CSWIP-BGAS

Grade-II
Painting Inspector Course
ONLINE PREPARATORY CLASS
SEPTEMBER 2020
 CHAPTER 2
SURFACE PREPARATION & STANDARDS

Surface preparation involves:

1.Removing these contaminants from substrate
2.Increasing the area available for adhesion by roughening up the
substrate
Preparation inspection involves, thus:
1.Degree of Cleanliness
2. Degree of Roughness (Surface profile)
 CHAPTER 2
SURFACE PREPARATION & STANDARDS

METHODS OF SURFACE PREPARATION

1.Dry Abrasive Blast Cleaning
2.Water Blasting
3.Hand & Power tool cleaning
4.Pickling
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SURFACE PREPARATION & STANDARDS

ADHESION
Adhesion: The force required to separate two surfaces in touch
Adhesion between surfaces occurs by two principles:
1. Molecular Interference: Adhesion occurs by physical locking of
profiles. In painting, paint wets the surface and locks into profile
2. Molecular Attraction: Adhesion occurs by chemical bonding of
two surfaces. In painting, paint wets the surface and forms bond
with the surface.
 CHAPTER 2
SURFACE PREPARATION & STANDARDS

PROFILE
Profile: It’s a physical dimension measured from top of the peaks to
bottoms of the troughs.
Also called as surface profile, anchor pattern, key, amplitude & peak
to trough height. As per BS profile shall be 30-75µm
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SURFACE PREPARATION & STANDARDS
PROFILE
 CHAPTER 2
SURFACE PREPARATION & STANDARDS
PROFILE
 CHAPTER 2
SURFACE PREPARATION & STANDARDS

PROFILE
-Blasting is a common practice to attain surface profile
-Blasting processes uses fast moving abrasives to struck a surface
thereby attaining a degree of roughness and cleaning
-Commonly used abrasives are metallic grit and shots
- Profile by grit blasting
- Created stress raisers
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SURFACE PREPARATION & STANDARDS

PROFILE
-Profile by shot blasting
-Will cause work hardening of surface
- In order to avoid the formation of stress raisers and work hardened
substrate a mixture of grit & shot is use(70 to 80% shot & 20 to
30%grit) . Giving a more neutral profile
 CHAPTER 2
SURFACE PREPARATION & STANDARDS
PROFILE
-Excessive non-uniform blasting can cause larger & uneven profile
size.
- Will give rise to imperfections like rogue peak, hackle & lamination
- Rogue peaks can cause spot rusting (rust spotting)
- Moisture will cause flash rusting
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SURFACE PREPARATION & STANDARDS

PROFILE
-Hackle height ≤ 13 mm. easily removed
-Lamination(sliver) has crack like appearance, lip rolls back.
-Engineer shall be informed. Shall be verified by ultrasonic testing
-May require grinding & reblast
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SURFACE PREPARATION & STANDARDS

PROFILE MEASUREMENT
-Its inspector duty to ensure specified profile requirement is met
- Can be measure by:
1. Surface profile needle gauge
2. Dial micrometer with replica tape
3. Surface Comparators
 CHAPTER 2
SURFACE PREPARATION & STANDARDS

PROFILE MEASUREMENT
SURFACE PROFILE NEEDLE GAUGE
-Uses a spring loaded needle to locate a peak or trough
-Shall be calibrated to zero on a glass piece
-Not suited for curved surfaces
-Full dial revolution is 200 µm
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SURFACE PREPARATION & STANDARDS

PROFILE MEASUREMENT
DIAL MICROMETER WITH REPLICA TAPE
-Also called as corn plaster method
- Uses a replica tape (testex tape). Provided in two grades
- Coarse grade: measures profiles 20-50µm
- Extra coarse grade: measures profiles 37-115µm
- Replica tape base is called mylar plastics. Thickness 50µm
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SURFACE PREPARATION & STANDARDS

PROFILE MEASUREMENT
SURFACE COMPARATORS
- Uses the methods like direct visual, using a magnifying glass or tactile
method to compare the profile of the blasted suraface with a standard
comparator
- Comparators in BS standard are approx: 8sq.cm size with a 2 cm dia
hole at center and have 4 segments
- Segment one is the smoothest and roughness increases progressively
- Comparators are not for assessing cleanliness
 CHAPTER 2
SURFACE PREPARATION & STANDARDS

