Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Tom N. Bortak
September 2002
Acknowledgments
Page
C h ap te r III— S p e ci f icati o n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9. Con stru ction Sp ecification Institu te . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10. R e clam atio n C o atin g S p ecificatio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11. Coating Tabu lations an d Categor ies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12. M an u factu rer's Prod u ct Data an d Ap p lication She ets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
13. A d d e n d u m s a n d M o d ifica tio n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
vii
Page
C h ap te r V I I— En v i ro n m e n t al Co n d i ti o n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
32. E n v ir o n m e n t a l Fa ct o r s A f fe ct in g C o a t in g s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
C h ap te r X— M a i n te n an c e C o ati n g s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
43. De f in itio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
44. Pu rp ose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
45. R isk E v alu atio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
46. In sp ectio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
47. Toxic-Based Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
48. W ork er Pr otection from Toxic-Based Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
49. L e a d E x p o s u re L ev els b y Rem o v a l M e thod s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
50. C o r rectiv e A ctio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
51. M a t e r ia l Se le ct io n F act o r s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
52. Sch ed u lin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Bi b li o grap h y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
viii
Appendices
A Or gan izationa l Sou rces for Stan d ard s and References
B Read ing Sources
C Insp ection Ch ecklist
D Re fer en ce St a n d a r d s C ite d in G u id e
E Inspection Equ ipm ent
F Exam p le of Insp ection Daily Ch eck Sheet
G P r oc ed u r e fo r D et ect in g M ois tu r e a n d O il in C om p r es se d A ir (A STM D 4285)
H Pr o c e du re fo r D etectin g C h lo rid es and Solu ble Sa lts in A bra s ive s by C on d u c tivity M e thod
I Proced u res for Detecting Ch lorid e Ion in W ater
J P r o ce d u r e s fo r D e te r m i n in g Bla s t C le a n in g A i r P r es su r e
K D e t er m in a t io n o f E n v ir o n m e n t a l Fa ct o r s
L Proced u res for Detecting Ch lorid e Salts on P rep ared or Existing Su rfaces
M D eter m inin g Su rface P ro file of Blast-Clean ed Steel Usin g Rep lica Tap e
(N A C E RP 0 28 7 o r A S T M D 4 41 7, M e thod C )
N P r oc ed u r es for M ea su r in g W et Film Th ick n es s (A STM D 4414)
O W e t Film T h ick n es s F o rmu las an d Exa m p le C a lcu la tions
P P r oc ed u r es for D r y Film Th ick n es s G a u g es (SSPC -P A 2) an d Exa m p le
Q P r oc ed u r es for D isco n tin u ity (H olid a y ) Tes tin g (N A C E RP 0188)
R P r oc ed u r e fo r M ech a n ical (P u lloff) A d h es ion Te st in g (A STM D 4541; An n ex A 2)
S P r oc ed u r e fo r H y d r a u lic A d h es ion Te st in g (A STM D 4541; An n ex A 3)
T P r o ce d u r e fo r M e a s u r in g D r y F ilm T h ick n e s s b y D e s tr u c t iv e M e a n s W i th T o o k e G a u g e
(A STM D 4138)
U Pr o c e du res fo r SSP C-V IS 2 (2 00 0 R evis ion)
V P r o ce d u r e to D e t er m in e t h e P r es en c e o f So lu b l e Le a d a n d In s o lu b l e Le a d C h r o m a t e in C o a t in g s
W P r o ce d u r e to D e t er m in e t h e P r es en c e o f C h r o m a t e in C o a t in g s
X D et er m in a tio n of T ox ic M et a ls in H a r d en ed P a in t
Figures
Figure Page
1 C o m p o n e n t s o f co a t in g s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tables
T able Page
1 N u m ber of spot m easu rem ents based on total coated sur face area . . . . . . . . . . . . . . . . . . . 44
2 Typ ical and m axim u m lead exposu re levels in m icrogra m s per cubic meter
b y rem o v al m eth o d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3 G alv an izin g m eth o d s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 Fo r m u l a tio n -r e la t ed fa ilu r e s fo r o r g a n ic co a t in g s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5 Fo r m u l a tio n -r e la t ed fa ilu r e s fo r in o r g a n i c co a t in g s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6 Ad hesion-related failu res . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7 Su bstrate-related failu res . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8 Ap p lication-related failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9 Design-related failu res . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10 Failures related to exterior forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
ix
Chapter I
1
Guide to Protective Coatings: Inspection and Maintenance
(a) U niform Co rrosio n.— C o r r o s io n t h a t red ep osit of th e cath od ic con stitu en t. The
oc cu r s m or e o r les s u n ifor m ly an d r es u lts in elem en t rem ove d is alw ays an od ic to the
ru st and m etal loss over th e m etal sur face. m atrix. With d ealloying , there is n o m etal loss,
d im en sion ch an ges, cracks, or gr oov es;
(b) G alvanic C orro sion.— C o r r o s io n t h a t how ever, the affected area m ay be ev iden t
occu rs on the m ore active m etal of tw o because of a color cha ng e. The affected area
d issim ilar m etals that are electrically coup led b e co m e s lig h t e r , p o r o u s , a n d lo s e s it s o r ig in a l
to g eth er in th e sa m e electr o ly te (e.g ., w a te r ). m ech a n ical p r op er tie s (i.e., it b eco m es b r itt le
The m ore active m etal w ill corrod e. a nd los e s te ns ile s trength ). Tw o c omm on
form s of d ealloying ar e:
(c) Crevice Co rrosio n.— C rev ice co r ros ion
is a for m of lo ca lize d cor r os ion th a t o ccu r s in De zincifica tion.— The s e le ctive d is s olu t ion
c r e v ic es w h ere th e en v iro n m en t d iffers from of zinc from brass alloys. It is recognized by a
th e su r r ou n d in g bu lk en v ir on m e n t . Th e c olor c ha nge (e .g., from its origina l ye llow
d iffe r e n t e n v iro n m en ts res u lt in co rro s ion b r a s s co lo r t o a d i st in c tly r e d , co p p e r y
b e c a u se o f d ifferen ces in co n cen tratio n a p p ea r a n ce).
(e.g ., oxy g en , p H , an d fer r ic ion s). If th er e is
a n o x y g e n co n cen tratio n d ifferen ce, co rrosion De grap hitization.— Th e se le ct iv e
w ill pr oceed at crev ices w h ere th ere is less d issolu tion o f iron from som e cast iron s,
o xy g en th a n in th e en v ir on m e n t su r r ou n d in g u su ally gra y cast iron s. It norm ally p roceeds
the crev ice. Crev ices are form ed w he n tw o u n ifo r m ly in w a r d f r o m t h e s u r fa ce , le a v in g a
su rfa ces ar e in p ro xim ity to on e a n ot h er , su ch p orou s m a trix a lloy tha t is c omp os e d m os t ly of
a s w h e n t w o m etal s u rfaces are ag ain s t one ca r b o n . D e g r a p h i t iz a t io n c an b e r e co g n iz e d b y
a n o t h e r , w h en a g as k et is ag ain s t a s u rfa ce , or a c ha nge from a n origina l s ilve r-gra y c olor t o a
w h en an g le ir o n s a r e p la ce d b a ck to b a ck . d ar k g ra y . Th e a ffecte d m et al ca n b e e as ily cu t
Cre vice corro sion can occu r u nd er d ep osits or p ierced w ith a k nife.
(e .g ., b a r n acles , d irt, g reas e, an d s lim e) on a
m et al s u rfa ce. 5. Service Exposure.— Coatings are sp ecified
by ser vice exposu re or th e env ironm en t the
(d) Pittin g corrosio n.— A form of localized co a t in g w ill b e su b je ct to . T h e fo llo w in g a r e
co r r os ion w h er e t h e d ep th of p en et r a tio n is t h e b a sic s er v ice e xp o s u r e s d e fin e d b y
g r e a t er t h a n t h e d ia m e t er o f t h e a ffe ct e d a r e a . R e cla m a tion:
2
Introduction and Background
3
Chapter II
Materials
C o a t i n g fo rm u latio n is g en erally b as ed on g e n e r a l ca t e g o r ie s : (1) co lo r a n d (2) in e r t a n d
organ ic, inorgan ic, p olym er, an d co-p olym er r ein for ced . Figu r e 1 illu st r a te s t h e r ela tio n sh ip
ch em ist r y . It is n ot th e in te n tio n of t h is of these com p on en ts.
chap ter to d iscu ss coating chem istry b u t,
r a th er , to p r ov id e a b a sic k n ow led g e o f coa tin g W hen a coating is ap p lied , the solvent
com p onen ts and gen eric coating typ es ev a p or a te s d u r in g th e cu r in g p r oc es s, lea v in g
sp e c ifie d b y R eclam atio n . only the re s in a n d the p igm e nt c omp one n ts on
t h e s u b s t r a te . T h e r e m a i n in g r e s in a n d
6. Components of Coatings.— A ll or g a n ic p ig m en ts ar e s om et im es calle d th e “ co a tin g
co a tin g s co n sis t of t h r ee b a sic co m p o n en ts: s olid s ,” a nd the y form the p rote ctive film for
(1) so lv en t, (2) r es in , an d (3) p ig m en t. N ot all co rr osio n p r ote ctio n .
coating s contain solven t and p igm ented
co m p on en ts . Th er e a r e s olv en t-fr ee (100 (a) So lvent.— Or gan ic solven ts are form u lated
p ercent solids) coating s an d clear, p igm en t- in t o co a t in g s t o p e r f or m t h r e e e ss e n t ia l
free coating s, bu t n ot resin -free coat ings. fun ction s: (1) dissolve the r esin com p on en t;
(2) co n t r o l e v a p o r a t i o n fo r film fo r m a t io n ; a n d
C oa tin g ch em ical fo r m u lat or s co m m on ly (3) re d u c e the c oa ting v is cos ity for e a s e of
gro u p solvent, resin, and p igm en t com p on en ts a p p licat ion . Solv en ts w ill als o a ffect d r y film
in t o t w o g e n e r a l ca t eg o r ie s. T h e fir s t ca t eg o r y a d h es ion an d d u r a b ility coa tin g p r op er tie s. In
co m b in es t h e so lv en t a n d th e r esin to g eth er . g e n e r a l, r e sin s t h a t a r e le ss so lu b l e w i ll r e q u i re
Th e s olv en t p or tio n is ca lled th e “ v ola tile either m ore solven ts or stron ger solven ts to
veh icle,” an d the r esin p ortion is called th e d issolve th e resin s.
“n on volatile veh icle.” The com bination of the
so lv en t a n d th e r es in , w h er e t h e r es in is T h e te r m s “ s o lv e n t s ” a n d “ t h in n e r s ” a r e
d is so lv e d in t h e s o lv e n t , is ca lle d t h e “ v e h i cle .” o ft e n u s e d i n t er ch a n g e a b ly , b u t t h e r e ar e
d ist in ctio n s w ith in an d b etw een th e tw o te r m s.
The secon d category is the p igm en t. Pigm en ts The term “solvent” can im p ly tw o d ifferen t
are ad d itives th at im p art sp ecific pr op erties to u sa g es : (1) th e s olv en t o r so lv en t b len d s in
the coating an d are su bd ivided into tw o the coating form u lation a t p red eterm ined
So lv en t Re sin C olor In e rt a n d
(Volatile) (No nv olatile) Pigm en ts Reinforced
Ve h icle P ig m e n t
C oa tin g
5
Guide to Protective Coatings: Inspection and Maintenance
6
Materials
7
Guide to Protective Coatings: Inspection and Maintenance
s u i ta b le fo r a lk a lin e (co n c re t e o r m a s on r y ) (g) Epoxy, Fusio n-Bo nde d.— Fus ion-
su r face s o r en v ir on m en ts . A lk y d s cu r e b y air bon d ed ep oxies (com m only called p ow d er
oxid ation of d ry ing o ils. coating s) are com p lete coating s in p ow d er
form . The re a re tw o ap p lication m eth od s,
(c) Bitumin ous.— Bit u m in o u s co a t in g s a r e flu idized -bed an d electrostatic. In the
h ea v y -bo d ied m at er ials a p p lied w ith a cu tb ack flu i d i z ed -b e d m e t h o d , t h e m e t a l it e m s a r e
solven t. They h ave go od m oistu re barr ier p r eh e ate d to a fu s io n te m p e r atu r e a n d
re sist an ce a n d fair to g oo d ch em ical r es ista n ce im m er se d in th e p ow d er -ep ox y so lu tio n . In
b u t a r e n o t r es is t an t t o so lv e n t s . C o m m e r cia l the electrostatic meth od , the ep oxy p ow d er
bitum inou s pr od u cts are sp ecified on a lim ited p a r t icle s a r e ch a r g e d w it h h i g h v o l ta g e , a n d
b a sis b y R e clam atio n fo r p ro tectio n o f t h e m e t a l it e m i s t h e n s p r a y e d . A ft e r s p r a y in g ,
alum inu m su rfaces in contact w ith the ite m is pla ce d in a n ove n to c ure a t a bo u t
cem en tit iou s m a te r ial o r st ee l an d cop p er cab le 350 to 650 d e gre e s Fa hre n he it (F). Fus ion-
w e ld co n n e c tio n s . Bit u m in o u s co a t in g s cu r e b o n d e d e p o x ie s a r e s p e c ifie d fo r b u r ia l a n d
b y so lv en t e va p o ra tio n . im m er sio n se r v ice e xp os u r es , bu t t h ey w ill
fa d e a n d c h a lk in d ir e ct su n lig h t a n d a r e
(d) Ep oxy, Am ine.— A m in e e p o x ie s a r e brittle. A n ew m aterial is fu sion-bon d ed
tw o-com p onen t coatings that are catalyzed nylon. This ma te ria l is s up e rior to the fu s io n-
(hard en ed ) by an am ine cur ing ag en t to bon d ed ep oxy an d w ill be incorp orated into
p r o d u ce a h a r d , t ig h t l y b o n d e d , ch e m ica l Re clam a tio n 's sp ecifica tio n . Po w d er coa tin g s
r esis ta n t (a lk a li, a cid , an d so lv en t) p r o d u ct, b u t cu r e b y fu sio n (h ea t).
t h ey a re m o is tu r e a n d t em p e r a tu r e se n sit iv e
d u r i n g a p p licatio n . Th ey are s p ecified for (h) Ino rgan ic Zinc Prim ers.— In or g a n ic
b u r i a l a n d im m e r sio n s e rv ice e xp o s u r e s, b u t z in c s a r e p r im e r s t h a t in c o rp o r a t e a h ig h
th ey w ill fa d e an d ch a lk in d ir ect su n lig h t. loa d ing (p ou nd s pe r ga llon) of m e ta llic z in c for
Am in e e p o x ies cu re b y ch em ical reactio n. p ig m e n t a t io n ( h e n c e, t h e t er m “ z in c -r ich ” ) a n d
a r e e ith er so lv en t o r w a te r b a se d . D ep en d in g
(e) Ep oxy, Polyam ide.— Polyam ide ep oxies on th e s olv en t a n d r es in s u se d , th e co a tin g
are tw o com p onen t coatings that are catalyzed m ay be a zinc-rich ep oxy o r u reth an e. Th ese
b y a p oly am id e cu rin g ag en t to p ro d u ce coating s are exclusively p rim ers because th ey
su p erior r esistance to w ater an d salt solution s, p rovid e galvan ic or cathod ic p rotection to steel
b u t t h e y d o n o t p r o v i d e t h e c h e m ica l s ub s tra te. Inorg a nic z inc s a re sp e cifie d for
resistance of the am ine ep oxy. Polyam ides atm osp h eric and im m ersion serv ice exp osu res,
h a v e a g r ea te r flexib ility th a n th e a m in e b u t t h ey can b e t op co a te d to ex te n d th eir
e p o x ie s . T h e y a r e sp e cifie d fo r b u r ia l a n d s e rvic e life . Su ita ble topc oa t m a te ria l s e le ct ion
im m er sio n se r v ice e xp os u r es , bu t t h ey w ill is requ ired to p rev en t ou t-gassing from the
fad e a n d ch a lk in d ir ect su n lig h t. P oly a m id e in or g a n ic zin c th a t p r od u ces sm a ll p in h ole s in
e p o x ie s cu re b y ch em ical reactio n . th e t op co a t. Re clam a tio n sp ecifie s in or g a n ic
zinc coatings only to fraying su rfaces or heated
(f) Epo xy, Coal Tar.— C o a l t a r ep o x ie s a r e tre ated m etalw or k (A STM A 325 or A STM
ge n era lly a n am ine o r p olya m id e ep oxy A 4 90). A p p lica t io n r e q u ir e s sp e cia l s k ills a n d
m od ified w ith coal tar pitch r esin to p rod u ce a kn ow ledge. Inor gan ic zincs cure by either
h i g h -b u ild film t h a t h a s g o o d c h e m ica l re a c tion to w a te r (s olve n t re du c ible ) or
resistance and excellent w ater resistance. They r ea ctio n to car b on d iox id e (w a te r r ed u cib le).
h a v e a t e n d e n c y to b e co m e b r it t le w it h a g e a n d
d ela m in a te b et w ee n coa ts or b en ea th r ep a ir (i) Organic Zinc Prim ers.— O rg an ic zin cs
p a t ch e s . T h e y a r e sp e cifie d fo r b u r ia l a n d a r e p r im er s t h a t in cor p or a te a h ig h loa d in g
im m er sio n se r v ice e xp os u r es , bu t t h ey w ill (p ou nd s pe r ga llon) of m e ta llic z inc for
fa d e a n d ch a l k in d ir e ct su n l ig h t . C o a l t a r p igm en tation w ith a w ide v ariety of solven ts
e p o x ie s cu re b y ch em ical reactio n . a n d r esin s. D ep e n d in g on th e so lv en t a n d
8
Materials
9
Chapter III
Specifications
Reclam ation constru ction jobs are ad vertised P a rt 1 : G e nera l.—Includ es cost,
t o co n t r a ct o r s t o p e r fo r m t h e r eq u i r e d w o r k , r efer en ce s, s u b m itta ls, q u a lity ass u r a n ce ,
a n d con tr a cto r se lect ion is m a d e b y a b id d elive ry , stora ge, ha n d lin g, an d restr ictions.
p r o c e ss. T h e m o s t co m m o n b id ty p es are low
p r ice , n eg o tia te d , fixe d co st , an d so le so u r ce . P a rt 2: P rod uct .—Includ es requ irem en ts
O n ce Re cla m a tio n acce p ts a co n tr a cto r ’s b id , a for m aterials to be u sed
contra ct exists betw een Reclam ation an d the
contractor. The contract is often called a P a rt 3 : Execut i o n.—Inclu d e s m od e of
sp ecification. The sp ecification can be d efined co n s t r u c t io n , te s t m e t h o d s , a cce p t a n c e cr it e r ia ,
a s a w r i tt e n , d etailed , tech n ical d es crip tion of and repair
w o rk to be p er fo rm e d , d e scr ib in g th e
m a te r ia ls, q u a n tities, a n d m o d e of 10. Reclamation Coating Specifications.—
co n str u ctio n . The Techn ical Service Cen ter (TSC) in D env er
m a in ta in s C SI g u id elin e co a tin g sp ecifica tion s.
