Inspection and Testing Equipment

Dry Film Thickness -

There are numerous types of dry film thickness gauges available around the
globe.

It is essential that the correct gauge or instrument is chosen to suit the

requirements of the task or contract.

It is always advisable to check the painting specification and the

manufacturer's instructions.
Magnetic Dry Film Thickness Gauge (Pull off Gauge)

 Available in a number of dry film thickness ranges

 Intrinsically safe. (no batteries)
 Robust and hard-wearing
 Easy to use
 Reliable
 Track record

Meets the requirements of SSPC-PA2 Type 1 gauge

Electronic Dry Film Thickness Gauges (Constant Probe Type)

There are a number of electronic (digital and analogue) gauges available to

suit the task.

 Electronic gauges are accurate and easy to use

 They can be a simple measure and read or sophisticated gauges
 Capable of storing a great number of dry film thickness readings
 Various ranges are available from zero to 1000 microns (40 mils) and
some up to 20 millimetres or more

Meets the requirement of SSPC-PA2 Type 2 gauge

Dry Film Thickness Gauge

This animation demonstrates the use of a digital dry film thickness gauge.

 The gauge works on the principle of 'electromagnetic induction'

 The gauges are generally available in ferrous and non-ferrous
 Simple to operate in trained hands

Always read the operating instructions prior to use.

Calibration Foils/Shims

Calibration of the dry film thickness gauge is essential prior to every use.

 Calibration shims are required to calibrate the gauge

 The shims are available in different colours which relate to different
thicknesses
 Use a shim with a thickness close to that of the film thickness you intend
to measure.
 Change the shim when worn or damaged
 Although the term calibrate is used, the only party that can perform a
calibration is the manufacturer or an approved laboratory

The user verifies the accuracy of the gauge prior to and after each period of
use.
Wet Film Thickness Gauge

It is essential that the coating applicator can conduct wet film thickness
following coating application.

 Applying too much paint will not only waste paint but could lead to
premature coating defects
 Apply too little paint and there is a risk of under protection

The use of wet film combs is 'value for money'

Wet Film Thickness Gauge

The wet comb should be used immediately after the application of the
coating.

 Easy to use and economical

 All applicators should have a wet comb
 All applicators should use a wet comb
 They are available in metal or plastic

Always keep the comb clean and free of dried paint and debris.
Wet Film Thickness Gauge - Combs

A range of combs is available to suit the thickness of the coating.

The wet film combs are generally available in aluminium, steel or plastic.

The plastic type wet film combs are designed to be used once while the
aluminium and steel combs can be cleaned and re-used.

Plastic combs are generally 'use once' only as the paint/solvent can melt the
plastic.
Wet Film Thickness Gauge - Wheel

Another type of wet film gauge is the wet film thickness wheel.

This instrument is, however, used for specialist processes such as coil coating.

Most industrial type contracts use the traditional combs which are more
economical.
Relative Humidity

Relative humidity is extremely important to coating application and cure.

Relative humidity must be checked on a regular basis.

There are a number of instruments for checking the relative humidity, the
most popular being the whirling hygrometer.

This instrument is manually used by trained personnel.

Ambient Conditions

Once the whirling hygrometer has been used, the user must then calculate the
relative humidity and dew point from tables or a specialist calculator.

Both the tables and calculator methods are accurate and simple to use.

The results of the tables or calculator must be recorded for permanent

evidence.
Ambient Conditions

It is also possible to utilise an electronic instrument which measures the air

temperature, relative humidity, surface temperature and dew point.

This instrument is simple to operate and will give instant readings.

Calibration must be conducted on a regular basis with this type of gauge.

Steel Temperature

The steel or substrate temperature is also an essential part of the

environmental conditions for paint application, especially when assessing the
dew point.

There are two basic methods of recording the steel or substrate temperature,
these include the magnetic thermometer and digital thermometer as
illustrated.

The electronic or digital version will give instant and accurate readings.
Infrared Thermometers

Infrared thermometers are also available and can very accurately measure the
surface temperature without contacting the surface.

There maybe circumstances when on surface treatments where a high surface

temperature is required or coating cure etc.

You can also record the coating material temperature.

Some infrared thermometers can store readings and save to computer or

storage.
Magnetic Surface Temperature Gauge

These type gauges require 15-20 minutes to stabilise and give accurate
results.

They are safe to use as no batteries are necessary to operate the equipment.

Don't forget to remove them before applying the coating system!

Digital Vs Magnetic Temperature Gauge

This animation gives a comparison in the time taken to record the

temperatures with a digital and magnetic thermometer.

Although the digital thermometer gives almost instant results it may not be
possible to use in all working environments due to the potential hazards with
use of battery operated equipment.
Surface Profile Gauge

The surface profile is important when abrasive blast cleaning.

