Inspection and control

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What is QA - QC ?

QA = Quality Assurance (A documented management system)

QC = Quality Control (Inspection and testing routines)

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The tasks of the paint inspector

To ensure that the requirements of the coating specification are met. Verify the quality of work carried out by the contractor/yard. Prepare written records of the standard of work - Approval (Satisfactory ? / Conforming ?) - Non-conformance
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An inspectors work includes:

Be capable of interpreting
the specifications Understand the objective of the inspection Inspect all structures to be painted Ensure that all specified requirements are met Document the results from the inspections In case of non-conformance: Issue written reports

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Daily logs

Steel temperature Air temperature % Relative Humidity Dew point Object no. and name Exact specification Pre-treatment, specified and actually conducted.

Film thickness (to be

measured also at spot repair) Area, m Product name, place of production and batch no. Name of relevant persons What was discussed Non conformance report (remember signatures) Other comments

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An inspector needs to know

All paints that will be used All relevant inspection
methods and inspection tools Relevant standards Relevant TDS and MSDS Methods involved in cleaning, pre-treatment and paint application The equipment used for pre-treatment and application: Benefits and limitations

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What needs to be inspected ?

If relevant, the following stages of the production need to be inspected

Shop-priming of the steel The steel work

(Pre-blasting preparation) Cleaning and surface preparation prior to paint application Application of paint The applied paint film and its curing/drying conditions.
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Inspection tools

Cd-4932-80

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Inspection tools. Mirror and flash light

Visual inspection Important tools for inspecting areas difficult to access For inspection in confined spaces: Use Ex approved equipment

Cd-4932-83

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Using Inspection tools. Mirror and flash light

Visual inspection Important tools to be able

to inspect areas difficult to access

Cd-4932-84

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Inspection of steel work (Pre-blasting preparation)

The following items need to be inspected during construction

Rounding of sharp edges. Smoothing of rough welding seams. Removal / grinding of weld spatter
and beads. Cracks and pittings. Surface faults like laminates etc. ISO 12944 - 3 , or ISO 8501 - 3
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Pre-blasting preparation

Rounding of edges Removing of weld spatters etc.
0589-6

0589-5 C3

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Inspection of cleaning and surface preparation prior to application

If relevant, the following conditions must be inspected / verified

Cleanliness (salt, oil, grease and dust/dirt) Evaluation of present condition (rust grade) Surface preparation (e.g. blast cleaning) Cleanliness of prepared surface

(salts, oil, grease, dust and dirt) Climatic conditions (temperature, relative humidity etc.)

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Relevant standards for assessing surfaces prior to paint application

Standard
ISO 8501 ISO 8502 ISO 8503

Area
Visual assessments of surface cleanliness. Tests for the assessment of surface cleanliness. Surface roughness characteristics of blast-cleaned steel substrates.

ISO 8504

Surface preparation methods.

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ISO 8501 - 1

Surface preparation

Visual assessment of surface cleanliness after blast cleaning, hand or power tool cleaning or flame cleaning Rust grades and preparation grades of uncoated steel

Photographic examples of steel when blast cleaned with different abrasives

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Surface preparation

Standard for deciding rust grades

ISO 8501 - 1 Rust grade A, B, C and D

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ISO 8501-1 Evaluation of rust grades

Rust grade A Rust grade B

Cd-0631-59

Cd-0631-58

Rust grade C Cd-0631-57

Rust grade D

Cd-0631-56

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ISO 8501 - 1

Standard for deciding preparation grades

Sa: St.: Blast cleaning (grades 1, 2, 2 and 3) Hand and power tool cleaning (grades 2 and 3) Flame cleaning (one grade)

Fl:

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ISO 8501 - 2

Surface preparation

As for ISO 8501-1, but: For steel where previous coating has been removed locally, not completely.

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ISO 8501 - 2
Standard for deciding preparation grades

PSa :

Localised blast cleaning (grades 2, 2 and 3)

PSt

Localised hand and power tool cleaning (grades 2 and 3) Localised machine abrading (one grade)

PMa :
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ISO 8502
Assessment of surface cleanliness (1 of 2)
Part 1 Field test for soluble iron corrosion products Part 2 Laboratory determination of chloride on cleaned surfaces. Part 3 Assessment of dust on steel surfaces prepared for painting (pressure- sensitive tape method) Part 4 Guidance on the estimation of the probability of condensation prior to paint application. Part 5 Measurement of chloride on steel surfaces prepared for painting. Ion detector tube method.
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ISO 8502
Assessment of surface cleanliness
Part 6 Extraction of soluble contaminants for analysis. The Bresle method. Part 9 Conductometric measurements of soluble salts Part 7, 8 and 10 are not prepared