Sp e cific a tio n s are d iv id ed in to m an y d ivis ions The g u ideline coating sp ecification s are th e
t o d e s cr ib e t h e v a r io u s jo b r e q u i r e m e n t s a n d b a s is fo r s p e c ific p r o je ct r e q u i r em e n t s a n d a r e
m a y in clu d e ge n er al jo b d e scr ip t io n , b a se d on h ist or ica l Re cla m a tion st r u ctu r es.
su bm ittals, p re-existin g con d ition s, Th e g u id elin e s p ecifica tio n s co n ta in
e n v i r o n m e n t a l r e q u i r e m e n t s , a n d t e ch n ica l instru ction al notes an d footnotes to aid the
a r ch ite ctu r a l, civil, e lect r ical, m ech a n ical, sp ecification w riter in p rep aring the
co a tin g , an d ca th o d ic p r o te ctio n d isc ip lin es. sp ecificat ion s to m ee t sp ecific p ro ject
E a ch d iv i sio n i s s o m e t im e s ca lle d a t e ch n ica l r eq u ir em en ts . Th e g u id elin e co a tin g
p a r ag ra p h o r se ctio n . sp ecifica tion s ar e av a ila b le on Recla m a tion ’s
in tr a n et w eb sit e: <h tt p :/ / in tr a .u sb r .g ov > .
9. Construction Specification Institute.— Reclam ation u ses the follow ing sp eciality
Re clam a tio n h a s ch a n g ed fro m a n a r r a tiv e sections for coating s and haz ard ou s based -
p a r a g r a p h fo rm at to th e C o n s tru ctio n p aints:
Sp e cific a tio n In s titu te (CSI) fo rm at fo r
sp ecifications. CSI form at style is m ore concise Sect io n 09902.—C oa tin g s fo r n ew m et a llic
an d u se s im p er at iv e la n g u ag e. Refe re n ce su b st r a te s t h a t in clu d e: st ee l, cas t o r d u ctile
st a n d a r d s a re s p ecified to d es crib e q u ality of iron; ga lva n iz e d , a lu m inu m ; bra s s ; bron z e ; or
m a t e r ia ls , w o r k m o d e , t e st m e t h o d s , a n d copp er
accep tance criteria tha t are a recognized
in d u st r y p r actice, th u s red u cin g th e n eed for Sect io n 09908.—M a inte na nc e coa tings f or
len g th y v er b iag e. Th e m os t co m m on re fer en ce p r e v io u s l y co a t e d m e t a llic s u b s t r a t es th a t
s ta n d a r d s u s ed in t h e co a t in g s in d u s t r y a r e inclu d e: steel, cast or d u ctile iron; galvan ized,
A ST M , N A C E , a n d SSP C . alum inu m ; brass; bron ze; or copp er
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Guide to Protective Coatings: Inspection and Maintenance
12
Specifications
• Su r f a ce p r e p a r a t io n m e t h o d s a r e • G e n e r i c ch e m ica l co a t in g n a m e
id en tifie d b y let te r or alp h a n u m er ic (acrylic, alkyd , ep oxy, p olyur ethan e)
la b e l in t h e t h ir d co lu m n a n d a r e
d e fin ed in th e ex ecu tio n p art fo r • Typ ical u ses, such as on br id ges,
su r face p r ep aratio n . p i p e s , o r w a t er t a n k s
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Guide to Protective Coatings: Inspection and Maintenance
• Su b st r a te ty p es th a t a r e co m p a tib le • D r y i n g , r e co a t , a n d cu r in g t i m e s a t
w ith th e co a tin g m a te r ia l (e .g ., va riou s tem p eratu re an d hu m idity
a lu m in u m , con cr et e, g a lv a n ize d , ste el, ran ges
cast iron , or existin g coated su rfaces)
• A p p l ica t io n m e t h o d : b r u s h , ro lle r ,
• Su r face p r ep a r a tio n m et h od , n or m a lly conv en tiona l airless sp ray , or airless
list ed as a m in im u m sp r a y . M a y in clu d e s p ecific
equ ipm en t at re com m en d ed p ressu res,
• Thinn er p rod u ct nam e an d am ou nt to h os e d iam et er siz es , sp r a y g u n , n oz z le
be ad d ed tip siz es , etc.
14
Chapter IV
Inspector's Role
The coating insp ector ensu res th at: (1) the 15. Daily Responsibilities.— Th e fo llow in g is
w or k is a cco m p lish ed in a t im ely m a n n er in a p artial list of d aily in sp ection resp on sibilities:
a c co r d a n c e w ith th e s p ecificatio n s ; (2 ) w ork
a ctiv itie s a r e d oc u m en te d ; an d (3) w or k is (a) Pre paratory.—
p erform ed safely. The coating insp ector at the
jobsite is eithe r th e contra cting officer’s or th e • En su r e s p ecifica tio n s co n ta in all
field en gineer’s rep resentative. a d d e n d u m s a n d m o d i fica tio n s
15
Guide to Protective Coatings: Inspection and Maintenance
(d) Precoating Applicatio n.— resp on sible rev iew ing office is listed in the
r eq u ir ed su b m itt a l n u m b er (RSN ) ta b le in
• E n s u r e a ll co a t in g m a t er ia ls a re Sec tion 01330 (Su b m itta ls) of th e C SI
ap p roved sp ecifications.
16
Inspector's R ole
• Referen ce stand ard s referred to in th e 19. Substrate Inspection.— The ins p e ctor
sp ecifica tio n s t h a t r ela te to th e fie ld s h o u l d i n sp e c te d t h e s u b s t r at e s u r fa ce b e fo r e
in s p ectio n su rface prep aration . Ferrou s su bstrates w ith
localized ru st or m ill scale are m ore p ron e to
• Re fer en ce s ta n d a r d s a r e d iscu ss ed in p r em a tu r e co a tin g failu r e. Ru st an d m ill sca le
m or e d et a il for th e p er tin en t a re a s s hou ld be ins p e cte d m ore thorou ghly f or
in sp ectio n m eth o d in oth er ch a p te r s. clea n lin es s a fte r su r face p r ep a r a tio n . If m ill
A p p e n d ix D lis ts r efe r e n ce st a n d a r d s s ca le is note d a nd a bra s ive bla s ting is not
cited in this docu m ent sp ecified , notify the field en gine er b ecau se
ab ra siv e b las tin g is r eq u ire d . For m ain te n an ce
18. Instruments, Gauges, and Tools.— Th e coating w ork w her e overcoating is sp ecified ,
insp ector shou ld a cqu ire the equ ipm en t, t h e ex is tin g c o at in g m a t er ia l s h o u l d b e
in st r u m en ts , an d in st r u ctio n a l m a n u a ls insp ected for loose coatings by scrap ing w ith a
n ece ss a r y to p er fo r m th e in sp ectio n w o r k . sh a r p en ed p u tt y k n ife. O v er co a tin g loo se ly
Sp a r e b a tt er ies sh ou ld b e a v a ilab le if e lect r on ic a d h er in g ex ist in g coa tin g w ill re su lt in
in st r u m e n ts are u s ed . T h e ty p es o f p rem atu re failure.
in st r u m en ts w ill be d iscu ss ed in th e fo llow in g
cha p ter s an d ar e listed in a p p en d ix E. Fo r ite m s co a te d in a s h op , th e co a tin g s s h ou ld
b e in s p e ct e d a n d id e n t ifie d fo r d a m a g e a n d
(a) Conflicts.— A t t im e s, t h e r e a r e faile d coa tin g ar ea s t h a t w ill re q u ir e r ep a ir
d isa gr ee m e n ts b etw e en th e co n tr acto r a n d th e e ithe r be fore or a fte r ins ta lla tion.
in s p e ct o r o v e r in s t r u m e n t r e a d i n g s s u c h a s
su r fa ce an ch o r p r o file s o r d r y film th ick n ess es. 20. Coating Inspection Checklist Sheet.—
Th er e m ay b e r ea so n ab le e xp lan at ion s for su ch R e cla m a tion s p e cific a tion c oa ting ta bu la tions
d is cr e p a n c ie s. T h e se d i scr e p a n c ie s s h o u l d b e (see cha p ter III, su bsection 11) id en tify th e
investigated to av oid futu re conflicts and to item s to be coated , coatin g m ater ials, the D FTs,
d evelop a w ork ing relationsh ip w ith the an d th e su rface p rep ara tion m eth od s;
c o n t r a ct o r . T h e fo llo w in g ar e s o m e how e ve r, the ins pe c tor ma y w is h to e xpa n d on
p ossibilities for instr u m en t d isagree m en ts: th e co a tin g ta b u lat ion s b y cr ea tin g a co a tin g
in sp ect ion ch eck list u n iqu e t o t h e job . Sin ce
• T h e t w o p a r t ie s a r e n o t u s i n g t h e s a m e sp ecifica tio n coa tin g ta b u lat ion s ca n id en tify
typ e of instru m en t sets: se v er a l ite m s t o b e co a te d w ith in a s in g le
ta bu la tion, a n ins pe c tion s he e t c a n p rovid e for
" O n e in s t r u m e n t m a y b e the in d ividu al coating op eration s an d for the
m a lfu n ctio n in g co m p l e te d i n s p e ct io n fo r a sin g l e it e m t o b e
co a t e d , s u c h a s a p i p e lin e i n t er io r o r a r a d i a l
" O n e in s tru m en t m ay b e o u t of g a t e . T h e ch e c k lis t ca n b e c o m e a p e r m e a n t
calib ratio n r e co r d o f th e jo b . A c h e ck lis t e xa m p l e ap p e a r s
in ap p en d ix F.
• T h e t w o p a r t ie s a r e u s in g t h e s a m e
typ e of instr u m en ts bu t: 21. Precoating Conference.— R e cla m a tion
coating specifications d o no t requ ire a
" They ar e u sing d ifferen t p r eco a tin g co n fer en ce w ith th e co n tr a ctor .
p roced u res H ow ever , a m eeting w ith the con tractor to
d is cu s s co a t in g - r ela t ed is su e s w o u l d b e
" T h e y a r e ta k in g r e a d in g s a t he lpful. A p re c oa ting c onfe re nc e w ill a llow
d iffe re n t lo ca tio n s the con tractor to kn ow w ha t is exp ected an d to
ou tlin e t h e w or k p r og r a m . Th is m ee tin g
" O n e in s tru m en t m ay b e o u t of sh ou ld es ta b lish a w or k in g r ela tio n sh ip
calib ratio n be tw een th e con tra ctor a n d Reclam ation . The
fo llo w in g a r e p o s sib le it e m s f or d is cu s sio n a t
t h e m e e t in g :
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Guide to Protective Coatings: Inspection and Maintenance
18
Chapter V
19
Guide to Protective Coatings: Inspection and Maintenance
m a n u fact u r er an d m a te r ial t y p e. Sh elf life is the sh elf life sho u ld b e rem ove d from the
no ted on the m an u factu rer’s p rod u ct da ta job sit e. C on se q u en ces of e xce ed in g th e s h elf
sh e e t . T h e in s p ecto r s h o u ld ch eck th e d ate of life includ e gelling, od or, cha ng es in viscosity,
m an u factu re or th e exp iration d ate to fo r m a t io n o f lu m p s , p ig m e n t s et t le m e n t , a n d
d eterm ine that the exp iration d ate has n ot been c olor or liqu id s e pa ra tion.
reached . Coating m aterials that h ave exceeded
20
Chapter VI
Surface Preparation
The serv ice life of a coating d ep en d s on th e Dirt and dust.— D ir t a n d d u st o n th e
d e g r e e o f s u r f a ce p r e p a r a t io n a c h ie v e d a s su rface prev en t the a p p lication of a sm ooth
m u ch a s it d e p e n d s o n m a t e r ia l s e le ct io n a n d u n ifo rm f ilm a n d w e ak en th e ad h e sio n of th e
a p p licat ion . A ll coa tin g sy st em s w ill coating to the su bstrate.
even tu ally fail; how ever, pr em atu re failures
ar e o ften th e r es u lt o f in ad eq u at e s u rfa ce Soluble sa lts.— Solu ble s a lts de p os ite d on a
p r e p a r a t i on . Ev e n s u r fa ce p r e p a r a t io n s t h a t su rface can rem ain on th e sur face, even after
a ch i ev e a n a cce p t a b le m a r g i n o f cle a n lin e s s b u t ab rasiv e clean ing. Solu ble salts w ill in crease
leave contam inan ts on th e su rface w ill tend to m o istu r e p e rm e a tio n th r ou g h th e co atin g
lessen th e coating serv ice life. Thu s, (osm otic blistering) an d can accelerate th e
cle a n l in e s s o f t h e s u b s t r a te is a n e s se n t ia l a n d co r r os ion r a te u n d er th e co a tin g film
integral com p onen t of a coating system . (u n d erfilm corr osion or u n d ercu tting ). Th e
m o s t co m m o n so lu b le sa lts e n co u n te re d in th e
25. Surface Contaminants .— Su rfa ce co a t in g i n d u s t r y a r e ch l o r id e s , s u l fa t e s, a n d
c o n t a m in a t io n is o n e o f th e m o s t co m m on m et a llic sa lts . Th e ch lor id e io n is th e m os t
cau ses of coating failur es. To achieve th e aggr essive.
m a xim u m se r v ice life of a coa tin g sy st em , it is
ess en tia l to r em ov e su r fa ce co n ta m in a n ts . Water.— W a te r w i ll p r ev en t a d h e sio n an d
m a y e it h e r p r o d u c e fla s h r u s t in g b e fo r e
(a) Types o f Surface C ontam inan ts.— Th e coating ap p lication or it m ay accelerate
fo llo w in g a r e th e m o s t co m m o n ty p es o f u n d er film co r r osio n after co a tin g ap p lica tion .
su r f a ce co ntam in an ts an d th e co n s eq u en c es of M ois tu r e in th e liq u id or fro z en st a te w ill
not rem oving th em : p rev en t ad he sion of the coating to th e
s ub s tra te a nd c a n d is rup t cu ring re a c tions of
Rust.— Ru st is th e co rr os ion b y p ro d u ct coating s. M oistu re con tam ination can cau se
(fe r r o u s o x id e) o f s teel an d m ay b e lo o se or several typ es of failu re.
m a y ad h er e r ela tiv ely tig h tly to th e su b st r a te .
Rust is porou s and m ay inclu d e m oistu re, Chalk.— Ch alk is the r esidu e left after the
o x y g e n , a n d s o lu b le s a lt s . R u s t w i ll e x p a n d u p d ete r io r a tion of th e co a tin g ’s o r g a n ic b in d er .
t o e ig h t t im e s th e v o l u m e o f t h e b a s e m e t a l Ch alk resu lts from exp osu re of the coating to
consu m ed and fu rther corrod e the steel d ir ect su n lig h t o r ar tificia l U V lig h t. A ll
su bstrate, thu s d islodg ing an y coating ap p lied co a t in g s ch a l k t o so m e d e g r e e , b u t e p o x ie s a r e
ove r it. m ore p ron e to cha lk. Ov ercoating chalked
s u r f a ce s w i ll r e s u l t in p o o r a d h e s io n a n d m a y
Mill scale.— M ill sca le is a h ea v y ox id e re s ult in d e la m ina tion (s e pa ra tion of one
la y e r fo r m e d d u r in g h o t fa b r ica t io n o r h e a t co a t in g l ay e r fr o m a n o t h e r co a t in g l ay e r )
tr ea tm en t o f m et a ls a n d is a b lu ish colo r . M ill failure.
scale will even tu ally brea k loose from the steel
su b st r a te , ta k in g th e co a tin g w ith it. Ste el is De teriorated co atings.— Old , loose,
a n od ic to m ill sca le (s te el h a s a low er ele ctr ical- d e t er io r a t e d c o a tin g s t h a t a r e o v e r co a t e d m a y
ch em ical p ot en tia l d iffer en ce t h a n m ill sca le); p e el, d e la m in a te , o r lift fr om t h e su b str ate an d
ther efore, steel w ill corro d e (sacrifice itself) to take the n ew coating w ith th em .
p rotect the m ill scale.
(b) C om pressed Air C ontam inan ts.— A ir
Gre ase a nd o il.—Grea se an d oil p rev en t a co m p r e s so r s co n t a m in a t e d w it h m o is t u r e a n d
coating from ad her ing to the su bstrate. oil can resu lt in ad h esion -related failu res. Th e
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Guide to Protective Coatings: Inspection and Maintenance
22
Surface Preparation
26. Presurface Treatment.— P r io r t o a ct u a l (a) Nonme tallic Ab rasive s.— There are th ree
su rfa ce p re p ar at ion s, all st ee l su rfa ce b a sic ty p es of n on m eta llic ab r a siv es:
im p erfection s are to be corr ected . This is a (1) n a tu r a lly occu r r in g ; (2) b y p r od u ct s; an d
Re clam a tio n sp ecifica tio n r eq u ir em en t. W eld (3) m a nu fa c tu re d . The follow ing s e c tions
sp atter , slag, bu rrs, p oro sity, sh arp ed ges, p its, p r o v i d e a b r ie f d e scr ip t i on o f t h e ty p i ca l u s a g e
lam in a tio n s (sliv er s), cr ev ices , or ob ject ion a b le a n d t h e d e g r e e of d u s t in g p r o d u ce d b y
irr eg u lar ities n ee d to b e r ep air ed . Su rfa ce n on m et a llic ab r a siv es d u r in g b las tin g
d ep ressions, such as p its or crevices, can be a op era tions.
co lle ct io n p o in t fo r e xce s siv e co a t in g m a t e r ia l
t h a t m a y n o t fu lly c u r e . P r o je ct io n s s u c h a s Na turally occu rring.—
w e ld s la g , s la g b u r r s , o r s h a r p e d g e s th a t m a y
st ick ou t t h r ou g h th e co a tin g can r es u lt in • Nonsilica or heavy mineral sands
p i n p o in t co r r o sio n . A l l t h e se ir r e g u l ar it ie s a r e (magnetite, olivene rutile,
t o b e r e p a ir e d b y w e ld in g , s cr a p p in g , straurolite).— Th es e s a n d s a r e t y p ically
gr ind ing, or o th er sp ecified m ean s. to u g h , d en se , r ou n d -sh a p ed m a te r ia ls.