PROFILE MEASUREMENT
USING SURFACE COMPARATORS
- While using comparators the newly blasted surface should not be
touched. In tactile use a nail tip or clean wooden stylus
- The grading used is:
- Fine: Profiles equal to segment one & upto but excluding segment two
- Medium: Profiles equal to segment two & upto but excluding segment
three
- Coarse: Profiles equal to segment three & upto but excluding segment
four
 CHAPTER 2
SURFACE PREPARATION & STANDARDS

PROFILE MEASUREMENT
USING SURFACE COMPARATORS
- Any profile below first segment is referred as finer than fine
- Any profile above fourth segment is referred as coarser than coarse
- This is a qualitative method
 CHAPTER 2
SURFACE PREPARATION & STANDARDS

PREPARATION OF SURFACES
RUST GRADES
-Rust Grade A: Steel surface largely covered with adherent mill scale
with little, if any, rust
-Rust Grade B: Steel surface which has begun to rust, and from
which the mill scale has begun to flake
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SURFACE PREPARATION & STANDARDS

PREPARATION OF SURFACES
RUST GRADES

-Rust Grade C: Steel surface on which the mill-scale has rusted away,
or from which it can be scraped, but with slight pitting visible
under normal vision.
-Rust Grade D: Steel surface on which the mill-scale has rusted away,
and on which general pitting is visible under normal vision
 CHAPTER 2
SURFACE PREPARATION & STANDARDS

PREPARATION OF SURFACES
BLAST GRADES
- SA 1 (Light Blast Cleaning)
When viewed without magnification, the surface shall be free from
visible oil grease and dirt, and from poorly adhering mill scale, rust,
paint coatings and foreign matter.
- SA 2 (Thorough Blast Cleaning)
When viewed without magnification, the surface shall be free from
visible oil grease and dirt, and most of the mill scale, rust, paint
coatings and foreign matter. Any residual contamination shall be
firmly adhering.
 CHAPTER 2
SURFACE PREPARATION & STANDARDS

PREPARATION OF SURFACES
BLAST GRADES
- SA 2 1/2 (Very Thorough Blast Cleaning)
When viewed without magnification, the surface shall be free from
visible oil grease and dirt, and from mill scale, rust, paint coatings and
foreign matter. Any remaining traces of contamination shall show only
as slight stains in the form of spots or stripes.
- SA 3 (Blast Cleaning to Visually clean steel)
When viewed without magnification the surface shall be free from
visible oil grease and dirt, and shall be free from mill scale, rust, paint
coatings and foreign matter. It shall have a uniform metallic colour.
 CHAPTER 2
SURFACE PREPARATION & STANDARDS

PREPARATION OF SURFACES
-Rust Grades give 4 photographs
- Blasting Grades give 14 Photographs
 CHAPTER2
SURFACE PREPARATION & STANDARDS

PREPARATION OF SURFACES
1. DRY ABRASIVE BLAST CLEANING
- Uses pressurized air + abrasives
- Air pressure is 100 psi
- Velocity of abrasives is 450 mph
- The Abrasives used are commonly Grit, Shot, Garnet etc
 CHAPTER2
SURFACE PREPARATION & STANDARDS
PREPARATION OF SURFACES
1. DRY ABRASIVE BLAST CLEANING
 CHAPTER2
SURFACE PREPARATION & STANDARDS
PREPARATION OF SURFACES
1. DRY ABRASIVE BLAST CLEANING
Abrasives:
- Sand:
San notd cotaining silica allowed to use as per COSHH due to safety
issues. Silica can cause respiratory diseases like Pneumonicosis &
Silicosis
SI 1657 allows release of only 1% of silica from abrasives
 CHAPTER2
SURFACE PREPARATION & STANDARDS
PREPARATION OF SURFACES
1. DRY ABRASIVE BLAST CLEANING
Abrasives:
- Copper slag
Also called iron silica. Pic identification ( contaminated copper slag)
Black glowing in color
- Garnet
Diamond like hardness. Reddish brown in color. Pic identification
 CHAPTER2
SURFACE PREPARATION & STANDARDS
PREPARATION OF SURFACES
1. DRY ABRASIVE BLAST CLEANING
Abrasives:
- METALLIC GRIT
Grey in color. Pic identification
Stress raisers
- METALLIC SHOTS
Work hardening. Pic identification
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SURFACE PREPARATION & STANDARDS
PREPARATION OF SURFACES