(2 of 2)

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ISO 8502-1. Annex. 3 Water soluble salts on blast cleaned steel

Filter paper impregnated with Potassium Hexacyanoferrate

Blast cleaned steel

Blue spots

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ISO 8502-3 Assessment of dust

Steel Surfaces Prepared for Painting.
Tape Blast cleaned steel

Approved Not approved

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ISO 8502 - 3 Assessment of dust

Assessment of dust on steel surface prepared for painting
1. Quantity ratings 1, 2, 3, 4 and 5 corresponding to pictorial references 2. Dust size classes 0, 1, 2, 3, 4 and 5

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ISO 8502 - 3 Assessment of dust

Assessment of dust on steel surface prepared for painting

1. Quantity ratings 1, 2, 3, 4 and 5 corresponding to pictorial references 2. Dust size classes: 0, 1, 2, 3, 4 and 5
Inspection / Dust_control1

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ISO 8502-4 Estimating probability of condensation

Guidance on estimating probability of condensation prior to paint application
Psychometer Thermometer

Wet cotton
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ISO 8502 - 4 Humidity

Guidance on the estimation of the probability of condensation prior to paint application
1. 2. 3. 4. Air temperature % Relative humidity Steel temperature Dew point

Steel temperature min. 3 oC above the dew point

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ISO 8502-4 Measuring the relative humidity

Photo: Sling psychrometer
for measuring: - Dry temperature - Wet temperature Measure the temperature in the vicinity. Calculate the relative humidity Use together with dew point calculator

Cd-4932-88

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Contact thermometer

Electronic instrument for measuring the steel temperature Other types of thermometres are also available. E.g. magnetic thermometers

Cd-4932-87

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ISO 8502-4 Dew point calculator

For calculation of dew point To be used together with
surface temperature thermometer and sling psychrometer. Use this frequently during pretreatment, application and drying of the paint. Recommendation: Every 6 hours and when weather conditions are changing

Cd-4932-89

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Atmospheric conditions. Requirement during blasting and painting

Surface temperature of the

structure must be minimum

3 C above the dew point

of the surrounding atmosphere

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ISO 8502 - 4

Estimating probability of condensation

Cold liquid inside hull and warm air outside causes condensation See how frames inside keeps the cold longer

B-24/2-4 4847-693

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Relative humidity, RH
% R.H.:
% water vapour in the air as percentage of the total amount water vapour the air can contain at the same temperature.

Example
Air at 20 oC can contain 17.31 g. water/m3, but contains 15 g/m3. What is the R.H. ?

R.H. =
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15 x 100 17.31

= 86.65 %

Ambient temperature and steel temperature

Is the temperatures important ? YES !

Ambient temperature will influence: shelf life pot life viscosity/sprayability steel temperature Steel temperature will affect: speed of cure degree of cure recoating interval service life of the coating
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Determination of water soluble salts

The most frequently used methods are:

Conductivity Titration Colour-reactions

Other Methods: SCM 400 Salt Contamination Meter

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ISO 8502 - 6

The Bresle method.

A method for extraction of soluble contaminants on steel substrates for analysis: The Bresle method This is a quantitative test

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ISO 8502-6 Salt test equipment - Bresle test

ISO 8502 - 9 (Conductivity) Equipment for measuring content of water soluble salt on substrate Bresle method

Cd-4932-96

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ISO 8502 - 9 Conductometric measurement of soluble salts.

Field method for measuring soluble salts by conductivity ( S) of solutions containing water soluble salts

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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

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Calculation of salt level on the substrate

Formula: (L2 - L1) x 6 = mg salt per m2
L2 = S after cleaning L1 = S before cleaning Water sample, ml.: 10 Constant in formula: 4 15 6 20 8 50 20

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Instruments for measuring surface roughness

Stylus instruments Elcometer Mod. 123 Testex Press-O-film Microscope Comparator Rugotest No. 3 ISO 8503 etc.