 There are various methods of testing or checking the surface profile

 One of the oldest forms of checking the surface profile is with a surface
profile needle gauge

This gauge measures the peak-to-valley height of a blast cleaned surface.

Needle Gauge

The needle gauge is placed on the steel surface where the needle falls into the
surface profile.

 The profile measurement can be read directly from the gauge

 The needle is quite delicate and care must be taken when using,
cleaning and putting away after use

A number of readings are necessary to achieve an average surface profile.

Surface Profile - Digital Type

A digital surface profile gauge is also available.

This gauge is battery operated compared to the analogue type which does not
require any power.

As with all electrical equipment, there may be areas where this gauge cannot
be used.

The gauge is quick and easy to use.

Surface Profile - Replica Tape

A replica tape is a method of checking the surface profile while keeping a

permanent record.

 The type consists of foam with a non-compressible backing

 The foam side is rubbed into the surface providing the permanent
mould of the surface profile
 Various size tapes are available to match the requirement of the
specified surface profile

The tapes currently being manufactured and used in the industry are Coarse,
Extra Coarse, and Extra Coarse Plus.
Surface Profile Testing - Replica Tape

The tape is pressed onto the surface profile and rubbed with a round head
spatula.

The surface profile is copied onto the tape, which is then measured with a
micrometer.

The tape can be kept as a permanent record of the surface profile.

Surface Profile - Replica Tape

Replica tape demonstrated on an abrasive blast cleaned surface.

Three surface profile ranges are available.

The example demonstrates X coarse 1.5-4.5 mil or 40 (38)-115 microns

The tapes currently being manufactured and used in the industry are Coarse,
Extra Coarse, and Extra Coarse Plus.
Surface Profile - Tape Measurement

A thickness gauge is required to measure the peak to valley height of the

surface profile which is formed on the tape.

The gauges are usually available in imperial and metric versions.

Surface Profile - Comparator Gauge

The surface profile can also be assessed with the use of a surface comparator.

The comparator is available in:

1. Grit
2. Shot

Limits of profile grades* are:

1. Fine
2. Medium
3. Coarse

*ISO 8503-1 Table 2 - Limites of profile grades

Use of a Comparator in Operation

 The surface comparator is available in grit and shot versions

 ISO 8503-2: 1988 outlines three limits of profile grades:

1. Fine
oProfile equal to segment 1 and up to but excluding segment 2
2. Medium
o Profile equal to segment 2 and up to but excluding segment 3
3. Coarse
o Profile equal to segment 3 and up to but excluding segment 4
Surface Comparator with Magnifier

Kean-Tator Gauge

The comparator segments are designed to be used with magnification.

Three versions are available:

1. Sand
2. Shot
3. Grit

This instrument finds more use in North America than the rest of the globe.
Rugotest No.3

The Rugotest is a surface profile comparator that is rectangular shaped and

has blast cleaned specimens that are grouped vertically according to the
shape of the abrasive used for the blast cleaning.

One side shows shot blasted plates while the other shows grit blasted plates.

Each side is divided into six roughness areas from N6 (lowest) roughness to
N11 (highest) roughness.

The popularity of this gauge has decreased since the introduction of the ISO
comparator.
Pinhole and Porosity Detection

Referred to as spark tester, porosity or holiday detectors, and pinhole testers.

This Instrument is used on cured coatings to establish any breaks in continuity

in a coating along with coating defects.

Various accessories are available with this type of gauge and can be used on
flat and round surfaces such as pipelines etc.

Most high build coatings which are immersion or buried should be tested for
breaks in continuity.
Pinhole and Porosity Testing

Pinhole and porosity detection is frequently specified for coating and lining
systems where a full continuous coating is essential.

Examples include ballast, cargo and specialist linings.

There are various suppliers of this type of equipment.

The coating manufacturer will advise on the voltages that are to be set on the
gauge.

The Voltage may also be specified in the coating specification.

High Voltage Holiday Detector

Suitable for coatings above 500 microns or 20 mils up to approximately 7

millimetres.

A high dc voltage instrument which is suitable for pipelines and protective

linings such as tanks and vessels.
High Voltage Holiday Detector

This video demonstrates the use of a high voltage holiday detector being used
on a coated piece of steel that has flaws such as;

 pinholes (a very narrow hole running from the coating surface to the
substrate)
 holidays (small uncoated areas)
 inclusions (objects trapped in the coating, e.g. grit from blast cleaning)
 air bubbles, cracks, and thin spots.

The instrument generates a high voltage which is applied to the surface of the
coating via a probe.