Th ey ar e e ffect iv e fo r b las t cle a n in g
27. Abrasive Blast Material.— Th e a br a siv e new steel bu t are not recom m end ed
b las t m a te r ial is im p or ta n t b eca u se it for m aintenan ce coating w ork. Degree
d ete r m in es t h e su r fa ce p r o file p r o d u ce d . of d u s ting d u ring bla sting op e ra tions
Th er e ar e tw o g en er a l ca teg o r ie s of a b r a siv es: is m ed iu m .
m etallic and non m etallic. M etallic abrasives
a r e u s e d p r im a r ily t o b la s t cle a n s t ee l a n d • Flint, garnet, novaculite (siliceous
for g ed or cas t ir on w h er e a su r face p r ofile is rock ), and zircon.— These are d ense,
se ld o m cr itica l o n th e fin ish ed p r o d u ct. tou gh , an gu lar or cu bic abr asives tha t,
N o n m e t allic a b r a siv e s , d e p e n d in g o n t h e t y p e because of their high costs, are u sed
u se d , can p r od u ce t h e d es ir ed su r face p r ofile p r im a r ily in sp e cia l cle an in g
a n d clea n lin es s o n h a r d , d en se fer r ou s m et a ls a p p licat ion s. Th e d eg r ee of d u st in g
o r o n so f t m etals (alu m in u m , b ras s , b ro n z e , or d u r in g b las tin g op er a tio n s is m ed iu m
cop p er) w ithou t d am aging or altering th e for flint a n d ga rn e t a nd low for
m et al s u rfa ce. n o v acu lite an d z ir co n .
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Guide to Protective Coatings: Inspection and Maintenance
24
Surface Preparation
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Guide to Protective Coatings: Inspection and Maintenance
26
Surface Preparation
27
Guide to Protective Coatings: Inspection and Maintenance
(b) SSPC-VIS 3: Visual Standard for Powe r- SP11: Pow e r rota ry fla p p e e n or
and Ha nd-Tool Cleaned S teel.— Th is g u id e n ee d le g u n (to p ro d u ce a su rfa ce
show s a series of p hotog rap hs of un p ainted p r ofile ).
an d p ainted carbon steel before an d after SP11/ R: Pow er tool using n onw oven
h a n d - a n d p o w e r -t o o l cle a n i n g . Be lo w is a n d isk s (to re sto re exis tin g su rfa ce
abb rev iated exp lanation of the p roced u res to p r ofile ).
follow befor e an d after clean ing th e stee l. Th e
p roced u res are follow ed by an exam p le. 4. Fr o m t a b le 1 in t h e v is u a l s ta n d a r d ,
s e le ct the s pe c ifie d s urfa ce pr e p a rat ion
1. Be fo r e h a n d - o r p o w e r -t o ol cle a n in g , stan d ard an d the initial cond ition to
m a tch th e ex is tin g s u rface co n d ition ob ta in th e co r r ect p h ot og r a p h ic
tha t m ost closely rep resen ts the d e sig n atio n .
a p p earan ce w ith th e “in itial co nd ition”
sh ow n in on e o f th e p h ot og r a p h ic 5. Evaluate th e finished han d or p ow er
stan d ard s. Initial cond ition s (or ru st tool su rface against the selected
g r a d es ) A , B, C , an d D are fo r p ho togr ap h in step 4 above to
u n c o a te d s u r f a ce s ; co n d it io n s E , F , a n d d e te rm i n e if th e su r fa ce m e ets th e
G a re for p rev iou sly p ainte d su rfaces. s pe c ifie d s urfa ce pr e p a ra tion
In i tial co n d itio n s are d efin ed in s e c tion req u irem en ts for clean lin ess.
4 .1 o f th e s tan d ard . V ario u s area s of
th e s u rfa ce t o b e clea n ed m ay m at ch Example: An existing coated rad ial gate
o n e o r m o re in itial co n d itio n r e q u i r e s s p o t r e p a i r s. T h e co a t in g h a s
p h otog rap h s. d et er ior a te d or p ee led off in sm a ll
lo ca liz e d a r e a s, a n d r u s t is ev id e n t b u t
2. From the sp ecification s, d eterm ine th e there is no visible pitting . The sp ecified
sp e cified s u rface p r ep aratio n su r face p r ep a r a tio n m et h od is SSPC -SP11,
st an d ard . T h e s u rface p r ep aration a n d th e co n tr acto r u s ed a n e ed le gu n .
28
Surface Preparation
29
Guide to Protective Coatings: Inspection and Maintenance
30
Surface Preparation
31
Chapter VII
Environmental Conditions
Cold w eath er, high h u m idity, w ater, fog, frost, (b) Su rface Sub strate Tem perature.—
m i st, r ain , ice , a n d sn o w a re so m e of th e R ecla m a t io n s p e c ifica t io n s r e q u i r e th a t
en viron m en tal factors d etrim en tal to the co a t in g s b e a p p lie d w h e n t e m p e r a tu r e s a r e
p e r f or m a n c e o f co a t in g s . C o a tin g s s h o u l d b e 50 d egrees F or h igher an d w ithin th e
a p p lie d u n d e r o p t im u m e n v i r o n m e n t a l m an u factu rer’s u p p er lim it or accord ing to
co n d itio n s, b u t t h e w ea th er can ab r u p tly t h e m a n u f a ct u r e r ’s in s t r u ct io n s . T h e m o r e
ch a n g e. Th e p r ev a ilin g en v ir on m en ta l ru le-o f- r est r ict iv e r eq u ir em en t w ill b e fo llo w ed .
th u m b is t h a t e v a p o r a tio n sh o u ld b e occu r r in g . In gener al, ind u stry p ractice requires
C o m m o n s e n se , t h e m a n u f a ct u r e r ’s su r face te m p er a tu r e b et w ee n ab ou t 40
instru ction s, an d ind u stry p ractices ap p ear to a n d 125 d eg r ees F.
be the m ost com m only follow ed gu idelines
r eg a r d in g en v ir on m en ta l con d itio n s d u r in g (c) Relative Hu mid ity.— R e cla m a tion d oe s not
co a tin g ap p lica tio n an d th e cu r in g p er io d . sp ecify lim its for r ela tiv e h u m id ity ; ra th er , it
F a ilu r e t o co n f o r m w it h e n v i r o n m e n t a l sp ecifies that th e coating be ap p lied w ithin th e
r e st r ic tio n s res u lts in a v ariety o f ap p lica tion m a n u fa ctu r er ’s r eco m m en d ed h u m id ity r a n g e.
failu res. G en er a l in d u st r y p r a ctice r eq u ir es a m a xim u m
relative hu m idity of abou t 80 to 85 p ercent,
32. Environmental Factors Affecting e xce p t fo r t h o se co a t in g s t h a t a r e le ss m o i st u r e
Coatings.— Th e fo llow in g ar e fiv e s e n s it iv e o r a r e m o i s tu r e cu r e d . H o w e v e r , a s
en v ir on m en ta l fact or s t h a t r eq u ir e m on ito r in g a gen eral ru le-of-thu m b, the closer to th e
d u r i n g co a t in g a p p l ica t io n a n d t h e cu r e op tim u m relative h u m idity, the m ore likely to
p e r io d . (Se e ap p en d ix K fo r tes t p ro ced u re s on a ch iev e th e d esig n ed se r v ice life .
th e fa cto r s b elo w .)
(d) D ew Poin t.— Th e d ew p oin t d et er m in es if
(a) Amb ient T em perature.— D u r in g th e m o is tu r e w ill fo r m o n t h e fe r r o u s su b s t r a te s b y
a p p lic a tio n o f co atin g s , Reclam atio n co n d en sa tion or if m oist u r e w ill e v a p or a te .
sp ecificat ion s r eq u ire th at th e a ir a n d su rfa ce M oisture w ill form on ferrou s su bstrate
t e m p e r a t u r e b e 50 d e g r e e s F o r h i g h e r a n d su rfaces w he n th e d ew p oint is higher tha n th e
w it h in t h e m a n u fa ct u r e r ’s u p p e r t e m p e r a tu r e s u r fa ce te m p e r a t u r e . C o n v e r s ely , m o is tu r e
lim it or acco r d in g to th e m a n u fa ctu r e’s w ill n ot for m w h en th e s u r face te m p er a tu r e is
in st r u ctio n s, w h ich ev er is th e m or e r es tr ictiv e h ighe r th an th e d ew p oint. Dew p oint is a
r e q u i r em e n t . E xce p t io n s a r e m a d e fo r co a t in g s fun ction of am bient tem p eratu re, sub strate
fo r m u la te d fo r co ld w ea th er ap p lica tio n s. tem p eratu re, an d relative h u m idity. All three
Am b i e n t (a ir) tem p eratu re is im p o rtan t for o f t h e se e n v ir o n m e n t a l co n d it io n s m u s t b e
su c ce ssfu l film fo rm atio n an d cu rin g . Som e kn ow n to d eterm ine th e d ew p oint.
ep ox y coa tin g s a p p lied b elo w 50 d eg r ee s F w ill
n ot cu r e, a n d cu r in g w ill n ot p r oc ee d ev en if Reclam ation sp ecification s requ ire that th e
tem p eratu res exceed 50 d egrees F at a later fer r ou s s u b st r a te te m p er a tu r e b e a m in im u m
tim e. of 5 d egrees F higher th an the d ew p oint w hen
co a t in g s a r e a p p lie d . Th e co a t in g i n d u s tr y
A g en er a l ru le-o f-th u m b in th e co a tin g im p ose s t h e sa m e d ew p oin t r est r ict io n .
ind u stry is to ap p ly coatings at am bient Reclam ation specifications requ ire su rfaces
tem p er at u re s b etw ee n 40 an d 95 d eg re es F, th a t a re n ot th o ro u g h ly d r y to be h ea te d o r th e
d ep en d in g on th e co a tin g m a te r ial. e n v i r o n m e n t co n t r o lle d b y d e h u m id ify in g a n d
heating equ ipm ent to d rive off m oistu re.
33
Guide to Protective Coatings: Inspection and Maintenance
M oisture cond en sation w ill begin w he n th e overcom es the sp raying op eration an d carries
su bstrate tem p eratu re is less than the d ew coating p articles aw ay from the intend ed
p o in t . To a llo w fo r p o s s ib le in s tru m en ta tion s u r fa ce . T h is p r o b le m is k n o w n a s a ir b o r n e
e r r o r o r v a riatio n , a m in im u m s afety m argin of ov er sp r a y . A ir b or n e o v er sp r a y m a y r es u lt in
5 d e g re es F su b str ate te m p e r atu r e a bo v e th e p r e m a t u r e d r y i n g o f t h e co a t in g b e fo r e
d e w p o i n t is r eg a r d e d a s a g e n e r a l in d u s t r y r e a ch i n g t h e in t e n d e d s u r f a ce , a lo w e r D F T a t
requ irem en t. th e sp ra y a p p lication p oin t, a h igh er D FT
d o w n w in d , o r sp r a y b ein g ca rr ie d to ad ja ce n t
(e) W ind.— R ecla m a t io n d o e s n o t sp e c ify a veh icles, hom es, or oth er su rfaces not intend ed
m a xim u m w in d v elo city r es tr ictio n in coa tin g to be coated. Com m on sen se shou ld be u sed
ap p lication s. W ind becom es a factor w he n it to av oid airbo rn e ov ersp ray p rob lem s.
34
Chapter VIII
35
Guide to Protective Coatings: Inspection and Maintenance
thr ee coats are of the sam e m aterial. Base coats 36. Application Method.— O n ce t h e s u rfa ce
a r e n o t n o r m a lly co n s id e r e d s u n l ig h t o r U V su b str ate h as b ee n p ro p er ly p r ep a r ed a n d
resistant. env ironm ental cond itions are w ithin sp ecified
to ler a n ces , th e a p p licat ion of t h e co a tin g
35. Mixing.— Befo r e a p p licat ion , th e co a tin g m aterial m ay p roceed. There are severa l
m a t er ia ls r eq u ir e m i xin g to m a k e th e p ain t equ ipm en t choices from tran sferring the
h o m o g e n e o u s a n d u n i fo r m . L iq u id s a n d co a tin g fr om th e co n ta in er to th e su b st r a te .
p igm ents of different d ensities m ay sep arate, A p p lica tio n eq u ip m e n t m a y b e d icta te d b y th e
se tt le, o r for m a s k in w ith in th e s h ip p in g m a te r ia l ty p e an d th e siz e of th e su r fa ce ar ea .
container. M ixing is to be p erform ed Th e m a n u fact u r er ’s in st r u ctio n s w ill n or m a lly
accord ing to th e m an u factur er’s instru ction s. p rovid e the p re fe rre d a p p lic a tion m e thod for
sm a ll a n d la r g e ar ea s.
C o a t i n g s a r e eith er s in g le-co mp o n en t o r
m u ltip le-co m p on en t. M os t m u ltip le- The follow ing is a de s c rip tion of a pp lic a tio n
co m p o n en t co a tin g s a r e tw o -co m p o n en t. equ ipm en t an d m eth od s.
Epo xies are an exam p le of a two -com p onen t
co a tin g . Th ey co n ta in a r esin an d a h a r d en er . (a) Brush.— The re tw o ge ne ra l type s of
The com p onen ts of a m u ltiple-com p onen t bru s he s : w a ll a nd s a s h. The y c ome in va riou s
co a tin g can b e in eq u a l p r op or tio n s (e .g., 1:1) sizes, shap es, and bristle typ es. For steel
o r u n e q u a l p ro p o rtio n s (e.g ., 1:4 ). P ro p o rtions s ub s tra tes , w a ll bru s he s a re norm a lly u s e d f or
are d eterm ined by vo lum e. Com p on en ts m u st sm a ll a r ea s, r ep a ir ar ea s, a n d cr ev ice s o r g a p s.
be sh ipp ed in sep ara te con taine rs. Regard less W a ll or ov a l b r u sh es ar e w ell s u ite d for st r ip e
of the p rop ortion volu m e for m u ltiple- coating irregu lar su rfaces su ch as ed ges,
co m p on en t m a te r ials , th e m a n u fact u r er w ill corn ers, bolth ead s, an d sim ilar a rea s. Sash
ship on e container large en ou gh to ho ld a ll the bru s he s a re be tte r s uite d for coa ting n a rrow
co m p o n e n t s fo r m ix in g . are as.
If th e m an u factur er r ecom m en d s th inn ers, Pipe roller.— Pipe rolle rs cons ists of tw o or
they are ad d ed in the r ecom m en d ed am ou nts m ore rolle rs hinge d toge the r to conform to a
d u ring m ixing. After m ixing, som e m u ltiple- curv ed sur face such a s a sm all-diam eter p ipe.
co m p on en t m a te r ials r eq u ir e a 10- to 30-
m in u t e in d u ct io n p e r io d t o a llo w ch e m ica l Fence ro ller.— Fe n ce r o lle r s h a v e a n e x tr a
r e a c tio n s t o b eg in b efo re ap p licatio n . long n a p s o tha t w he n a p p lying a c oa ting fr om
36
Application and Curing
Equipm ent.— A n air com p r es so r , an oil Ad van tages.— The m ethod has a b etter
a n d w a t e r s ep arato r, a p res s u re tan k (p ot) or t r a n s fe r e fficie n c y (le s s m a t e r ia l lo s t) t h a n h a s
p u m p , a ir a n d flu i d h o s es , a n d a s p r a y g u n a r e th e co n v en tio n al s p ra y m et h od , an d b ou n ce
ne ed ed . For ho t sp ray , a h eater is ad d ed to ba ck an d ov ersp ra y a re r ed u ced . Th e H VLP
h ea t th e m at er ial to ab ou t 150 to 160 d eg re es F. sp ray g u n is m ore controllable than other
sp ray gu ns. The m etho d w ork s w ell w ith
Working principle.— C om p r es se d air is h ig h -so lid s co a tin g m a te r ial.
in t r o d u ce d in t o t h e co a t in g s t r e a m a t t h e s p r a y
g u n n oz z le, th u s b r ea k in g d ow n th e co a tin g Disa dva ntag es.— The cove ra ge or
in t o t in y d r o p l e t s (co a t in g a t o m iz a t io n ) a n d p r o d u ct io n r a t e is le s s t h a n w it h o t h e r s p r a y
p rop elling the coating to the su rface sub strate. m ethod s, and the m ethod m ay not atomize
certain coa ting m ater ials.
Ad van tages.— T h e co n v e n t io n a l sp r a y
m et h od p r ov id es m or e fin ely at om ize d coa tin g Use s.— This meth od is lim ited to sm aller
p a r t icle s, r e su l t in g i n a sm o o th e r a n d m o r e a re a s or s urfa ce s tha t conta in nu m e rou s
u n ifor m film . Lar g e a r ea s ca n b e co v er ed in a recesses.
relatively sh ort tim e. Op erator control of the
sp ray gu n is excellen t. Th e sp ray gu n h as a (f) Airless Spray (Ap plied Co ld or Ho t).—
high d egree of versatility regar d ing d ifferen t
co a tin g m a te r ials an d sp r a y p a tt er n s. Str ip in g Equipm ent.— This m eth od req u ires a
c a n b e a cc omp lis h ed b y th is meth o d . p ow er so u r ce (e lect r ic m ot or or air
co m p r ess or ), a h y d r a u lic p r ess u r e p u m p , a
Fo r h ot sp r a y ap p licat ion , th e v isco sit y is h i g h -p r e s su r e flu id h o s e , a n d a n a i r le s s s p r a y
low ered to im p rove a p p lication o r to m eet g u n w ith a s a fet y ex te n sio n tip .
m inim u m m aterial tem p eratu re.