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ISO 8503 Surface roughness

Example of a reference comparator Surface profile comparator comprising four segments. Grit (G) Shot (S) Check if the profile is according to specification and the paint manufacturers recommendation

Cd-4932-86

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ISO 8503 - 1

Limits of profile grades

a) Comparators for steel. Blast-cleaned with grit abrasives
Fine (G) Medium (G) Coarse (G) Profiles equal to segment 1 and up to, but excluding segment 2 Profiles equal to segment 2 and up to, but excluding segment 3 Profiles equal to segment 3 and up to, but excluding segment 4

b) Comparators for steel. Blast-cleaned with shot abrasives

Fine (S) Profiles equal to segment 1 and up to, but excluding segment 2 Profiles equal to segment 2 and up to, but excluding segment 3 Profiles equal to segment 3 and up to, but excluding segment 4

Medium (S)
Coarse (S)
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Contamination of abrasives
The abrasives can be contaminated with

Water Oil and grease Chlorides Sulphates

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How to check the abrasives

According to ASTM D 4940

Mix 300 ml of abrasive and 300 ml water Stir for 1 min. let stand for 8 min., stir again for 1 min.
Conductivity (AB-1) Fill the liquid for test and measure the conductivity. Max 25 mS/m
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Oil content (AB-1) No presence of oil, either on top or as an emulsion after 30 min.

Inspection during application

The following must be verified, inspected or tested:

Record name of coating and batch no. Ensure proper mixing of 2-pack paints Ensure use of the correct thinner Measuring the wet film thickness (WFT) Number of coats as given in the specification Cleanliness between coats (salts, dust, oil etc.) Drying time / recoating intervals Control of equipment: Pressure, nozzle etc. Climatic conditions (Ventilation, Air and steel
temperature and the relative humidity)
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Information to be found from the technical data sheet, TDS

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Product description Generic type etc. Recommended use Where to use the product Technical information Solids by volume, WFT, DFT Application data Methods, mixing, potlife Surface preparation Different methods given

Conditions during application Drying and overcoating time at different temperatures Typical recommended system Storage Handling Packing control Health and safety Details in MSDS

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

Microns
250 225 200 175 150 125 100 75 50 25

Wet paint

Steel

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Inspection after application

After application the following must be checked

Climatic conditions (Ventilation,

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

ISO 2808 - 97

Determination of film thickness

Method No. 10 - On blast cleaned steel substrates

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

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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

Inspection \ Dryfilmthickness1

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ASTM D 4752-87

Curing test of Zinc - ethylsilicate with MEK.

Glove

MEK

Rag

Rubbing 50 x

No Zinc on the Rag: Cured Approved

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A lot of Zinc on Rag: Not cured Further curing / Reblasting

ASTM D 4752-87

Curing test of Zinc - ethylsilicate with MEK.

Glove

MEK

Rag
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Inspection / Zincsilicate_curing1

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: 0 - 60 microns: 60 - 120 microns: 121 - 250 microns:
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1 mm spacing, hard substrates 2 mm spacing, soft substrates 3 mm spacing, hard/soft substrates 3 mm spacing, hard/soft substrates

ISO 2409 Cross 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

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ISO 2409 Classification of Cross-cut test

Classification
0 1 2 3 4 5
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Description

Appearance of surface Six parallel cuts

Completely smooth: none of the squares detached Small flakes at the Intersections. Area affected 5 %
Flaked along the edges and/or at the Intersections. Area affected: 5-15% Flaked along the edges, wholly in large ribbons, and/or partly or wholly on different parts of the squares. Area affected: 15-35% Flaked along the edges in large ribbons and/or some squares have detached partly or wholly. Area affected: 35-65% Any degree of flaking that cannot even be classified by 4.

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ISO 4624

Pull-off test for adhesion

Instruments: Elcometer Adhesion Tester Saeberg Adhesion Tester (pneumatic) Hate Adhesion Tester (hydraulic) PAT
Failure:
Adhesion failure: Between coats or between or substrate and 1st coat Cohesion failure: Inside a coat
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ISO 4624

Pull-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:

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Adhesion failure - fracture between coats or substrate and 1. coat Cohesion failure - fracture within a coat

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ISO 4624 Pull-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

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ISO 4624 Pull-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

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ISO 4624 Area after pull-off testing

Pull off adhesion test The adhesive failure fracture between coats - or between coating and substrate must be evaluated Note adhesion failure, % The cohesive failure fracture within the coatingmust be evaluated. Note cohesion failure, % Also: Note glue failure, %

Cd-4932-103

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ISO 4624 Pull-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 failure

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Inspection / Adhesion_pulloff1

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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.

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ASTM G-62-85, method A 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
Inspection / Pore_detection1

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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.

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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

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ISO 12944

General standard for corrosion protection:

Paints and varnishes - Corrosion protection of steel structures by protective paints systems.
Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 General introduction. Classification of environments. Design considerations. Types of surface and surface preparation. Protective paint systems. Laboratory performance test methods. Execution and supervision of paint work. Development of specifications for new work and maintenance.

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