When the probe is passed over a coating flaw, the electrical circuit is
completed and current flows from the probe to the substrate. As a result, the
instrument gives audible and visual alarms and a spark may be produced at
the flaw.
Methods of Testing

Wet sponge low voltage technique and the high voltage technique.

The low voltage instrument is suitable for measuring coatings on metal with
less than 500 microns of coatings applied.

The high voltage instrument is suitable for measuring coatings on conductive

substrates above 500 microns up to around 7 millimetres.
Low Voltage Holiday Detector

Suitable for coatings with less than 500 microns or 20 mils on conductive
substrates. Always check the specification for the exact maximum dry film
thickness as some specifications may say less than 500 microns (20 mil)

The sponge is dampened with a wetting agent.

During use, the liquid penetrates flaws and highlights breaks in continuity to
the user.
Adhesion Testing Equipment

Used to quantify the strength of the bond between substrates and coating or
between different coating layers.

Adhesion testing is generally specified as a test procedure for newly applied

coatings.
Adhesion Testing

This animation demonstrates the use of an adhesion gauge on a painted

surface.

A 'dolly' is glued to the surface and the gauge is used to pull the dolly from
the surface.

This is usually a job for an experienced inspector.

The coating supplier will advise on the recommended adhesion value for their
particular coating.
Adhesion Test Equipment

Various hydraulic and pneumatic adhesion test gauges are available.

Potential users must take advice from the suppliers on which gauge is
recommended for which task.
Cross Hatch Adhesion Tester

Simple process for determining the adhesion of a coating.

Suitable for coatings on flat surfaces with a film thickness of less than 125
microns or 5 mils.

Various size cutting blades are available to suit the task.

Cross Hatch Cutter

Suitable for thin, thick or tough coatings on flat or curved surfaces.

Used on sites and with laboratory coated panels.

Always check the specification for acceptance criteria along with the specific
standard and manufacturers instructions and guidelines.
Surface Contamination

Surface contamination from soluble salts such as chlorides and sulphates will
lead to blistering of a coating, particularly in immersed conditions.

These salts are virtually invisible to the human eye and special inspection
equipment is required to check the substrate during cleaning or surface
preparation.
Salt Contamination Meter

 Measures the conductivity of wet paper which is pressed onto the

surface and placed in the meter.
 Calculates soluble salt levels on a surface.
 Follow the manufacturer's instructions and review the painting
specification for the acceptance criteria.
Soluble Salt Detection on Blast Cleaned Surfaces

Detects chlorides on the prepared substrate.

Special kits are available to find the specific contaminant such as soluble
chloride salts.

Always observe the suppliers recommendations on the use of the equipment

and the paint specifications for acceptance criteria.
Specialist Inspection Equipment

A kit designed to measure chlorides, sulphates and nitrate ions.

All contents are supplied in a robust case and ready for instant use.

Specialist training should be conducted on this type of equipment.

Bresle kit and Patches

 Conductivity Kit
 Used in accordance with ISO 8502-6 standard
 This method extracts material for analysis soluble contaminants from a
surface by use of a flexible pad which is fixed to a surface

SSPC Technology Guide - 15 Field Methods for Retrieval and Analysis of

Soluble Salts on Steel and Other Non-porous Substrates is a reference source
for these and other test methods.
Pictorial Surface Standards

Numerous standards exist in the protective coatings industry.

Various organisations have developed their own standards. Examples include

the SSPC and NACE.

It is important to have the latest revision of these documents.

Inspection Manual

Various inspection manuals are available which detail inspection techniques

and equipment use.

Inspection manuals are generally available from specialist organisations such

as SSPC the society for protective coatings, NACE and specific instrument
manufacturers.
Coating and Application Defects Manual

Visual photographs and text description of coating faults and defects.

These manuals are extremely useful for identifying basic coating defects.

A full-colour version is, however, necessary as some manuals are in black and
white.
Saberg Drill

The Saberg drill is a destructive instrument used to assess paint thickness,

number of coats and coating defects such as voids etc. The portable
equipment uses conical drill. A marker is used on the surface and the
instrument drills a hole through the paint film.

A microscope is used to inspect the coating.

Individual coats can be determined along with the full paint system.
Full Inspection Equipment kit

Some of the leading suppliers of inspection equipment have produced full

inspection kits.

These inspection kits:

 Contains most use types of equipment

 Can be complemented by specialist equipment
 Are available by major instrument suppliers
 Ensure adequate training is conducted before using the equipment
Summary

Within this training unit, we have reviewed the various types of inspection
equipment including wet and dry film thickness, environmental monitoring,
surface profile, low and high holiday detection, adhesion and visual standards
along with industry related guides.

The Coatings industry has numerous types of inspection equipment, some

basic and some quite complex.