Working principle.— A t om i za tio n of th e
Disa dva ntag es.— T h e co n v e n t io n a l sp r a y co a t in g i s a ch i e v e d b y f o r cin g t h e m a t e r ia l
m eth o d u se s la r g e am o u n ts of a ir . th r ou g h a s m a ll or ifice u sin g h y d r a u lic
C o n se q u e n tly , tran s fer efficien cy is lo w p r e s s u r e r a th e r t h a n a ir p r e s su r e . T h e h ig h -
(m at er ial is lo st) b eca u se of b ou n ce b ack p r e s s u r e p u m p m u l t ip l ie s t h e in p u t p r e ss u r e
(rebou nd ) an d oversp ray. The rebou nd m akes by a m inim u m factor of 30, su ch th at th e
it d ifficu lt t o co a t co r n er s a n d cr ev ices . Th is ou tp u t p ressur e at the sp ray g u n p rod u ces
m et h od is n ot g en er a lly su ita b le fo r h ig h -b u ild p r e s su r e s u p t o a b o u t 6,000 p s i. T h e sp r a y g u n
co a tin g m a te r ia ls w ith o u t e xcess iv e th in n in g . ha s a fixed orifice size an d variou s fixed ang les
t o a llo w s e v e r a l s p r a y f a n p a t t e r n s a n d
Use .— Th is m et h od is u se d on n ea r ly all t h ick n e s s e s t o b e ap p lie d w it h t h e s a m e
R e cla m a t io n s tru ctu res w h ere o v ers p ray is not a m ou n t o f m a te r ial.
a concern. The h ot spr ay m ethod is u sed
d u r i n g co o le r w e a t h e r . Ad van tages.— This meth od p rovid es
g r ea te r cap a city for ap p ly in g h ig h b u ild
(e) High-Volume, Low-Pressure (HVLP) coating s, gr eater su rface p en etra tion b ecau se
Spra y.— of high a p p lic a tion p re s s ure s , high c ove ra ge or
37
Guide to Protective Coatings: Inspection and Maintenance
38
Application and Curing
39
Guide to Protective Coatings: Inspection and Maintenance
40
Chapter IX
41
Guide to Protective Coatings: Inspection and Maintenance
D u r in g in sp ect ion s, p r ot ect iv e g lov es sh ou ld for accep tan ce. The first is to m eet the
be w orn to avoid contam inating the finished m i n im u m a n d m a xim u m D F T, a n d th e se co n d
p r ep a r ed su r fa ce w ith oil a n d sa lt p er sp ir a tion . is to d etect and rep air an y p inh oles in th e
W h e r e fo o t tr a ffic is u n a v o i d a b l e, s u c h a s coating or d am ag ed are as.
w ithin p ipe interiors, p lastic slip cover booties
are recom m end ed . (a) D ry Film Thickness.— Th e D FT o f a co a tin g
c a n be m e a s ure d w he n the m a te ria l d ries or
(c) Dust.— U se clea r ce llop h an e t ap e (o ffice h a r d e n s b u t b e f or e t h e r e co a t w i n d o w h a s
v a r i e t y ) t o d eterm in e am o u n t o f d u s t from expired . The thickness is com m only sp ecified
a b r a s iv e b la s tin g a n d o t h e r s ou r ce s th a t h a s in m ils, a lth ou g h som e m a n u fa ctu r er ’s
no t been blow n o r v acu u m ed off. Press th e ins tru c tion s he e ts w ill a ls o us e m ic rome te rs (or
ta p e o n th e s u r face , p ee l off, a n d v isu a lly m icr on s) in th e m et r ic sy st em . Th e fo llow in g
observ e the a m ou nt o f du st that sticks to th e p rov id es conv ersion s of these u n its:
t a p e . C le a n th e tes t area w ith aceto n e o r
a l co h o l t o r em o v e tap e ad h es iv e fro m 1 m il = 0.001 in ch = 25.4 m icrom eters
p r ep a r ed s u r fa ce . Th e te st ta p e sh o w in g th e
d u st p a r ticle s ca n be d o cu m e n te d b y a p p ly in g 1 m icr om et er = 0.000001 m et er = 0.039 m il
it t o t h e d a ily in sp ect ion r ep or t o r an ot h er field
rep ort. Reclam ation specifies that th e har d ened coated
su r face sh a ll m ee t a m in im u m an d m a xim u m
40. Wet Film Thickens.— Reclam ation d oes s pe c ifie d thickne s s . D FT is m e a s ure d for
n ot req u ire testing th e w et film th ickn ess qu ality con tr ol a n d sp ecification D FT
(WFT). W FT is m easu red in accord an ce w ith accep tance criteria. There are n u m erou s typ es
A STM D 4414. (Se e p p e n d ix N f or th e o f D F T g a u g e s a v a ila b le o n t h e co m m e r cia l
p r oc ed u r e.) H ow ev er , it is a u se fu l m ark et. Th ese ga u ges m easu re th e th ickn ess
m easu rem en t for th e follow ing p u rp oses: of a n on co n d u ctiv e co a tin g on a m a g n et ic
co n d u ctiv e (fe r r ou s) o r n on m a g n et ic
• To v er ify th a t a con sis te n t t h ick n es s is cond u ctive (alu m inu m , brass, bron ze, copp er,
be in g a p p lied . A co n siste n t W FT et c.) su b st r a te . Th er e a r e D FT g a u g es av a ilab le
sh ou ld d ry into an ev en DFT. th a t w ill re a d on ly m a g n et ic or n on m a g n et ic
su b st r a te s a n d g a u g es t h at w ill m ea su r e b oth .
• T o p red ict th e res u ltin g D F T. Som e Th e in sp ect or sh ou ld en su re th at th e co rr ect
m an u factu rer’s instru ctions state a w et su b str ate ga u g e is b ein g u se d a n d th a t th e
film thickness coating a p p lied at a g a u g e r a n g e is w i th i n t h e film t h ick n e s s t o b e
cer ta in n u m b er of m ils w ill re su lt in a m e a su red .
p r ed ete r m in ed D FT. Fo r ex a m p le, a
co a tin g ap p lied 10 m ils w et w ill re su lt SSPC-PA2 .— Reclam ation sp ecifies that th e
in a D FT of 8 m ils. H ow ever , if the DFT is to be m easu red in accord an ce w ith
m a n u factu rer’s in s tru ctio n s d o n ot SSPC -P A 2, “M ea su r em en t o f D r y C oa tin g
state the D FT that w ill result from the Thickness w ith M agn etic Gag es,” w ith the
W FT, it can be calculated . (See e xce p t io n o f t h e fo llo w in g :
a p p e n d ix O fo r fo rm u la s a n d
exa m p les.) • Section 5 .2.1.— The sp ecified
m in im u m p er cen ta g e t h ick n es s is
M easu ring th e W FT on q u ick d ry ing m ater ials, chan ged from 80 to 90 p ercent.
s u c h a s in o r g a n ic z in c s , m a y y ie ld le s s t h a n
accur ate r ead ings. • Section 5 .2.2.— The sp ecified
m a xim u m p er cen ta g e t h ick n es s is
41. Hardened Painted Surfaces.— On ce a chan ged from 120 to 150 p ercent.
co a t in g s y s te m h a s d r i ed o r h a r d e n e d , b u t
before the recoat w ind ow has exp ired, DF T gauges.— T h e ty p e s o f D F T g a u g e s a r e
Re clam a tio n sp ecifica tio n s im p os e t w o cr ite r ia d eterm ined by th e specific m agn etic prop erties
42
Field Inspection and Testing
43
Guide to Protective Coatings: Inspection and Maintenance
Total coated surface area Number of 100-square-foot areas for spot measurements
Less than 300 square feet Each 100-square-foot area within the total area.
Greater than 300 square feet Three (3) 100-square-foot areas within the total area
but less than 1,000 square feet
Equal to and greater than Three (3) 100-square-foot areas for the first 1,000 square feet within the
1,000 square feet total area; plus
One (1) 100-square-foot area for each additional 1,000 square feet of
coated areas or fraction thereof
44
Field Inspection and Testing
voltages at DFT ranges are p rovid ed in table 1 Metho d B.— This m e thod is prim a rily f or
of t h e N A C E RP 0188. laboratory u se, althou gh it is often em p loyed
in th e fie ld . The m e thod is not s uita ble for
Re clam a tio n sp ecifie s t h a t t es tin g b e in co a tin g s w ith a th ick n ess g r ea te r th a n 5 m ils.
accord an ce w ith N A CE RP 0188, except th at: A lattice pattern of 6 to 11 evenly spaced
ho rizon tal and ver tical lines are cu t into the
• Te st in g is n ot r eq u ir ed on con d u ctiv e co a tin g to th e s u b st r a te . Pr es su r e-s en sit iv e
co a tin g s p ig m en te d w ith alu m in u m , t a p e i s a p p lie d o v e r t h e la t t ice p a t t e r n a n d
g r a p h ite , zin c, or ot h er ele ctr ically p u lle d o f f. C o a tin g a d h e s io n is a ss es se d b y
cond u ctive p igm en ts. m a king the be s t m a tch to a c om p a rison s c ale of
0B (lo w e s t) t o 5B (h i g h e s t) o f n a r r a t iv e a n d
• U sin g a d et er g en t w et tin g so lu tio n is p ho togr ap hic d escrip tions p rov ided in the
not p erm itted (d etergen ts m ay cover s ta n d a r d .
ove r p inh oles after testing, leav ing th e
false im p ression th at no p inholes (b) Adhesion, Pulloff Method (ASTM D
ex ist ). 4541).— T h is m e t h o d is m o r e q u a n t it a tiv e b u t
re qu ire s a n e xpe rie nc e d op e ra tor for
P r ev iou s v er sio n s o f Recla m a tio n coa tin g r e p r o d u c ib ilit y . T h e se te st e rs a re
sp e c ific a tio n s referen ce A S TM D 5 16 2 for recom m end ed for flat hor izontal su rfaces
h olid ay test ing . ASTM D 5162 an d N A CE RP u n less oth erw ise stated in th e ap p en d ix. Th e
0188 are essentially equivalent, but th e N AC E s ta nd a rd lis ts the follow ing th re e type s of
v er sio n is m o r e co m p lete an d ea sie r to fo llo w . tester s in th e an n ex:
(See ap p en d ix Q fo r th is p r o ce d u r e.)
Typ e I, fixed.— Typ e I testers are restricted
42. Destructive Test Methods.— D e st ru c tiv e to labora tory u se.
test m etho d s are n orm ally u sed to eva luate
ov er co a tin g or aid in d et er m in in g a co a tin g Typ e II, fixed alignm ent.— T y p e II t es te r s
failure. The follow ing sections are abbr eviated w e r e d e v e lo p e d fo r la b o r a to r y u s e b u t a r e
d e scr i p t io ns o f th e d es tru ctiv e tes tin g m e thod s em p loyed in th e field . Typ e II are th e m ost
list e d i n t h e ab o v e P h y s ical Co atin g In s p e ction co m m on p u llo ff a d h esio n te st er s fo r fie ld u se .
Su r v e y m e th o d . (See ap p en d ix R fo r th is p r oce d u r e.)
(a) Adhe sion, T ape Metho d (ASTM D 3 359).— Typ e III, self-aligning or hyd raulic.— T y p e
Th is t es t is con sid er ed su b ject iv e a n d sh ou ld III testers w ere d ev elop ed for labor ator y u se
be p erform ed by qu alified and exper ienced bu t ar e em p loyed in th e field . (See ap p en d ix S
p ersonn el. The choise of test m ethod d ep end s fo r p r oce d u r e.)
on coating th ickn ess.
Dry film thickness by Tooke gauge (ASTM D
Metho d A.— T h is m eth o d is u s ed o n 4138).— The Tooke ga ug e is us e d for
co a tin g s 5 m ils th ick or g r ea te r . A n “X” cu t is m e a s u r i n g t h e n u m b e r o f co a t s a p p lie d a n d
m ad e in th e coating to the su bstrate. Pressu re- D F T if t h e co a t in g l ay e r s ca n b e id e n t ifie d b y
s e n s it iv e t a p e i s a p p lie d o v e r t h e “ X” cu t a n d color d ifferen ce or by a d istinctive line. (See
p u lle d o f f. C o a tin g a d h e s io n is a ss es se d b y a a p p en d ix T fo r th is p r oce d u r e.)
co m p a r iso n sca le o f 0A (low es t) t o 5A
(h i g h e st ), as d es crib ed b y w ritten d efin it ions
p r o v i d e d in t h e s ta n d a r d .
45
Chapter X
Maintenance Coatings
Reclam ation infrastru ctures m ay still be coated m a y also b e a m a jor co n sid er a tion , an d th ese
w it h t h e o r ig in a l m a t e r ia ls fr o m t h e in i tia l asso ciated costs m ay be d ifficu lt to asse ss. To
in st a llat ion or th ey m a y h a v e r ece iv ed fu ll, p rovid e a ba s is for risk e va lua tion, ins p e ction
p artial, or sp ot coating rep air in th e of the coating an d sub strate is recomm end ed .
in te r v en in g y ea r s. O b v iou sly , an y coa tin g
m a t e r ia l h a s a fin i te s er v i ce life , a n d 46. Inspection.— To d e te rm in e th e co r re ct iv e
m a in t e n a n c e co a t in g s h a v e b e co m e a n a c tion re qu ire d , s truc ture s id e ntifie d for
im p ortan t com p on en t in m aintaining the m a in t e n a n c e co a t in g s w o r k sh o u ld b e
stru ctu ral integ rity of h igh-cap ital-cost in s p e ct e d b e f or e b e g in n in g w o r k . P r e lim in a r y
infrastr u ctu res. w o rk sh o u ld in clu d e ga th e rin g ba ck g ro u n d
in for m a tio n on th e s tr u ctu r e, in clu d in g
43. Definition.— A s im p lified d efin itio n of location , original installation d ate, d im en sions,
m a in t e n a n c e co a t in g s is “ th e r e co a t in g o f a n y d r a w in g s, s u b st r a te ty p e, an d co a tin g h ist o r y .
existing coated su bstrate sur face to p reven t The coating history sh ou ld includ e the
co r r o sio n or to m a in ta in ap p ea r a n ce .” follow ing inform a tion, if know n:
47
Guide to Protective Coatings: Inspection and Maintenance
48
Maintenance Coatings
49
Guide to Protective Coatings: Inspection and Maintenance
50
Maintenance Coatings
of airbo rn e p articles bu t w ill not elim inate d e te riora tion re qu ire s a tte ntion or u ntil s om e
t h e m . T a b le 2 p ro v id es O SH A res u lts for tim e w hen coating m aintenan ce is sched u led
t y p i ca l a n d m a x im u m le a d e x p o s u r e le v e ls b y w ith oth er m a jor m a in te n a n ce p r og r a m s.
r e m o v a l m e th o d . A n ot h er r ea so n for n ot p a in tin g is th a t fu n d in g
m ay n ot be av ailable for “ x” n u m ber of year s.
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Guide to Protective Coatings: Inspection and Maintenance
52
Chapter XI
Galvanizing
Ga l v a n i z in g is th e ap p licatio n o f zin c o n to a aesthetics (color ap p earan ce). Coating ov er
st ee l su r face . Zin c is a n od ic to st ee l (i.e., zin c galvan ized su rfaces pr esents u niqu e p roblem s
w ill sa cr i fice its elf to p ro tect steel fro m th a t a r e ch a r a cte r ist ic of z in c an d th e co a tin g
c o r r o sio n ) . Reclam atio n s p ecifies n u m erou s m aterial selected .
st eel m eta lw o r k ite m s t o b e g a lv a n iz ed .
M etalw ork item s m ay ran ge from sm all item s 53. Galvanizing Methods.— T h e r e a r e s e v e r a l
s u c h , a s b o lt s a n d n u t s , t o la r g e it e m s , s u c h a s m ethod s to use w hen ap p lying zinc. Table 3
gates. The follow ing are reason s to coat over p rovid e s the m os t com m on m e thod s for
g a lv a n izin g : (1) to for m a b a r r ier coa tin g in g a lv a n izin g an d in clu d es m a n u fact u r in g
bu rial or im m ersion serv ice exp osu res b ecau se p r oc es se s, sp ecifica tio n r efe r en ces , zin c coa tin g
the z inc w ill be rap idly con su m ed ; (2) to th ickn es se s, an d ty p ical a p p licatio n s for ea ch
rep air da m aged areas; and (3) to im p rove m e th od :
Electro- Electrolysis ASTM A 591 Up to 0.14 mil Interior service exposure: appliance
galvanizing panels, studs, and acoustical ceiling
members
Zinc Electrolysis ASTM B 633 0.2 to 1.0 mil Interior or exterior service exposure:
plating fasteners and hardware items
Mechanical Peening ASTM B 695 0.2 to 4.0 mil Interior or exterior service exposure:
plating fasteners and hardware items
Continuous Hot-dip ASTM A 653 Up to 4.0 mil Interior or exterior service exposure:
galvanizing roofing, gutters, culverts, automobile
bodies
Hot-dip Hot-dip ASTM A 123 1.4 to 5.0 mil Interior or exterior service exposure:
galvanizing ASTM A 153 nearly all shapes and sizes, ranging
from nails, bolts, and nuts to large
structural items
Thermal Hot zinc AWS C2.2 3.3 to 8.3 mil Interior or exterior service exposure:
Spraying spray items that cannot be galvanized by
other methods because of their size
and shape or because galvanizing
must be performed onsite.
Zinc-rich Brush, roller, Varies with 0.6 to 5.0 mil Interior or exterior service exposure:
painting airless, or owner's or per coat Items that cannot be galvanized by
conventional manufacturer’s other methods because of their size
spray specifications and shape or because galvanizing
must be performed onsite. Aesthetics
(color).
53
Guide to Protective Coatings: Inspection and Maintenance
54
Galvanizing
• Newly galvanized m etalw ork.— Th e Repair of physical defects (high spots and
su r face is u n d er g oin g th e a ctiv e dro plets).— H ig h sp o ts o ccu r w h e n exce ss z in c
55
Guide to Protective Coatings: Inspection and Maintenance
56
Galvanizing
57
Guide to Protective Coatings: Inspection and Maintenance
58
Chapter XII
Coating Failures
Coatings fail for m an y reason s. These failu res w it h lim it e d k n o w le d g e o f in d u s t r ia l
c a n b e r e la t ed to m aterial s electio n , co a tin g s ca n se lect th e w r on g or p oo r ly
form u lation, ad hesion, substrate typ e, p er for m in g m a te r ials , re su ltin g in
a p p lic a tio n , stru ctu re d es ig n , o r ex terio r p r em a tu r e fa ilu r e.
for ces . Th es e r ela te d failu re ty p es m ay act
ind ep en d en tly of each oth er or in concert w ith • Se le ction of a pa int s ys tem tha t is no t
each oth er. The read er is strong ly u rged to c omp a tible w ith a n othe r p a int. For
p u r ch a se on e o f th e p h ot og r a p h ic coa tin g exam p le, a coating p rim er
fa ilu r e b o o k s lis ted in ap p en d ix B. m a n u f actu r ed b y on e co atin g co m p a n y
s h o u ld n o t b e t o p c o at e d w it h a m a t e r ia l
59. Material Selection.— To p r ote ct th e m a n u fa ct u r e d b y a d i ffe r e n t co m p a n y ,
su bstr ate, coatings a re r equ ired to resist e ve n if the tw o c oa ting m a te ria ls a re of
d e t er io r a t io n f r o m a t m o s p h e r ic, b u r ia l, a n d th e sam e gen eric typ e, such as a
im m e r sio n s erv ice ex p o s u re. N o o n e ty p e of p olya m id e e poxy. Inc om p a tibility of
coating has ev er been d eveloped to p rotected solven ts betw een tw o sim ilar p aints is a
a ll su b st r a te ty p es in all ser v ice ex p o su r es. com m on cau se for p rem atu re failure.
R a t h e r , m a n u factu rers fo rm u late co atin g s for
s p e c ific s e r v ice e xp o s u r e s . C o a t in g m a t e r ia l 60. Formulation.— Fo r m u l a tio n fa ilu r e s a r e
se lectio n is g en er ally b as ed on se rv ice failu r es th a t a r e in h er en t w ith in th e co a tin g
expo su re su itability, past history p erform an ce, m a t er ia l itse lf. Th e co m p o n e n ts o f a co atin g
recom m en d ation s from oth er facility ow n ers, co n sis t o f r esin s, s olv en ts , an d p ig m en ts , an d
an d accelera ted p erform an ce tests. th ey ar e m ixe d in v a r io u s p r op or tion s.
