIFIC PAINT APPLICATION
S.P.A.6a PREPARATION OF NON FERROUS SURFACES

SURFACE SYSTEM/PRIMER SYSTEM/PRIMER SYSTEM/PRIMER COMMENTS

New galvanizing Water borne Epoxy high build Alkyd or modified Damaged
Weathered acrylic alkyd galvanizing
galvanizing MIO pigmented Pigmented high Alkyd or modified repaired with zinc
Previously water borne build epoxy alkyd rich epoxy
painted acrylic
galvanizing 65 µm DFT MIN 65 µm DFT MIN 40 µm DFT MIN
Aluminium
Stainless Steel Water borne Epoxy high build Zinc rich paints
acrylic must not be used
MIO pigmented Chloride free on stainless steel
water borne epoxy high build
acrylic
45 µm DFT MIN 65 µm DFT MIN
Pre-painted Water borne Moisture cured Alkyd or modified Where steel
cladding acrylic urethane alkyd substrate is
(plastisol or MIO pigmented Compatible Compatible alkyd exposed repair as
equivalent) water borne moisture cured or modified alkyd in SPA1
acrylic urethane
45 µm DFT MIN 25 µm DFT MIN 40 µm DFT MIN
Glass reinforced Water borne Moisture cured Alkyd or modified
plastic acrylic urethane alkyd
Fusion bonded MIO pigmented Compatible Compatible alkyd
epoxy water borne moisture cured or modified alkyd
Multi component acrylic urethane
liquids 45 µm DFT MIN 25 µm DFT MIN 40 µm DFT MIN
Concrete (walls Water borne Moisture cured Alkyd or modified For new concrete
and floors) acrylic urethane alkyd a sealer coat may
Single pack water Moisture cured Compatible alkyd be required
borne acrylic urethane sealer or modified alkyd
primer
30 µm DFT MIN 40 µm DFT MIN

NB Other compliant systems which meet the requirements of PA9 may be proposed to Trans Co as
variants
 PAINTING INSPECTION
MAGNETIC TEMPERATURE GAUGE, LIMPET GAUGE

The air temperature (ambient) is the temperature recorded from the dry bulb
thermometer. To measure the steel substrate temperature a magnetic gauge,
known commonly as a limpet gauge is used, or a digital thermometer,
thermocouple, sometimes called a touch pyrometer. Limpet Gauge must be in
contact with the substrate for at least 15 minutes and not in direct sunlight.
 ATC 88 BGAS PAINTING INSPECTION
CLEANING METHODS INFORMATION Hand out. Nov 09

Summary of cleaning methods:

Preparation of Surfaces.

1. Before cleaning operations commence, any oil or grease on the substrate shall
be removed by washing with an approved solvent, or by other means approved
by the Engineer.
2. All algae and mould growth shall be removed, by scrubbing with stiff bristle
brushes, using sweet water. Following the removal of algae or mould growth,
a biocidal wash should be applied to prevent contamination of the new plant
system.
3. All surfaces, after completion of the surface preparation, and immediately
prior to painting, shall be cleaned by air blasting using clean, dry, oil-free air:
or are to be vacuum cleaned to ensure that all traces of abrasive and corrosion
products are removed.
4. Any oil or grease on the surface of the steel after preparation, shall be
removed by washing with an approved solvent. These surfaces shall then be
re-blasted.
5. Prepared surfaces shall be brushed to remove all dust, and cleaned to remove
all contaminating matter immediately before the paint is applied.

Cleaning of Existing Painted Surfaces.

1. Painted surfaces on which there is evidence of atmospheric contamination or

salts disposition, shall be washed down using soft nylon brushes and clean
water and thoroughly dried before further coats of paint are applied.
2. Oil, grease and other contaminations of paint films shall be remonved by
brushing and washing with an approved solvent. Such cases shall be scrubbed
with a 2% solution of detergent and then thoroughly rinsed with ckean hot
water.
3. In the event of any foreign materials (e.g. shot or grit) being found embedded
in the paint film, the affected areas shall be re-blasted and the complete
painting system re-applied. All paint shall be applied in such a manner as to
ensure a continuous covering film, free from misses, tears, runs, sags etc.

Painting of Galvanised Steel.

1. All dirt and other adhering contaminating matter shall be removed from
galvanised surfaces by brushing with clean wire or clean stiff bristle brushes,
or by other methods which are approved by the Engineer. Any such cleaning
shall not damage the galvanising.
2. Any oil or grease shall be removed by swabbing with approved grease
removing solvents.
3. The products of zinc corrosion, if any, shall be removed by washing with
water and scrubbing with stiff bristle brushes.
 ATC 88 BGAS PAINTING INSPECTION
CLEANING METHODS INFORMATION Hand out. Nov 09
 SURFACE PROFILE
MEASUREMENT.
DIAL MICROMETER

TO CALIBRATE: CLEAN ANVILS &

ENSURE DIAL IS SET TO ZERO, LOCK THE DIAL.
REPLICA TAPE TO BE USED AS INSTRUCTED.
PLACE TAPE BETWEEN ANVILS AND READ
MEASUREMENT, DEDUCT THICKNESS OF TAPE
TO OBTAIN SURFACE PROFILE READING.
 SURFACE PROFILE
MEASUREMENT.
NEEDLE GAUGE

CALIBRATE ON FLAT GLASS.

ENSURE DIAL IS SET TO ZERO.
TAKE MINIMUM OF 10 READINGS AND
CALCULATE AVERAGE.
 SURFACE PROFILE
MEASUREMENT.
SURFACE PROFILE COMPARATOR

PLACE ON SUBSTRATE AND ASSESS THE

SUBSTRATE IN COMPARISON TO SEGMENTS.
ENSURE YOU USE CORRECT TYPE.
THE 2 TYPES ARE FOR SHOT AND GRIT.
THE GRIT COMPARATOR MAY BE USED FOR
SHOT/GRIT MIXTURE.
 SURFACE TESTING
The Silver Nitrate Test

Incotest CIS 3S (Chloride Ions) (SALT) Equipment

Bottle of reagent, test tubes, wooden spatulas, plastic
dropper, distilled water and spray bottle.

Method
Test purity of the distilled water. Spray approximately 20ml
distilled water onto surface of steel. Collect run off into test
tube. Fill test tube to approximately ¾ full. Add 4 drops of
reagent. The presence of soluble chlorides will show up as a
white precipitate.

Limitations
Provides a stop/go indication only. Does not provide
quantifiable results.
 PAINTING INSPECTION
WET FILM COMB GAUGES

TO USE
IMMEDIATELY AFTER APPLICATION OF PAINT DIP END OF GAUGE IN TO WET
FILM ENSURING BOTH END FEET ARE AT THE SURFACE OF THE SUBSTRATE OR
PRECEDING COAT. REMOVE AND LOOK AT THE TEETH TO SEE WHICH ARE
COVERED WITH WET PAINT. SOME WILL BE FULLY COVERED AND SOME
PARTIALLY, THE READING IS RECODED AS THE WET FILM IS “BETWEEN”.
SPRAYERS SHOULD BE COMPLETING THIS AS THEY SPRAY TO ENSURE THEY HAVE
APPLIED SUFFICIENT PAINT, IF THEY HAVE NOT THEY CAN APPLY MORE AT THAT TIME.