CONTAMIANTES COPPER
SLAG

COPPER SLAG
 CHAPTER2
SURFACE PREPARATION & STANDARDS
PREPARATION OF SURFACES

GARNET METALLIC GRIT

 CHAPTER2
SURFACE PREPARATION & STANDARDS
PREPARATION OF SURFACES

METALLIC SHOT
 CHAPTER2
SURFACE PREPARATION & STANDARDS

PREPARATION OF SURFACES
1.DRY ABRASIVE BLAST CLEANING
-Abrasive sizing:
G prefix for Grit (amorphous, points and cutting edges, irregular profile)
S prefix for shot (spherical, smoother profile )
Eg: G140 means
Grit of size 1.4 mm (1400 µm)
 CHAPTER2
SURFACE PREPARATION & STANDARDS

PREPARATION OF SURFACES
1. DRY ABRASIVE BLAST CLEANING
-EQUIPMENTS
2. Wheelabrators
3. Air Blasting system
 CHAPTER2
SURFACE PREPARATION & STANDARDS
PREPARATION OF SURFACES
WHEELABRATORS Abrasives in

substrate
Air in

Air wash
separator

Weir plate
 CHAPTER2
SURFACE PREPARATION & STANDARDS

PREPARATION OF SURFACES
WHEELABRATORS
-Other name is centrifugal blast pump
-An enclosed system. Operator safety
-Shot is used as abrasive
-Abrasive velocity-220 mph
-Fan speed-2600 rpm
-Reduced accessibility to tight areas like bolt pockets & gussets crates
shadow areas
 CHAPTER2
SURFACE PREPARATION & STANDARDS
PREPARATION OF SURFACES
AIR BLASTING SYSTEMS

Miser valve

compressor

Vapor & oil 7-8 m

traps
 CHAPTER2
SURFACE PREPARATION & STANDARDS

PREPARATION OF SURFACES
AIR BLASTING SYSTEMS
-compressor: pressurizes air to 100 psi
-Miser valve: Control the flow of abrasive(metering/reccova valve)
-Vapor & Oil traps: condenses and traps the oil and water vapor in the air
flow
-Hoses: air-abrasive mixture flows through the hose.
The hose is usually 7-8 m long and carbon impregnated to avoid
static shock produced inside the abrasive
 CHAPTER2
SURFACE PREPARATION & STANDARDS

PREPARATION OF SURFACES
AIR BLASTING SYSTEMS
-Nozzle: Fires the air-abrasive mixture on to the substrate
types: venturi nozzle (450 mph)and straight bore nozzle(200
mph)
Size: half inch nozzle-413 cfm, quarter inch nozzle-103 cfm
Stand of distance 450 mm
 CHAPTER2
SURFACE PREPARATION & STANDARDS

WATER BLASTING
- Spark Free
- Used to remove soluble salt( chlorides/sulphates , toxic substances like zinc
chromium, red lead, calcium plumbate etc
- Water blasting shall be followed by dry blasting
- Water blasting can lead to slurry formation and corrosion initiation(inhibitors added)
- Types: Water blasting upto 30000 psi without abrasives-
High pressure Water blasting with abrasives (20000 psi)
Low pressure water blasting with abrasives (100 psi)
Steam cleaning & Air blasting with water injection
 CHAPTER2
SURFACE PREPARATION & STANDARDS

HAND AND POWER TOOL CLEANING

- Less efficient than modern methods, specified only for maintenance programs
(localized repair)
- This method will not produce a profile, rather reduces existing profile leads to
burnishing
- Burnishing shall be treated by abrading with coarse emery
- Equipment can be any hand or power tool like needle guns, wire brushes,emery
cloth grinders etc
- Degree of cleanliness in hand power tool preparation is different from blasting
 CHAPTER2
SURFACE PREPARATION & STANDARDS

HAND AND POWER TOOL CLEANING

-St 2: Thorough hand and power tool cleaning
When viewed without magnification the surface shall be free from
visible oil, grease and dirt, and from poorly adhering mill scale, rust,
paint coating and foreign matter.
-St 3: Very thorough hand and power tool cleaning
As for St2 but the surface shall be treated much more thoroughly, to give
a metallic sheen arising from the metallic substrate.
 CHAPTER2
SURFACE PREPARATION & STANDARDS

HAND AND POWER TOOL CLEANING

- Bristles of wire brush shall be made from phosphor bronze or
beryllium bronze.
- If needle guns, (jasons hammers,) are used, they tend to leave a very
coarse profile which invariably needs to be reduced by abrading with
emery, or grinding.
- Rust Grade A cannot removed as it is very adherent
 CHAPTER2
SURFACE PREPARATION & STANDARDS

PICKLING
- Chemical removal of oxides
- Pickling fluid: dilute sulphuric acid
- Passivation: Phosphoric acid or chromic acid
- Pickling + passivation = Footners Duplex System
- Rust Grade A cannot removed as it is very adherent