Im p rop er com p on en t m ixtu re d u ring the
The follow ing are som e exam p les of im p rop er m a n u fa ctu r in g p r oce ss ca n lea d to fa ilu r e.
m a t e r ia l se lectio n : Form u lation failur es are su bd ivided into th e
follo w in g or g a n ic an d in or g a n ic coa tin g
• Se lectio n o f a p ain t fo r th e w ro n g cla sses:
s e r v ice e xp o s u r e . Fo r e xa m p le , if a n
a t m o s p h eric co atin g is sp ecified for (a) Fo rmulatio n - O rgan ic Co atings.— O r g a n ic
im m e r sio n s e rv ice e xp o s u r e , fa ilu r e co a tin g s ca n fail b eca u se of ch a n g es in
w ill occu r in a r ela tiv ely sh or t t im e form u lation, raw m aterials, imp rop er
p er io d . p rop ortioning, insu fficient m illing , and other
m an u factur ing p rocesses, . Table 4 p rov id es a
• Se lectio n o f a p ain t b as ed s o lely on d escription of form u lation for or ga n ic failur es,
co st s. N o t a ll p a in ts ar e eq u a l. A the cau se of failu re, and the r em ed y for th e
m a n u factu rer m ay p ro d u ce s o m e failu res.
excellent p rod u cts but o ther p aints
fr o m th e s am e m an u factu rer m ay not (b) Fo rmulatio n - Ino rgan ic Zinc.— In or g a n ic
p e r f or m w e ll. A s a r u l e-o f-t h u m b , co a t in g s s u f fe r fr o m in h e r e n t p r o b l e m s t h a t
w h at y o u p ay fo r is n o rm ally w h a t you resu lt in failu res cau sed p rincipally by silicate
get, and this, in gen eral, ap p lies to v eh icles an d m et a llic zin c th a t a r e u se d in th eir
p aint m ater ials. c omp os ition. Ta ble 5 p rovid e s a de s c rip tion of
th e t y p es an d cau se s o f in or g a n ic zin c coa tin g
• Se le ct io n o f a p a in t b a s e d s o le ly o n a n failu res an d th e rem ed ies for th e failu res.
u n s u b sta n tia te d o p in io n . A p e rso n
59
Guide to Protective Coatings: Inspection and Maintenance
ALLIGATORING - Very large Internal stress where surface Remove failed coating. Apply thin coats
macrocracking, generally cross- shrinks more rapidly than the and thoroughly dry before applying
hatched pattern. body of the coating. Hard additional coats. Never apply hard
topcoat applied over soft topcoat (epoxy) over soft coats
undercoat. (asphalt).
CHALKING - Surface is soft, Surface disintegration caused Select coatings formulated with UV-
powdery, and easily removed by UV sunrays on an organic resistant resins (acrylics) and light
by wiping. resin binder; formulated with stable, high hiding pigments.
improper pigmentation.
CHECKING - Surface Surface stresses resulting from Select a coating formulated with
phenomena with uneven, small, shrinkage caused by weather-resistant resins, inert
noncontinuous fissures in weathering and continued reinforcing pigments, and light stable
coating that do not penetrate to coating polymerization and pigments.
the substrate. oxidation.
CRACKING - Small breaks in Stress set up in coating Select coating formulated from
coating to substrate. May be because of continued nonreactive, weather-resistant resins;
linear, cross-hatched, or polymerization and oxidation; reinforcing pigments; and nonreactive
curved. Cracks may or may not improper pigmentation or colored pigments. Primer must be
be continuous. improper coating system. compatible with intermediate and finish
coats.
DISCOLORATION - Yellowing, Resin or pigment color change Select coating formulated with both
graying, or darkening of caused by weather or chemical color stable resins and pigments.
coating. reaction.
EROSION - Similar to chalking. Chalking mechanism, coating Select a tough, chalk-resistant coating
Surface removed on high spots surface removed by weathering with good flow out characteristics that
and brush marks to base or and abrasion. will form a smooth film.
primer coating.
MICROORGANISMS - Blotchy The biodegradation of the Use oil coatings containing permanent
brown or black spots on coating coating by bacteria or fungi. fungicide or bactericide. Nonoil
surface causing poor, dirty Bacteria or fungi use coating coatings should use modifiers that will
appearance with softening or ingredients for nourishment. not biodegrade.
slimy feel.
MUD CRACKING - Large Rapid drying of high filled Select coatings with strong adhesion.
cracking. Coating may curl at coatings, especially water- Apply coatings under proper drying
cracks and lose adhesion. based materials (water conditions and avoid sags or areas of
emulsion paints). excess thickness during application.
WRINKLING - Furrows and Surface reaction where surface Select coating with even, thorough
ridges in coating surface. May of coating expands more rapidly drying characteristics. Apply evenly
be linear or random pattern. during drying than does the and avoid excessive thickness.
Wrinkle may be fine or quite body of the film.
large.
60
Coating Failures
CHECKING - Usually fine, visible, or The zinc pigment to binder ratio is Formulation should include
microscopic checks. Does not high, causing rapid drying and reinforcing pigments. Apply
penetrate to the substrate. resulting in surface cracking. coating as thin as
recommended. Apply second
coat only if necessary. Apply
under favorable conditions.
CHEMICAL - Pinpoint rusting Acid or alkali reaction on both Apply resistant topcoats over
progressing from spotty to silicate binder and metallic zinc. inorganic zinc coatings.
continuous area.
MUD CRACKING - Fine to fairly Application too heavy or drying Apply coating at no more than
large segments, about 1/4-inch too rapidly. recommended thickness and
across, flaking from the coating apply under favorable drying
surface. conditions.
PINPOINT RUSTING - Pinpoint Uneven coating thickness. Thinly Apply a maintenance coat at
spots of corrosion progressing from coated areas show failure first. first sign of pinpoint failure.
a few spots per square foot to almost This is a normal failure pattern for
continuous rusting. inorganic zinc coatings.
61
Guide to Protective Coatings: Inspection and Maintenance
BLISTERING - Small to large Blisters may be due to poor Select a coating with very strong
(1/32 to 1 inch plus) surface preparation, internal adhesion strength and low moisture
hemispherical bubbles in the soluble materials (salts), or poor vapor transfer rate. Ensure clean
coating that contain gases or wetting of substrate. Osmosis substrate with proper surface
liquids. Bubbles may range causes absorption of gases into preparation and reduced soluble salt
from 1 per square foot to substrate or solvent entrapment levels to suit service exposure.
several hundred per square (also referred to as “solvent
foot. blistering”).
FLAKING or SCALING - Small Normally, coating is brittle, with Select a coating with very strong
to large (1/16 to 1 inch plus) internal shrinkage characteristics adhesion strength and low moisture
pieces of coating, curling at and marginal adhesion strength. vapor transfer rate. Ensure clean
edges. Easily removed from Oil type coatings may scale or substrate with proper surface
surface, leaving substrate flake from galvanized surface preparation and reduced soluble salt
exposed. (never apply an alkyd to a levels to suit service exposure. For
galvanized surface). galvanized surfaces, use a primer
compatible with zinc.
PEELING - Coating may be Adhesion is less than the tensile Select a coating with very strong
smooth and lying on the surface strength of the coating. Coating adhesion strength and low moisture
or hanging in shreds. Little or peelings can easily be pulled vapor transfer rate. Ensure that the
no adhesion is evident. from the surface down to bare substrate is clean, the surface has
substrate. been cleaned properly, and salt has
been reduced to levels suited to the
service exposure.
UNDERCUTTING - Corrosion Poor adhesion because of Select a coating with very strong
byproducts from the substrate improper surface preparation adhesion strength. Apply coating over
build up under the coating and (dirt, dust, soluble salts, other a surface that has been abrasively
will break the coating at edges contaminates); smooth surface cleaned or cleaned by water jet
or pinholes. The corrosion (no surface profile); or coating blasting. Use of a zinc-rich primer
progresses under the coating. incompatibility with the substrate reduces undercutting.
surface.
62
Coating Failures
AGED STEEL - The surface Substrate surface retained Water jet blast surface with water;
includes blisters, rust, pitting, minute corrosion byproducts or dilute phosphoric acid; or salt-
tubercles, or adhesion loss in contaminants even if it was bonding, chemical-removal
areas where the substrate was abrasively blasted or water jet solution. Apply an anticorrosion
exposed to a corrosive blasted to a high degree of primer or barrier coating with high
environment. cleanliness. adhesion strength.
AGED CAST IRON - The surface Cast iron has a rough, more Water jet blast surface with water or
includes blisters, rust, pitting, porous, crystalline surface matrix salt-bonding chemical removal
tubercles, or adhesion loss in than steel, causing more solution. Heat surface to hot-to-
areas where the substrate was moisture to be retained. touch to drive off moisture. Brush
exposed to a corrosive apply primer while surface is warm
environment. For graphite corrosion, it is the to allow a maximum wet-coat
A silver gray to a dark gray color selective leaching of ferrous ions penetration. Select compatible
may indicate graphite corrosion. from some cast irons, normally intermediate coat and/or topcoat.
This kind of corrosion can be gray cast iron.
easily cut or pierced with a knife.
ALUMINUM - White aluminum Environmental pH outside the Light dust blast or soft abrasive
corrosion by-product is causing range of 5 to 8.5. Lack of blast or treat with commercial
pinpoint coating failure, adhesion accessible oxygen. Lack of aluminum treatment solution.
loss from smooth surface, adhesion to a very smooth Select a compatible primer with
blistering, or pitting. aluminum oxide surface, i.e., lack high aluminum surface adhesion
of sufficient surface profile. strength.
COPPER - Blue or gray-green Lack of adhesion to a very Light brush blast, soft abrasive
corrosion by-products, adhesion smooth copper surface (no blast, or treat with commercial
failure blistering, or pitting. surface profile) or the presence of copper treatment solution. Select a
oxides on surface. compatible primer with high copper
surface adhesion strength.
CONCRETE - Adhesion loss, Chemically reactive and high Abrasive blast or water jet blast
blistering, or peeling of coating. moisture content. Formation of (acid etching not recommended) to
calcium salts under the coating. obtain clean and dry surface.
Pinholes, air, and water pockets Select a low molecular weight, high
in concrete surface. Water vapor penetrating primer with high alkali
transmission through concrete. resistance (coal tar epoxy or
modified epoxy).
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Guide to Protective Coatings: Inspection and Maintenance
IMPROPER MIXING - Coating is Failure to sufficiently mix material, Thoroughly mix the liquid material
too thin, pigment distribution is resulting in improper pigment-to- to an even, smooth, homogeneous
nonuniform, or both. Entire or vehicle ratio; settled pigment consistency, with no color variation.
localized areas may have poor remains in bottom of container. During use, continue mixing as
adhesion, uneven color, necessary. Mechanical mixing is
checking, or cracking. the preferred method.
IMPROPER THINNING - Poor Thinner is incompatible with Use only the manufacturer’s
adhesion or pigment flotation, resins or pigments. Improper recommended thinner for selected
resulting in uneven color. drying, resulting in surface coating material in the amounts
Separation of pigment and tension change. Thinner specified. Add thinners slowly and
vehicle after application, resulting evaporated too rapidly causing mix thoroughly.
in pinholing or blushing. moisture to condense on liquid
coating. Excessive thinner,
resulting in curdling or
flocculation of pigment.
AMINE BLUSHING - Oily, amber- Material applied relatively thickly Wait for proper temperature and
colored film on coating surface for on cold, damp days or in similar humidity before application.
aliphatic, amine-cured epoxy environments where amine rises
materials. to surface and reacts with carbon
dioxide and moisture in the air.
BLUSHING - Milky or whitish Moisture condensation on coating Wait for improved humidity, reduce
appearance of coating film with a in high humidity because of fast atomizing air pressure to a
dull or flat finish. evaporation or unbalanced minimum, or add evaporation
thinners. Occurs most often on retardant to thinner.
hot, humid days or in similar
environments.
BLEEDING - Staining of topcoats. Soluble resins or pigments in Seal undercoat with coating in
undercoat migrate to topcoat. which bleeding components are
insoluble.
CRATERING - Small, uniform Air pockets trapped in wet film Abrasive blast, water jet blast, or
indentations in coating film (also during spray application. roughen affected area; ensuring
referred to as “pitting”). removal of contaminants within
craters; and reapply coating.
FISHEYES - Separation or pulling Coating applied over dirt, oil, Remove all material by abrasive
apart of wet film to expose silicone, or incompatible coating blasting or water jet blasting, ensue
underlying coat or substrate. material. substrate is contaminant free, and
reapply coatings.
64
Coating Failures
HOLIDAYS - Bare areas on the Improper and inconsistent Apply coating in a careful and
substrate that were not coated by application technique, reflecting a professional manner, consistent
the applicator (also referred to as lack of care. Most often occurs in with industry standards.
“painter’s holiday”). areas difficult to coat.
LIFTING - Wrinkling, swelling, or Solvents in a coating attack or Remove all material by abrasive
blistering appearance on the film swell the underlying coating, blasting or water jet blasting and
surface. resulting in film distortion. reapply coatings.
ORANGE PEEL - Overall Inherent with sprayed-on Brush out excess paint before
appearance is bumpy. Film materials; caused by improper material cures. Correct spray
surface is smooth but irregular. application techniques: gun too technique. After material has
Resembles skin of an orange. far from surface, solvent cured, sandpaper surface before
evaporation too rapid, spray applying another topcoat that
Note: Orange peeling is not a pressure too low for proper reacts more slowly.
coating failure, but the atomization, paint particles falling
appearance may be outside of spray pattern, or
objectionable. material too viscous.
OVERSPRAY - Very rough Improper application techniques: Before the material cures, remove
coating surface. Surface may be gun too far from surface, solvent the overspray by dry brushing,
dry, pebbly, or sandy. Some evaporation too rapid, spray followed by solvent wiping. After
coated areas may have the pressure too low, atomizing the material has cured, wire screen
appearance of dryness or feel dry pressure too high, paint particles and sandpaper the surface before
(also referred to as “dry spray”). falling outside of spray pattern, or applying another topcoat that
material too viscous. reacts more slowly.
PINHOLES - Small, tiny, deep Improper application techniques: Correct any improper application
holes (1/32 inch) in coating, gun too far from surface, solvent techniques. If pinholes already
normally through to the substrate. evaporation too rapid, spray exist and the material has not
Generally, the distribution of pressure too low, atomizing cured, apply additional coat by
holes appears to be random. pressure too high, paint particles brushing into holes. If material has
falling outside of spray pattern, or cured, but it is still within the recoat
pigment settlement. window, apply an additional coat. If
outside the recoat window, abrade
surface and apply additional coat.
RUNS or SAGS - Downward Excessive application of coating Correct any improper application
movement of coating material on material, spray gun too close, too techniques. Apply thinner coats. If
vertical or curved surfaces in the much thinner, surface too hard or material has not cured, brush out
form of droplets or streams. glossy to hold material, or excess material. If material has
Runs are the result of excess temperature too cold for proper cured and is still within the recoat
material continuing to flow after drying. window, apply an additional coat. If
the surrounding surface has set. outside the recoat window, abrade
Sags are the result of differences surface and apply additional coat.
between application and setting
times. Sags have the
appearance of a curtain.
65
Guide to Protective Coatings: Inspection and Maintenance
SPATTER COAT - Areas of thin Improper application techniques, Correct any improper application
coating (less than specified causing a noncontinuous coating techniques. If material has not
coating thickness), normally at over the surface: inconsistent cured, apply additional coat. If
end of the spray pass or around spray passes not overlapping by material has cured but it is still
complex sections of structure. 50 percent, spray gun flipped at within the recoat window, apply an
Under good lighting conditions, end of spray pass, or spray gun additional coat. If outside the
coating appears continuous; not held perpendicular to the recoat window, abrasive blast or
under poor lighting, coating surface. water jet blast all material off and
appears discontinuous. May recoat.
develop into pinpoint corrosion at
a later date.
BACK-TO-BACK ANGLES and Impossible to apply coating in Design: Use T bar or pipe in
PLATES - Corrosion between crevice between angles and construction.
back-to-back angles and plates is plates.
resulting in undercutting of Precoat: Coat angles and plates
coating. before construction assembly.
EDGES - Linear corrosion along Surface tension causing coating Brush or stripe coat surfaces
edge and undercutting coating to pull away from edges. before full coating. Overlap full
away from the edge. coating on both sides of edges.
Spray directly at edge to build up
thickness and reduce surface
tension.
INTERIOR CORNERS - A void or Excessive coating thickness, Apply multiple thin coats and allow
blister is developing under resulting in coating shrinkage coating to thoroughly dry between
coating. during or after curing. coats, but within recoat window.
SKIP WELDS - Corrosion in weld Impossible to apply coating in Provide continuous weld in gaps
gaps and between overlapping crevices in weld gaps and and overlap areas before applying
metal is causing undercutting of between metal surfaces. coating in any corrosive
coating. environment.
SMALL DISCONTINUOUS Small surfaces with high ratio of Brush or stripe coat surfaces prior
AREAS - Corrosion is developing edges and corners to plain, flat to full coating. Overlap brush or
on edges of bolt heads, bolt area will increase coating surface stripe coat with each full coat
threads, nuts, washers, rivets, tension and cause coating to pull applied. Applying multiple thin
and other small edged or away from edges and corner coats is more beneficial than one
cornered surfaces. points. thick coat.
66
Coating Failures
STORAGE TANK ROOFS Impossible to apply coating in Butt weld or double weld roof
(Interior of umbrella type for crevices between roof and rafter plates. Precoat rafters and
center post and rafters) - and between lapped roof plates. underside of roof.
Corrosion is developing between
roof and rafter and between
lapped roof plates.
WELDS - Corrosion along welds, Welding flux in undercuts along Remove all soap solution and blue
particularly hand welds, is weld. Rough weld surfaces. scale. Grind rough welds smooth
undercutting coating away from Soap remaining after pressure or nearly smooth. For interior of
weld. Corrosion along weld may testing of welds. Blue scale hydraulic structures, such as
be continuous or discontinuous. (similar to mill scale) remaining on pipelines, grind welds down to
weld surface. 1/8 inch, minimum. Abrasive blast
weld and apply brush or stripe coat
2 to 3 inches on each side of weld,
working coating into all rough
areas before applying full coating.
ABRASION or EROSION - Wear caused by wheeled traffic, Select coating with strong
Thinning or wearing away of impact, wind, or liquid-borne adhesive properties and specific
coating is resulting in a bare abrasives. abrasion and erosion resistance.
substrate subject to corrosion. Thoroughly prepare surface (near-
white blast minimum) and apply
new coating.
CAVITATION - Loss of coating Drop in water vapor pressure, Select coating with strong
and metal material. Appears as forming air bubbles that adhesive properties and high
tiny craters overlain by multiple repeatedly collapse at high cavitation resistance.
craters in metal surface, pressure.
accompanied by significant metal
loss.
67
Guide to Protective Coatings: Inspection and Maintenance
FAYING SURFACES - Coating Concentration (or crevice) Precoat metal surfaces before
failure and corrosion in joint area. corrosion caused by oxygen assembly with inorganic zinc
differences between closely coating or a suitable coating with a
spaced or joined coated surfaces, high coefficient of friction.
subject to friction-producing
movement (e.g., steel plates and
high strength bolts).
GRAFFITI - Painted words or Vandals painting coated surfaces, Select the manufacturer's graffiti
graphics over coated surface. especially with spray cans. remover and antigraffiti coating
68
Bibliography
Bechtel Pow er Corp oration, Steel Stru ctures N a tion a l A ss ocia tion of C or r osio n En g in eer s,
P a in tin g C o u n cil, C oat in g an d Corrosion Basics: A n In trodu ct ion , H o u s to n ,
Lin in g In spect ion M an u al, P ittsb u r gh , Te xa s, 1984.
P en n sy lv a n ia, 1991.
The Society of Pro tective Co ating s, Good
Bookcock, Simo n K., R.E.F. W eaver, Pain tin g Pract ices, v olu m e 1, th ir d ed itio n ,
B. A p p lem a n , an d G .C . Soltz , Effect s on John D . Ke a ne , D e a n Be rge r, H a rold
S u rface Con tam in ant s on C oatin g Life. H o w er , Ber n an d R. A p p lem a n , Josep h
Bechtel Pow er Corp oration, Steel Bro n o, K itt i C on d iff, M a r k O 'D on n ell,
Stru ctu res P aintin g C ou n cil, Pittsbu rg h , Ja n e t Re x , A i m e e Be g g s , V ilm a M a c u r a ,
P en n sy lv a n ia, 1991. Te r r y Sow er s, a n d M on ica M a d a u s, e d s.,
P itt sb u r g h , Pe n n sy lv a n ia, 1993.
D ep a r tm en t o f th e N a v y , Paint Failures -
Cau ses an d R em edies, N a v y C iv il The Society of Protective Coatings, Steel
Engineering Laboratory , Port H u enem e, Str u ctu r es P a in tin g C ou n cil, S y st em s an d
C a lifor n ia, 1982. S pecificat ion s, volum e 2, s e ve nth e d ition ,
Ber n a r d R. A p p lem a n , Ja n et R ex, a n d
Ele ctr ica l P o w er Re se a r ch In st itu te , In c., T er r y So w e r s, e d s . P it ts b u r g h ,
Ste el P en st oc k C oa tin g an d Lin in g P en n sy lv a n ia, 1995.
Reh a b ilit a tio n : A H y dropower Techn ology
R oun du p R eport, v olu m e 3, TR -113584, Th e Socie ty of P r ote ctiv e C oa tin g s, T he
P lea sa n t H ill, Ca lifor n ia, 2000. In spection of Coatin gs an d Lin in gs: A
H andbook of Basic Practice for In spectors,
Fit z im o n s, Br en d a n , Protective Coatin g O w n ers, an d S pecifiers, Be r n a r d R .
In spect ion M an u al, Rob in so n Irw in A p p lem an , Rich ard W . Drisko, Ju d ith K.
Te ch n ical Su p p or t Lt d ., En g lan d , 1997. N eu gebau r, Simo n K. Bookcock, Russel
D a v i so n , L aw r e n ce J. G r a b ia k , C IH , C SP ,
Fit z im o n s, Br en d a n , V isu al Com parison Jan et R ex, a n d Te r r y Sow er s, e d s.,
M anu al: A pplication an d Coatin g D efects. P itt sb u r g h , Pe n n sy lv a n ia, 1997.
Ro b in so n Ir w in Te ch n ica l Su p p o r t L td .,
En g lan d , 1998. Th e Socie ty of P r ote ctiv e C oa tin g s, C-1:
Fun dament als of Protective Coatings
Gen eric Coatin g T y pes: A n In trodu ct ion to for In du st rial S tru ct u res, v er sio n 10,
In du strial M aint enan ce Coatin g M aterials, P itt sb u r g h , Pe n n sy lv a n ia, 1999.
Sm it h , Llo y d M ., ed ., T ech n o lo g y
P u b lish in g C om p a n y, P ittsb u r gh , Th e Socie ty of P r ote ctiv e C oa tin g s, C-3:
P en n sy lv a n ia, 1996. S u perv ision /Com pet en t Person T rain in g for
D eleadin g of In du st rial S tru ct u res, tw o
M u n g er , C h a r les G ., Corrosion Prev en tion v o lu m e s, v e r sio n V 7-T , P it ts b u r g h ,
by P rotectiv e Coatin g, N atio n al A s s o cia tion P en n sy lv a n ia, 1999.
of Cor rosion Eng ineer s, H ou ston , Texas,
1984. Th e Socie ty of P r ote ctiv e C oa tin g s, C-2:
S pecifyin g and M anagin g Prot ective Coatin g
N A C E In te r n a tio n a l, N A CE Corrosion Projects, tw o v olu m es, v er sio n 7,
En gin eer' s R eferen ce Book, s eco n d ed ition, P itt sb u r g h , Pe n n sy lv a n ia, 2000.
R.S. Tr ese d er , R. Ba b o ia n , an d
C .G. M u n g er , ed s., H ou st on , Tex a s, 1991.
69
Guide to Protective Coatings
70
Appendix A
Bu r e a u o f R eclam atio n
G u id e Sp e cifica tio n s
W eb site A d d re ss: h tt p :/ / in tr a.u sb r.g ov / g u id es p ecs
A-1
Appendix B
Reading Sources
Goo d Painting Pra ctice, Steel Stru ctur es Painting M an u al, Volum e 1, Third Ed ition , 1993. (The four th
ed itio n is d u e in 2003.)
Sys te m s a n d Sp ecifica tio n s, Ste el Str u ctu r es P a in tin g M a n u a l, Vo lu m e 2, Eig h th Ed itio n , 2000.
Coating an d Lining Insp ection M an u al, Bechtel Corp oration, 1983, exclusively d istributed by Steel
Str u ctu r es P a in tin g C ou n cil (SSPC ), A u g u st 1991, SSPC P u b licat ion N o. 91-12.
FH W A Field M an u al for Bridg e Paint Inspection, U.S. Dep artm ent of Transp ortation, Feder al
H ig h w a y A d m in ist r a tio n (FH W A ), FH W A Brid g e C oa tin g s Te ch n olo g y Te a m , O cto b er 1997.
Steel Penstock Co ating a nd Linin g Reh abilitation, A H yd rop ow er Techn ology Rou nd u p Rep ort,
Vo lu m e 3, Te ch n ical R ep or t TR -113584-V3, A u g u st 2000.
Av a i la b le fro m E lectric P o w er R es earch Ins titute (EPR I), 3412 H illvie w A v e nu e , Pa lo A lto C A
94304; t ele p h o n e: (650) 855-2000; C u stom er Se r v ice: (800) 313-3774; W eb sit e A d d r ess:
w w w .e p ri.co m
Vis u a l C om p a r iso n M a n u a l, A p p licat ion an d C oa tin g s D efe cts , Bren d a n Fitz im on s, Ro b in so n Irw in
Te ch n ical Su p p or t Lt d ., En g lan d 1997-1998, (SSP C P u b licat ion N o. 00-8)
B-1
Appendix C
Inspection Checklist
G D eliv er ed m a te r ials
G A p p r o v e d m a t er ia ls , r e co r d b a t ch n u m b e r s
G Sto r ed p r op er ly
G Con tainers secu red
G Shelf life not exceeded
G A b r a s i v e m a t e r ia l
G C om p lies w ith SSPC -A B1, Cla ss A , Ty p e I o r II
G Con tam inan ts
G C h eck for p r es en ce o f oil, A STM D 4940
G C h eck for ch lor id e io n , if su sp ect ed w ith C h lor *Rid A te st k it
G Re ta in sa m p le
G A ir co m p r e sso r e qu ip m e n t
G Com p ressed air lines
G C h eck for oil a n d w a te r con ta m in a n ts , A STM D 4285
G Bla s t n o z z le p r e s su r e
G C h e c k p r e s s u r e a t b la s t n o z z le w it h h y p o d e r m ic n e e d l e g a u g e
G Su r f a ce p r ep aratio n
G D o n o t p r o ce e d w it h s u r f a ce p r e p a r a t io n i f t h e s u b s t r a te s u r fa ce t em p e r a t u r e is le s s t h a n
5 d eg r ee s F a b ov e t h e d ew p oin t
G D e t er m in e t h e r u s t g r a d e b y o n e o f t h e fo llo w in g p r io r t o cle a n in g :
G SSPC -VIS 1, for ab r a siv e b las t cle a n in g
G SSPC -VIS 3, for h a n d an d p ow er to ol cle a n in g
G SSPC -VIS 4(I), for w a te r jet tin g
G Ch eck for chlorid e ion con tam inant in w ash w ater or w ater u sed in w ater jetting , if su sp ected
G U se C h lor *Rid W te st k it
G P r ep a r a tio n co m p lie s w ith sp ecifica tion m eth od (i.e., N A C E N o. 2/ SSP C -SP 10, N A C E
N o . 3/ SSP C -SP 6, etc.)
G C h eck for ch lor id e io n con ta m in a n t a fte r clea n in g w ith C h lor *Rid te st k it
G D e t er m in e d e g r e e o f s u r fa ce cle a n lin e s s b y o n e o f t h e fo llo w in g a ft e r cle a n in g :
G SSPC -VIS 1, for ab r a siv e b las t cle a n in g
G SSPC -VIS 3, for h a n d an d p ow er to ol cle a n in g
G N A C E N o . 7/ SSP C -VIS 4(I), fo r w a t er je ttin g
C-1
G Su r face p r ofile
G D et er m in e s u r face p r ofile b y N A C E RP 0287
G E n v i r on m en tal co n d itio n s
G A m b ie n t (a ir ) t em p e r a t u r e
G Su b s t r a te su r f a ce te m p e r a t u r e
G Relative h u m idity
G D ew p o in t
G W in d v elo city , if ap p licab le
G C o a t i n g ap p licatio n
G C o atin g m aterial co mp lies w ith s p e cific a tions
G M ixed in acco rd an ce w ith m an u fa c tu re r’s ins tru c tions
G Typ e of ap p lication m ethod u sed
G Ensu re strip e coats are ap p lied before overall ap p lication p roceeds
G T e m p eratu re an d h u m id ity res tric tions
G A ir and su bstrate tem p eratu res are 50 d egrees F or g reater or com p lies w ith the
m a n u f actu r er ’s in str u ctio n s
G Su r face s a r e a m in im u m of 5 d eg r ee s F a b ov e d ew p oin t
G R elativ e h u m id ity w ith in m anu fa c tu re r’s ins tru c tions
G Su rfa ces fre e o f m ois tu re , fro st, a n d ice
G C u r in g
G C o a t ed it e m s a r e n o t m o v e d o r a llo w e d f o ot tr a ffic b e fo r e d r y
G C o m p lies w ith m an u factu rer’s ins tru c tions for te m p e ra ture a n d hu m id ity d u ring c uring p er iod
G Po st a pp licatio n in s p ectio n
G D r y film t h ick n e s s b y SSP C -P A 2
G H olid a y te st in g b y N A C E RP 0188
C-2
Appendix D
ASTM A 123 Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Productions
ASTM A 591 Steel Sheet, Electrolytic Zinc-Cated, Light Coating Weight [Mass] Applications
ASTM A 653 Steel Sheet Zinc-Coated (Galvanized or Zinc-Iron Alloy-Coated (Galvanized) by the Hot-
Dip Method
ASTM D 4138 Field Measurement of Dry Film Thickness of Protective Coating Systems by Destructive
Means
ASTM D 4940 Conductimetric Analysis of Water Soluble Ionic Contamination of Blasting Abrasives
ASTM E 337 Measuring Humidity with a Psychrometer (the Measurement of Wet- and Dry-Bulb
Temperatures)
AWS C2.2 Recommended Practices for Metallizing with Aluminum and Zinc for Protection of Iron
and Steel
D-1
NACE International (NACE)/Society of Protective Coatings (SSPC)
NACE RP 0188 Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates
NACE RP 0287 Field Measurement of Surface Profile of Abrasive Blast Cleaned Steel Surfaces Using
a Replica Tape
SSPC-SP8 Pickling
NACE No.5/ Surface Preparation and Cleaning by High- and Ultrahigh-Pressure Water Jetting Prior
SSPC-SP-12 to Coating
NACE No. 7/ Guide and Visual Reference Photographs for Steel Cleaned by Water Jetting
SSPC-VIS 4
NACE-VIS 9/ Guide and Reference Photographs for Steel Surfaces Prepared by Wet Abrasive Blast
SSPC-VIS 5 Cleaning
D-2
Appendix E
Inspection Equipment
In s p e c ti o n T o o l s :
• Fla s h lig h t
• 1 t o 1-1/ 2 in c h w id e st iff p u t ty k n i fe w it h s h a r p e n e d e d g e
• Kn ife
• Latex gloves
• Plastic booties
• M agn et
E-1
Appendix F
Project: Date:
Coating Category: ________ Total DFT (min.): ______ mils Tab Surface Prep. Method: _________
Primer:
Intermediate:
Topcoat:
Comments:
SURFACE PREPARATION Surface Preparation Method SSPC-SP _____ / NACE No. ______
Used:
Contaminants (ASTM D 4940): Fines __ yes / __ no; Oil __ yes / __ no; pH ____; Conductivity_______
Compressor Air: Type: _____________ ______ CFM Passes ASTM D 4285: ___ yes / ___ no
Surface Profile (NACE RP 0287): No. Measurements Taken ______; Averaged Measured ______
mils
Cleanliness: Chloride Specific Ion: Test Method Used _____________ _; Results _____________
Visual Standards (SSPC/NACE): VIS 1 __ yes / __ no; VIS 2 __ yes / __ no; VIS 4 (I) __ yes / __ no
F-1
COATING DAILY INSPECTION REPORT 2 of 2
Product Gal/Oz %
Environmental Control: Heaters ___ yes / ___ no; Dehumidification ___ yes / ___ no, Unit Size _________
Material Mixing: Power Mixing Time _____ minutes; Induction Time ___ yes / ___ no, _____ minutes
Stripe Coats Applied: ___ yes / ___ no; Method: ___ Bush/Roller ___ Spray
Application Method: ___ Brush; ___ Roller; ___ Airless; ___ Conventional; ___ Plural; ___ Electrostatic
Applied Within Recoat Window: Primer __ yes /__ no; Intermediate __ yes /__ no; Topcoat __ yes /__ no
Wet Film Thickness (WFT): Primer ______ mils; Intermediate ______ mils; Topcoat ______ mils
Comments:
Area Inspected: ___ less than 300 ft2; ___ less than 1,000 ft2; ___ equal to or greater than 1,000 ft2
Number of 5 Spot Measurement Groups Taken Within Above Inspected Area: _____ at _____ 100 ft2 areas
Average of 5 Spot Measurement Groups _______ mils; Conform to Specifications ___yes /___no
Set at _______ volts; Number of Defects Found _______; Defects Repaired ___ yes / ___ no
Comments:
F-2
Appendix G
A . Pu rp o s e
B . Eq u i p m e n t
C . Pro ce d u re
2. Sh u t o ff th e ab ras iv e flo w .
3. P la ce t h e a b so r b e n t m a t e r ia l w it h in 2 4 in c h e s o f t h e d is ch a r g e - p o in t -ce n t e r e d a i r st r e a m a n d
d ow n strea m from th e in-lin e oil and m oistu re sep ara tors.
A ny observ ed contam inan ts on th e cloth or in th e air flow w ill requ ire corre ctive action. Tests
sh o u ld b e p er fo r m ed at t h e b eg in n in g of th e sh ift or after th e air co m p r ess or h a s b een sh u t o ff.
Te st in g is r eco m m en d ev er y 4 h ou r s d u r in g b las tin g op er a tio n s o r m or e fr eq u en tly if h u m id ity is
h ig h .
G-1
Appendix H
A . P u rp o s e
T o d e t ect an d d eterm in e th e lev el o f s olu ble s a lts in a br a s ive s to pre v e nt s ub s tra te d e te riora tion
an d sub sequ ent coating failu re.
B. C o n d u cti v i ty M e t h o d
1. Eq u ip m e n t
2. P r o ce d u r e
a . Ca libr ate th e cond u ctivity m eter a ccord ing to th e m an u factur er’s instru ction s.
b . P la ce e q u a l v o lu m e s of a b r a s iv e m a t e r ia l a n d d is t ille d o r d e -io n i z ed w a t e r in a g l a ss a n d
st ir for 1 m in u te . Let st a n d for 8 m in u te s a n d st ir ag a in for 1 m in u te . A llow th e a b r a siv e
m aterial to settle.
C . C h l o ri d e -S p e c if i c Io n M e th o d
1. Pu rp ose
To d eterm ine th e concentr ation of chlorides in a bra sive m aterials and p rev en t su bstrate
contam ination a nd sub sequ ent coating failu re.
2. Eq u ip m e n t
H-1
3. P r o ce d u r e
a . O v e r fill t h e s m a l l co n t a in e r w it h a b r a s iv e b la s t m a t e r ia l a n d le v e l-o ff w it h t h e m e t a l
snap p er inclu d ed w ith th e kit or w ith a straigh t ed ge.
f. Im m ed iately after th e cotton tip ha s chan ged to an am ber color, rem ove the titration tu be
fro m th e tes t s leev e an d read the c hloride le ve l a t the inte rfa ce of the p ink-w hite color
ch a n g e. W h ite in d icat es th e p r es en ce o f ch lor id e. If n o co lor ch a n g e o ccu r s (r em a in s a ll
p ink ), th e chlor id e leve l is be low th e th resh old d etection lim it of the titration kit. The
chlorid e concentration level is read d irectly from the titration tu be in m icrogra m s per
s q u a r e ce n t im e t er o r p p m .
H-2
Appendix I
A . P u rp o s e
B. Eq u i p m e n t
C. Pro ce d u re
4. A llow the titration tu be to rem ain in th e extracted solution u ntil the solution ha s w icked -up to
t h e t o p o f co t to n w ick e t . Sa t u r a t io n o f th e w ick e t is co m p le t e w h e n t h e c o t to n t ip ch a n g e s to a n
a m b e r co lo r .
5. Im m ed iately after th e co tto n tip ha s c ha ng e d to a n a m be r c olor, re m ove the titra tion tu be from
th e te st sle ev e an d r ea d th e ch lo r id e lev el a t t h e in te r fa ce of th e p in k -w h ite co lo r ch a n g e.
W hite ind icates the p resen ce of chloride. If no color cha ng e occu rs (rem ains all p ink), the
ch lor id e le v el is b elo w th e t h r es h old d et ect ion lim it o f th e t itr a tio n k it. Th e ch lor id e
concentration level is read d irectly from the titration tu be in m icrogra m s per squ are centimeter
or p pm .
I-1
Appendix J
A . P u rp o s e
B. Eq u i p m e n t
H yp od erm ic need le p ressur e gau ge, 0 to 120 p ou nd s per squ are inch (psi) or m ore.
C. Pro ce d u re
1. Blast clean ing e qu ipm en t is to be op era tiona l at the tim e of testing. If m ore th an on e blast h ose
is to be u sed , ope rate all blast h oses.
4. Pr essu re r ead ings sh ou ld be ta ken p eriod ically or w h en blast clean ing e fficiency d ecreases.
N O TE:
2. T h e r e is n o cu r r e n t s ta n d a r d r e fe r e n ce t o d e t e r m i n e b la s t p r e s su r e ; A S TM D 4 264 w a s
w ith d r a w n .
J-1
Appendix K
E n v i r o n m en tal facto rs are d eterm in ed b y va r iou s ins tru m e nts , a nd s om e ins tru m e nts ca n p e rform
m u ltiple fu nctions. Electron ic and d igital instrum ents are becom ing increasing ly m ore accu rate,
fas te r , m or e a ffor d a b le, a n d acc ep ta b le. Th e in st r u m en ts ar e n ot d et a iled b elo w b eca u se of w id e
va riation am on g instru m en t typ es an d becau se of the va riation in the w ay instru m en ts are u sed . Bu t,
a s w it h a n y in s tru m en t, alw ay s fo llo w the m a nu fa c tu re r’s ins tru c tions . The follow ing s e c tions
d e scr ib e th e in s t r u m e n t a n d t h e p r o ce d u r e s t o b e u s e d t o d e t er m in e e a ch e n v i r o n m e n t a l fa ct o r :
A . A m b i e n t Te m p e ratu re b y T h e rm o m e te r
1. D e s cr ip t i on o f t h e P r oce d u r e
a . D e t er m in i n g t h e am b ie n t te m p e r a t u r e b y a s in g l e d ir e ct r ea d in g w it h a t h e rm o m e t er .
2. Eq u ip m e n t
a . A t h e r m o m e t er o r th e d r y b u l b th e r m o m e t er o f a p s y ch r o m e t er .
3. P r o ce d u r e
b . L et te m p e r a t u r e e q u i p m e n t st a b iliz e fo r 1 t o 2 m in u t e s if it w a s b r o u g h t fr o m a p l a ce w h e r e
th e t em p er a tu r e w a s d iffer en t fr om th e a r ea w h er e t h e e q u ip m en t w ill be u se d (e.g ., an air
co n d itio n ed or h ea te d r oo m or n ex t t o s om eo n e's b od y ).
c. A ll instru m en ts are d irect read . For electron ic instru m en ts, follow instru ction s an d en su re
th at th e co rrect m o d e is b ein g u s e d a n d the re a d ing is on the d e s ire d s ca le, d e gre e s F or
Celsiu s.
1. De s crip tio n
a . Determ ining the su rface tem p eratu re of the sub strate to be coated
2. Eq u ip m e n t
K-1
3. P r o ce d u r e
a . P lace th e d ial th erm o m eter o n the s te e l s ubs tra te a nd a llow the te m p e ra ture to s ta biliz e for
ab ou t 2 to 3 m inu tes.
1. De s crip tio n
a . D eter m inin g r elative h u m id ity an d d ew p oin t to a scerta in if eva p or ation w ill occu r. The
su bstrate su rface is to be at least 5 d egrees F abo ve th e d ew p oint.
2. Eq u ip m e n t
a . Psy chr om eter, either slin g or batt ery , and p sych rom etric table an d char ts.
b . Sa t u r a t e t h e w i ck o n t h e w e t b u l b , b u t k e e p t h e d r y b u lb t h e r m o m e t er d r y .
c. W hirl (sling typ e) or op erate fan (battery typ e) un til the th erm om eters stabilize, abou t 20 to
30 second s, and note th e tem p eratu re.
d . R ep e a t s te p s 2 a n d 3 w it h o u t r e -w e t tin g t h e w ick u n t il t w o o r m o r e w e t b u l b r ea d in g s a r e
equ al to the low est temp eratu re obtained .
f. Th e relativ e h u m id ity is d eter m ine d from the inte rse ct of the d ry a n d w e t bulb re a d ings on
p sychro m etric tables or char ts. Psychr om etric tables and charts n orm ally ar e inclu d ed w ith
the in stru m en t.
4. D ew P oin t
(1) D eterm in e th e atm o s p h eric (ba rom e tric ) p re s s ure for your ge ogr a p hica l loc a tion from
U .S. De p a r tm en t o f C om m er ce o r U .S. W ea th er Bu r ea u ta b les . Th e a v er a g e b a r om et r ic
p r es su r e a t s ea lev el is ab ou t 30 in ch es of m er cu r y , an d it w ill av er a g e le ss th a n 30
inche s at h ighe r eleva tions.
K-2
(2) D et er m in e t h e d iffer en ce b et w ee n th e d r y an d w et b u lb te m p er a tu r es . Th e w et b u lb
tem p eratu re is alw ays less than the d ry b u lb. The d ifference is com m on ly called the
“ d ep r ess io n of th e w et b u lb .”
D . Wind
1. De s crip tio n
a . Deter m ining w he n th e w ind velocity can cau se in d ry sp ray , over sp ray , or d am age to
n e a r b y e q u ip m e n t , m e t alw o r k , o r p r o p e r ty .
2. Eq u ip m e n t
3. P r o ce d u r e
K-3
Appendix L
A . P u rp o s e
T o d e t ect ch lo rid e io n s an d th eir co n c e ntra tion le ve l on p re p a re d s urfa ce s or e xis ting s u rfa ce s for
p recoating evalu ation to p reven t sub strate contam ination a nd sub sequ ent coating failu re.
B. Eq u i p m e n t
C. Pro ce d u re
1. T e st a sp o t w h e r e t h e s u r f a ce is r e la t iv e ly s m o o t h . D o n o t p ick ir r e g u l a r s u r fa ce s su ch a s
corrosion p its and w eld sp atter, and d o no t p ick areas betw een d ep ressed and raised su rfaces
becau se these su rfaces m ay allow the solu tion to leak ou t.
2. Pou r the en tire contents from the solution bottle into th e test sleeve.
3. P e a l o ff t h e b lu e b a ck in g f r o m t h e a d h e s iv e s t r ip o n t h e o p e n e n d o f t h e t es t s le e v e a n d
d is ca r d t h e b a ck in g . Re m o v e a ir fr o m t h e t es t s le e v e b y s q u e e z in g b e t w e e n fin g e r s a n d
thu m b. Do n ot sp ill any o f the solution. If solution is lost, d iscard the test sleeve an d the
rem aining solution a nd bega n w ith a n ew kit.
a. H orizon tal and ver tical - Lift the closed end of the test sleeve u p , allow ing th e solution to
flow tow ard s the test surface.
L-1
If th e s olu tio n is le a k in g ou t fr om th e t es t s lee v e, d isca r d th e t es t s lee v e a n d th e r em a in in g
solution an d begin w ith a n ew kit.
6. A fter m assag ing th e solu tion for 2 m inu tes, rem ov e th e test sleeve a n d solu tion from th e test
su r face . To r em ov e t h e t es t s lee v e a n d r et a in th e s olu tio n fro m th e t es t s u r face , th e fo llow in g
p roced u res ar e recom m en d ed for th e va riou s test su rface p osition s:
a. Vertical and over he ad - Low er th e test sleeve, allow ing th e solution to flow tow ard the
closed end of the test sleeve.
b. H orizontal - W ith th e test sleeve laying flat, squ eeze the solution tow ard s the closed end
of t h e t es t s lee v e. Th en , p in ch off a n d lift u p th e t es t s lee v e n ea r th e t es t s u r face , allo w in g
the solution to flow tow ard s the closed end of the test sleeve.
10. Im m ed iately after th e cotton tip ha s chan ged to an am ber color, rem ove the titration tu be
fr o m th e te st sle ev e an d r ea d th e ch lo r id e lev el a t t h e in te r fa ce of th e p in k -w h ite co lo r ch a n g e.
W hite ind icates the p resen ce of chloride. If no color cha ng e occu rs (rem ains all p ink), the
ch lor id e le v el is b elo w th e t h r es h old d et ect ion lim it o f th e t itr a tio n k it. Th e ch lor id e
co n c en t r a t io n le v e l is r ea d d ir e ct ly fr o m t h e tit r a tio n t u b e in m icr o g r a m s p e r sq u a r e
ce n t im e t er o r p p m .
11. Af ter co m p letin g th e test, clean the te s t su rfa ce (s ub s tra te) w ith a c e tone or a lcohol to re mov e
all ad hesive strip resid u e.
• The p resence of brom ide, iod ide, or cyan ide ions can yield a high er concentration level
than the actua l chloride ions extracted from the test surface.
• p H v a l u e s o f le s s t h a n 3 .5 a n d h i g h e r t h a n 1 1 ca n y i e ld a h i g h e r co n c e n t r a tio n l ev e l t h a n
the actua l chloride ions extracted from the test surface.
L-2
Appendix M
A . D e s cri p ti o n
To d eterm ine the an chor p attern d ep th of abrasive blasted sur faces by u se of a sp ring m icrom eter
an d rep lica im p ression tap e.
B. Eq u i p m e n t
C. Pro ce d u re
1. M easu rem en ts are to be ta ken on a sm ooth , flat or cu rv ed p late that is free of su rface dirt,
d u s t, an d ab ras iv e p articles th at w ill d is tort res ults . A n a c cu ra te profile ca nn ot be m a d e on
p itted or p artially coated are as.
2. Select the corr ect rep lica tap e ran ge for th e sp ecified p rofile dep th
a. 0 to 2 m ils, u se coarse
5. Before ap p lying the film to th e blasted sur face, the th ickn ess of the film m u st be sub tracted
from the final read ing. Su btra ction of the film thickness can be accom p lished by o ne of the
follow ing m eth od s:
M-1
a. M eas u re th e rep lica tap e w ith the s p ring m ic rome te r a t the rou nd c utou t portion
o p p o s it e t h e 0.4 in c h s q u a r e w h it e p l a st ic film a n d s u b t r a ct th e r e p l ica film t h ick n e s s b y
on e th e follow ing m eth od s:
(2) Set the d ial ind icator a rm at 8.0 (tu rn ing it cou nter clockw ise from zero) on the
s p r in g m icr o m e t er t o p r o v i d e a d ir e ct r ea d in g .
6. Ap p ly the film to the blasted su rface. The ad hesive backing w ill hold th e film in p lace.
7. W ith a rou nd ed tool (a bar p lastic sw izzle stick has b een foun d to w ork w ell), ru b ov er th e
rou nd cutou t p ortion o f the rep lica tap e w ith m od erate p ressu re. The circu lar area of the
r ep lica ta p e w ill b eco m e d a r k er or g r a y ish , in d ica tin g th e b la st ed p r ofile h a s b een r ep lica te d .
Ensu re the en tire circular area h as u niform ly da rken ed .
8. Rem ove the r ep lica tap e an d p lace it betw een the a nv ils of the sp ring m icrom eter (w ith
cir cu la r a r e a ce n t e r e d b e t w e e n t h e a n v i ls ). G e n t ly r e le a s e t h e t r ig g e r o f t h e m icr o m e t er a n d
t a k e r ea d in g . D e p e n d in g o n t h e g a u g e s e t tin g , eit h e r z e r o o r th e m e a s u r e d r e p l ica t a p e
t h ick n e s s, e n s u r e o r ig in a l r e p l ica t ap e t h i ck n e s s is su b t r a ct e d fr o m r e a d i n g .
9. T h r e e r ea d in g s s h o u ld t a k e n in o n e lo ca t io n w it h in a b o u t 3 in c h e s o f e a ch o t h e r a n d
a v e r a g ed . L oca t io n r e a d i n g s (t h r e e a v e r a g ed r e a d i n g s) s h o u l d b e t a k en o n e v e r y 100 s q u a r e
feet of sur face, or p ortion thereof, to establish consistency of the p rofile.
M-2
Appendix N
A . P u rp o s e
To d eterm ine th e w et coating th ickn ess bein g ap p lied an d to estim ate th e d ry film th ickn ess.
B. Eq u i p m e n t
N O TE: Th e p lastic gau ge s ar e d isp osa ble an d ar e int en d ed for a lim ited n u m be r o f read ing s. The
alum inu m and p lastic gaug es w ill wear d ow n an d becom e ina ccu rate w ith extend ed u se.
C. Pro ce d u re
1. If p ossible, test a flat area . For cur ved su rfaces, test along th e longitu d inal axis, no t the
c urv ed ax is . T est s mo o th areas tha t a re fre e from s urfa ce irre gu la ritie s su c h a s se a m s or
w eld s.
2. Select the m il th ickn ess ran ge a long th e ed ge o f the g au ge for th e an ticipa ted film th ickn ess.
4. Firm ly p ress the g au ge into th e w et coating , ho ldin g th e gau ge p erp en d icu lar to the su bstrate
w it h t h e tw o e q u a l o u t e r p r o je ct io n s r es tin g o n t h e s u b s t r at e . D o n o t tilt o r s cr a p e t h e g a u g e
t h r o u g h t h e w e t co a t in g .
5. Rem ove the g au ge from the w et coating an d no te the sh ortest coated step betw een the
notches. The w et film thickn ess lies betw een th is valve an d the ad jacent u ncoated step.
N-1
Appendix O
A . D e s cri p ti o n
D eter m inin g th e w et film th ickne ss (W FT) to a chiev e a d esired d ry film th ickne ss (DFT)
B. Fo rm u las
Exam p le: The d esired DFT is 8 m ils. The coa ting m ater ial conta ins 83 per cent solid s by
vo lu m e. Dete rm ine t h e W FT to ach ieve a n 8-m il DFT.
O-1
Appendix P
I. P u rp o s e
D e t er m in i n g t h e th i ck n e s s o f a h a r d e n e d c o a tin g .
II. Eq u i p m e n t
The n on d estru ctive gau ges d escribed in SSPS-PA 2 are gr ou p ed into tw o ge n era l categ ories:
III. T y p e I, M a g n e ti c P u l lo f f G au g e
A. De scr i p tio n
Typ e I, m agn etic p u ll off gau ges, com m on ly referred to as “ba na na ” gau ges, m easu re th e
co a t in g t h i ck n e s s o f a n o n - m a g n e t ic co a t in g o v e r a f er r o u s m e t a l s u b s t r a t e. T h e g a u g e h a s a n
exp osed m agn et attached to a sp ring . The am ou nt o f tension ap p lied on the sp ring to lift the
m agn et from the coated su rface is d irectly pr op ortiona l to the d istan ce of the m agn et from the
ferrou s surface.
B. C a l ib r a t io n
1. U se n on m ag n etic, stan d ard calibr ated shim s, com m on ly chro m e. Plastic and m ylar sh im s are
n o t a cce p t a b l e fo r ca lib r a t in g p u ll o ff g a u g e s b e ca u s e p l as t ic o r m y la r is n o n a d h e r e n t a n d
m a y ca u s e t h e m a g n e t w it h in t h e g a u g e t o lift p r e m a t u r e ly .
2. Select a shim that w ill be in th e ran ge of the expected d ry film th ickn ess to be m easu red .
3. Place the shim on the p rep ared su bstrate o r an y clean bar e steel an d p lace the g au ge on the
sh im .
6. If th e rea d ing d oes n ot ag ree w ith th e sh im th ickn ess, ch eck th e m ag n et for clean lin ess.
P-1
8. The gau ge is to calibr ated before u se, du ring u se, and after u se to v erify accur acy of rea d ings.
C . P r o ce d u r e
1. E n s u r e t h e m a g n e t is cle a n .
b. Soft or tacky coatings m ay inh ibit the lifting of the m agn et.
4. R ea d t h e co a t in g t h i ck n e s s o n t h e d i a l t h a t a lig n s w it h t h e m a r k e d lin e o n t h e g a u g e a n d
r e co r d t h e r e a d i n g .
A . De sc r ip tio n
The ty p e II, fixed or con stan t p ressu re p rob e gau ge, m easu res th e m agn etic flu x associated w ith
n on -m ag n etic coating s ap p lied to ferro u s su bstr ates. For reliable read ings, th e ga u ges m u st
r e m a in i n d ir e ct co n t a ct w it h t h e co a t e d s u r f a ce u n t il a r e a d i n g i s o b t a in e d . T h e se g a u g e s a r e
n orm ally faster an d m ore accur ate th an th e m ag n etic p u ll off gau ges.
B. C a l ib r a tio n
2. Select a shim that w ill be in th e expected ran ge of the d ry film th ickn ess to be m easu red .
3. Place the shim on the p rep ared su bstrate o r an y clean bar e steel an d p lace the g au ge on the
sh im .
4. P la ce th e g a u g e fir m ly a g a in s t th e s h im a n d o b t ain a r e a d i n g .
5. If the r ead ing d oes n ot agr ee w ith the sh im thickness, ad ju st the g au ge in accord an ce w ith the
m an u factur er’s instru ction s. A d ju stm en t is nor m ally cond u cted by p ressing key s to ad ju st
u p w ard or d ow nw ard u ntil the gau ge rea d ing an d the sh im thickness ar e in agr eem en t.
C. P r o ce d u r e
1. E n s u r e t h e p r o b e i s cle a n .
P-2
4. R e ad th e co atin g th ick n es s o n th e d igita l d is pla y. Som e ga u ge s w ill s tore se ve ra l re a dings for
d ow n load ing in to p rinte r an d m ay be cap ab le of avera ging rea d ings.
Exam p l e :
Step 1: Det erm ine th e n u m ber of sp ot m easu rem en ts req u ired on an are a ba sis.
Su rface area of stru cture: 26 feet x 10 feet = 260 squ are feet
P-3
Ste p 4: D ete r m in e m in im u m an d m a xim u m acce p ta n ce th ick n ess cr iter ia .
a. The sp ecified coating thickn ess is 19 mils. The allow able criteria are:
b. The follow ing evalu ates the resu lts for thickness accep tance:
(2) Aver age sp ot m easu rem en ts that a re less than the 90 per cent m inim u m of the
sp ecifie d th ick n es s o f 17.1 m ils a t s p ot m ea su r em en t D on th e lo w er g a te ar ea (16.9) ar e
not acceptable.
(3) Av erage sp ot m easu rem ents tha t are greater th an the 150 percent m axim u m specified
th ick n es s o f 28 .5 m ils at sp o t m e a s ure m e nt E on the u p p e r ga te a re a (30.2) a re not
accep table.
Step 5: From the abo ve eva luation, the follow ing can be conclud ed :
On e averag e sing le sp ot m easu rem ent (D) on the low er gate area w as less than th e 90 p ercent
m inim u m , and one av erage single spot m easu rem ent (E) on th e u p p er gate area w as greater
tha n th e 150 per cent m axim u m . Therefore, the coating th ickn ess d oes n ot conform to the
m inim u m and m axim u m thickn ess requ irem ents an d is not acceptable.
P-4
Appendix Q
I. P u rp o s e
To locate p inh oles an d oth er d efects in h ard en ed coating u sing low or h igh v oltage in stru m en ts.
II. U s i n g a Lo w V o l t ag e In s t ru m e n t f o r C o ati n g T h i ck n e s s e s o f 2 0 M i l s a n d Le s s
A . De sc r ip tio n
A l o w v o ltag e, n o rm ally b etw een 5 and 90 volts D C , ba ttery p ow e re d d e vice w ith a w e t s pong e
electric p rob e is d rag ged across the coated su rface to locate d iscon tinu ities (p inh oles) in the
coating film . Shou ld d iscontinu ities be encou ntered , an electric curren t w ill flow to the steel
su b st r a te . Th is p r oc es s w ill clos e a n ele ctr ical cir cu it w ith in th e in st r u m en t a n d se t o ff an au d ib le
o r v is u a l a la r m .
B. Eq u ip m e n t
a. Electrom agn etic-sensitive or a solid state electronic relay circu it tha t, w he n d iscon tinu ity
is d et ect ed , clos es th e cir cu it a n d p r od u ces an au d ib le o r v isu a l ala r m . Ge n er a lly , th is
instrum ent can b e field ad ju sted .
b. A n ele ctr on ic re lax at ion os cillato r cir cu it m ea su re s th e d ro p in ele ctr ical r es ista n ce
betw een th e coating and the steel sub strate and p rod u ces an a u d ible alarm w hen
d iscontinu ity is detected. Genera lly, this instru m ent typ e canno t be field ad ju sted .
C. P r o ce d u r e
4. Attach th e electrical grou nd (neg ative) w ire from the instru m ent to the steel su bstrate.
Q-1
N ote:
a. A l ow -s u d s in g w e t tin g a g e n t s u ch a s th a t u s e d i n p h o t og r a p h ic d e v e lo p m e n t ca n b e
ad d ed to th e p otab le w ater at a r atio of ½ fluid ou n ce to 1 gallon of w ater to increa se
s en s it iv it y .
b. The u se of d etergen t w etting solu tions is not p erm itted because a bu bble m ay form over
a d efect, rend ering it un d etectable.
8. T h e sp o n g e sh o u ld b e k e p t sa t u r a t ed , b u t n o t d r ip p in g w e t , w h i le m o v i n g o v e r th e co a t in g .
10. If w etting solu tions are u sed , the solu tions m u st be com p letely rinsed off before ap p lying the
r e p a ir co a t in g .
III. Usi n g Hig h V o ltag e I n s tru m en t fo r C oating T hic kne s s of G re ate r T han 20 M ils
A . De sc r ip tio n
B. Eq u ip m e n t
b. D i re ct cu r r e n t — d is ch a r g e s co n t in u o u s v o lt a g e
Q-2
C. P r o ce d u r e
2. If m oisture is p resen t on the coated su rface, d ry th e su rface before testing b ecau se m oisture
w ill in d icate inv alid d iscon tinu ities.
5. Attach th e electrical grou nd (neg ative) w ire from instrum ent to the steel su bstrate.
8. Using a sing le p ass, m ove th e p robe ov er the coated sur face at a rate of abou t 1 foot p er
se co n d .
9. W he n a d iscon tinu ity is d etected, m ark the sp ot for rep air. Use a grea seless m ark er th at be
ea sily clea n ed off.
Q-3
Appendix R
A . P u rp o s e
To d eterm ine the ad hesive strength betw een a fu lly cur ed coating and the su bstrate.
B. D e s cri p ti o n
C. Eq u i p m e n t
Th ere ar e sev era l d ifferen t typ es of p u lloff ad h esion tester s. The ty p e II tester , cited in A STM D
4541, ann ex A.2, is the Elcom eter M od el 106. This mod el is the m ost com m only u sed . Elcom eter
M od el 106 is available in six scale ran ges. The scale m ost com m only u sed is 0 to 1,000 pou nd s per
sq u a r e in ch (p si), a n d it is d iscu ss ed b elo w . A st a n d a r d 3/ 4-in ch -d iam et er alu m in u m d olly is
u se d w ith th e E lcom et er M od el 106.
D . Pro ce d u re
R-1
" C o n c a v e - o u t e r r a d i u s (e xa m p l e : p i p e e xt e rio r )
" C o n v e x - in n e r r a d iu s (e xa m p l e : p i p e in t e r io r )
5. W ipe clean an y gr it and rep eated ly solven t w ipe on the test sp ot.
9. R em o v e a n y e xce ss ep o x y a r o u n d t h e p e r ip h e r y o f t h e d o l ly w it h o u t d is tu r b i n g t h e d o l ly .
N o te: D o llies ap p lied w ith in s uffic ie nt a d he s ive or not pe rp e nd ic ula rly p os itione d a re no t
accep tab le and w ill pr ov id e err on eou s resu lts.
A fter the ep oxy h as cur ed , m ake a circu lar cut th rou gh the coating to the su bstrate a rou nd the
d olly w ith the cu tting tool tha t is p rov ided w ith the tester kit. The cu tting tool fits over the
d o lly . K its are p ro v id ed w ith a s m a ll d ia m e te r ba r to a ss is t in th is ope ra tion.
12. If testing a flexible coating or su bstrate, p lace the su p p ort ring over the test d olly. Set the
d rag in d icato r (s teel p in p ro jecting th rou gh a s lit on the s ha ft a t the s ca le ra ng e ) to z e ro.
N ote: Sho u ld th e tester be tilted , on e of the feet not be secu re, or the b earing of the
in s t r u m e n t b e u n e q u a l , a s h e a r in g f o r ce m a y b e im p a r t e d t o t h e co a t in g , r es u l tin g i n a n
e r r o n e ou s r e a d i n g .
14. Slow ly an d con tin u ou sly r ot a te th e t es te r h a n d w h ee l in a clo ck w ise d ir ect ion u n til t h e d olly is
p u lled free or a sp ecified m axim u m tension is achieved .
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15. R e ad th e h ig h es t v alu e attain ed a t the bottom of the d ra g ind ic a tor in ps i. If the d olly d id not
p u ll fre e, r ep or t t h e r es u lt a s g r ea te r th a n th e m a xim u m cap a city of t h e in st r u m en t (i.e., 1,000
p si fo r th e E lcom et er M od el 106).
16. Alw ays reset the d rag ind icator to zero after testing. Failu re to reset w ill resu lt in a d istorted
o r p e r m a n e n t ly d a m a g e d h e l ica l s p r in g .
17. Repor t one or a com bination of the follow ing typ es of failu re:
• A d h e siv e
• C o h es iv e
• G lu e
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Appendix S
A . P u rp o s e
To d eterm ine the ad hesive strength betw een a fu lly cur ed coating and the su bstrate.
B. D e s cri p ti o n
The ad hesion tester u ses a hyd rau lic system to m easu re the relative streng th of ad hesion betw een
a co a t in g a n d t h e su b s t r a te o r b et w e e n c o at in g l ay e r s. A u n i fo r m t en s ile lo a d i s a p p lie d t h r o u g h a
ho le in th e center of a p u ll stu b u sing a h yd rau lic piston a nd p in. An alum inu m p u ll off stu b
(dolly) is ad hesively bond ed to the coating and allow ed to cure. A p u lling force on th e bon d ed
d o lly is co n tin u o u sly in cr ea se d u n til th e d olly d eta ch es o r a sp ecific fo r ce is a ch iev ed .
Rep rod u cible resu lts are ach ieved becau se the ap p lied tensile load is consistent.
C. Eq u i p m e n t
The self-align ing ty p e III tester cited in A STM D 4541, ann ex A 3, is the H ate M ark VII. Testers ar e
a v a ila b le in th e fo llo w in g th r ee r a n g es: (1) 0 t o 1,500 p si, (2) 0 to 2,250 p si, a n d (3) 0 t o 3,000 p si.
D . Pro ce d u re
" C o n c a v e - o u t e r r a d i u s (e xa m p l e : p i p e e xt e rio r )
" C o n v e x - in n e r r a d iu s (e xa m p l e : p i p e in t e r io r )
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4. C l ean th e b o n d in g s u rface o f the loa d fixture , the Te flon p lu g, a nd the c oa ting a r e a to be
tested w ith solven t.
5. Ligh tly sand the test ar ea to achieve a n ev en , sm ooth su rface and w ipe clean. Rep eat th e
solven t w ipe.
6. Insert the teflon p lug into th e load ing fixtur e u ntil the p lug tip p rotru d es from the su rface.
7. A p p ly a thin coat of ad he sive ep oxy to th e bon d ing su rface of the fixtu re, taking care n ot to
g e t e p o x y o n t h e p lu g .
9. Rem ove the teflon p lug an d allow the a d he sive ep oxy to cu re in accord an ce w ith the
m an u factur er’s instru ction s.
11. E n s u r e th e g au g e is s et at zero .
12. In c reas e th e p res s u re s lo w ly b y tu rning th e ha n d le cloc kw is e un til the fixture p u lls fre e or
u ntil a sp ecified p ressur e is achieved .
14. Repor t one or a com bination of the follow ing typ es of failu re:
• A d h e siv e
• C o h es iv e
• G lu e
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Appendix T
A . P u rp o s e
To d eterm ine the d ry film th ickn ess and the n u m ber of ind ivid u al coats of a coating system
B. D e s cri p ti o n
C. Eq u i p m e n t
D . Pro ce d u re
3. A fter selecting the p rop er cu tting tip, p lace the cu tting tip a nd tw o gu ide stu d s against th e
coa tin g su rfa ce, w ith th e cu tt in g tip ju st a b ov e t h e m ar k ed lin e. A lign th e fo re ar m to cu t
across (p erp end icu lar to) the m arked line. Draw the forearm straigh t back w ith su fficient
p r es su r e t o cu t co n tin u ou sly th r ou g h th e co a tin g in to th e s u b st r a te . M a in ta in th e t h r ee p oin t
surface co n tact (cu tter an d 2 g u id e s tud s ) to e ns ur e a s tra ight a n d ve rtic a l c ut. The le ngth of
cut into the su bstrate need s to extend slightly beyon d the m arked line.
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4. View th e cu t th ro u g h th e lig h ted 50X m ic rosc ope a nd foc us on the c oa ting on e ithe r s id e o f
th e e xp os ed su b st r a te . Focu s a n d alig n th e r et icle s ca le p er p en d icu lar to th e cu t. Th e co a tin g
on on e s id e o f th e cu t w ill be sm oo th er th a n on th e o p p os ite sid e o f th e cu t. If th e cu tt in g tip
w as correctly p osition ed , the sm ooth er sid e w ill be on th e left. Alw ays m easu re on the
sm oother sid e.
2X 0.5 mil
1X 1.0 mil
• W he re th e p rim er is an inor gan ic zinc or galva nized zinc, it is d ifficult to d istingu ish the
zinc from the su bstrate. To d ifferen tiate betw een steel su bstrate and zinc, u se a 5 p ercent
solu tion o f copp er su lfate and d istilled w ater. The steel sub strate w ill tu rn a copp er
co lo r , a n d t h e z in c w i ll t u r n b l a ck .
• Fo r d a r k - co lo r e d c oa t in g s , u s e a liq u i d e r a s e r w h i te -o u t in s t ea d o f t h e fe lt tip m a r k e r .
• The th ickn ess of coating chips can be m easu red by v iew ing th e cross section of the
co a tin g ch ip th r o u g h th e To ok e g a u g e. (Ea ch d iv ision is e q u a l to 1 m il.)
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Appendix U
A . P u rp o s e
B. D e s cri p ti o n
C. Pro ce d u re
2. D e t er m in e t h e r u s t d is tr ib u t i on a n d t h e p e r ce n t a g e o f r u s t b y th e fo llo w in g .
a. Ch oose th e ru st d istribu tion (sp ot, gen era l, or p inp oint) for th e selected are a th at m ost
clo s e ly m a t ch e s t h e co r r e s p o n d in g c o lo r o r b la ck a n d w h i te p h o t o g r a p h .
b. Select the p ercentag e of ru st for th e eva luated area th at m ost closely m atches th e
co r r e sp o n d in g p h o t o g r a p h . R u s t s ta in i n g o r d i r t w it h t h e a p p e a r a n ce o f r u s t is n o t t o b e
in c lu d e d . Ru s t u n d e r th e co a t in g a n d b r o k e n b lis te r s w it h a p p a r e n t r u s t a r e to b e
inclu d ed . N on bro ken blisters are to b e d efine d by th e follow ing an d inclu d ed in the
p ercentag e of ru st:
(1) Ru st filled b lister (de term ined by o p en ing b lister) is to be incorp orated in the
p ercentag e of ru st.
(2) Flu id filled b lister (de term ined by o p en ing b lister) is not to b e incorp orated in the
p e r c en t a g e of r u s t , b u t it is to b e r eco r d e d s ep a r a t e ly .
3. De term ine th e ru st gr ad e accord ing to table 1 of the stan d ard . For exam p le, th e ru st
d is t r ib u t io n a r e a w a s d e t e r m in e d t o b e “s p o t ,” a n d t h e p e r c e n t a g e o f r u s t w a s “ g r e a te r t h a n
0.3 p er ce n t t o 1 p er ce n t;” th er efo r e, th e r u st g r a d e is “ 6-S.”
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Appendix V
A . P u rp o s e
T o d e t e r m i n e w h e t h e r t h e co a t in g c o n t a in s le a d .
B. D e s cri p ti o n
C. Eq u i p m e n t
1. C l ea n a n d r e m o v e a ll d u s t a n d d ir t fr o m t h e t es t a r e a .
2. Cu t abou t a 1/ 4 inch n otch throu gh all coating layers and expose th e sub strate.
3. Activate the sw ab by crush ing the g lass am p u les m arked “A ” an d “B” on the sw ab tu be.
6. Results
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7. N eg a tiv e t es t r es u lts sh ou ld b e co n firm ed b y u sin g th e “ Te st C on firm a tio n C a r d ” th a t is
includ ed w ith th e kit. Th e card h as ind ivid u al circles on o n e face, an d each circle con tains a
s m a ll a m o u n t o f le a d .
a. W ith th e u sed sw ab, squeeze a d rop onto r eagen t w ithin th e test circle.
c. If p ink o r re d d oes n ot ap p ear on th e circle, th e n ega tive test re su lt is inv alid, an d a rete st
is r e q u i r ed u s in g a n e w s w a b a n d t e st a r e a .
9. R ed b le e d i n g v e r s u s p in k - o r r ed -co lo r e d s w a b
" Cru sh th e colorless solu tion in glass am p u le “B” on ly and squ eeze a d rop on to the
s w a b t ip . Sw a b t h e t e st a r e a . If r e d a p p e a r s , it in d ica t e s b le e d i n g i s o ccu r r in g a n d
the p resence of lead canno t be confirm ed .
• If the coating is bleed ing red an d lead is su sp ected bu t cann ot be con firm ed , the
m a n u fa ct u r e r r e co m m e n d s o n e o f t h e fo llo w in g m e t h o d s to co n f ir m t h e p r e s e n c e o f le a d :
" U se a sod ium su lfid e solu tion su p p lied sep ara tely by th e m an u factur er a t a n ew test
area. If the test ar ea tu rn s black, lead is p resen t.
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Appendix W
A . P u rp o s e
B. D e s cri p ti o n
C. Eq u i p m e n t
1. C l ea n a n d r e m o v e a ll d u s t a n d d ir t fr o m t e st a r e a .
2. Cu t abou t a 1/ 4 inch n otch throu gh all coating layers and expose th e sub strate.
3. Activate the sw ab by crush ing the g lass am p u les m arked “A ” an d “B” on the sw ab tu be.
5. Ru b th e clear solu tion o n th e tip in th e exp osed coating n otch for 30 second s.
6. Results
a. If the sw ab tip or th e test sur face tu rn s p ink or p u rp le, chrom ate is pre sent.
W -1
c. If p in k o r p u r p le d o e s n o t a p p e a r o n t h e cir cle , t h e n e g a t iv e t e st r e su lt is in v a l id a n d a
r e t es t is r e q u i r ed u s in g a n e w s w a b a n d t e st a r e a .
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Appendix X
A . O b j e cti v e s
1. Id en tify ty p e of toxic m etals tha t m ay be in th e p aint o n existin g infra stru ctu res.
3. The resu lts of the an alysis of the existing p aint are requ ired b efore the p aint can be rem oved
fo r :
• P r ed es ig n sp ecifica tio n d a ta g a th er in g
• P r e m a i n t en a n c e w o r k
• W o rk er p ro tectio n
• Protection o f the en vironm ent
• P ro p er d isp o sa l o f th e old p a in t
B. S am p l i n g
1. T a k e p a i n t sa m p l e in a b o u t a 2- t o 3-in c h s q u a r e
2. M ak e su re th e sam p le in clu d es th e p rim er (p rim er con tains m ost toxic m etals)
3. Sam p le in a t least thr ee locations to v erify resu lts
4. Place th e s am p les in s ep arate b a gs a nd la be l e a ch ba g for ide ntific a tion
5. A su itable tool for sam p ling is a shar p ened ½- to 1-inch w ood chisel
1. T h e p r im a r y m e t als to t es t fo r :
• C o b a lt , a s so cia t ed w it h b lu e i sh a n d g r e en i sh c o lo r s
• C a d m iu m , a s so cia t ed w it h s a fe t y co lo r s
• C h r o m iu m , a s so cia t e d w it h le a d c h r o m a t e , z in c ch r o m a t e , a n d s a fe t y co lo r s le a d
• L e ad
• Z i n c (d e fin e d a s a to x ic m e t a l o n l y in t h e St a t e o f C a lifo r n i a )
2. T h e se co n d a r y m e t als to t es t fo r :
• A r se n ic
• Ba r iu m
• Ber y lliu m
• Sele n iu m
• Silver
• Va n a d iu m
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3. Requ est resu lts in p ercen t, by w eigh t of m etal, an d to at least th ree sign ifican t d igits.
4. T y p ical tes t m eth o d s are EP A 6010B, EPA 7420 (le a d s pe c ific ), O SH A 125G m e ta l s ca n, IC P , or
p or ta b le XRF in st r u m en t fo r lea d on ly (re q u ir es cer tifie d op er a to r ).
D . Co s ts
A bou t $20 to $25 for ea ch m etal tested —re d u ced cost for sev era l m etals.
E. T e s t Lab o rato ri e s
• Bu r ea u of R ecla m a tio n , Eco log ical R es ea r ch an d In v es tig a tio n (D -8220); con ta ct: C h r is
H old r en ; tele p h on e: (303) 445-2178
• E n v ir o n m e n t a l L ea d L ab o r a to r y A ccr e d i ta t io n P r o g r a m ( EL LA P )
• N a t io n a l L ea d L ab o r a to r y A ccr e d i ta t io n P r o g r a m ( N L LA P )
3. W ebsite A d d ress: w w w .aiha .org (accr ed ite d lab or a to r ies ar e lis te d b y city an d Sta te in
table form at)
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Mission Statements