Section 3

Surface Contaminants and Tests for

Detection
3 Surface Contaminants and Tests for Detection
Any contaminants left on a prepared substrate will affect the adhesion of a
coating to that substrate and therefore specifications often request that certain
tests are done to ensure that contamination is within set criteria. Some tests
are qualitative and some are quantitative. A qualitative test is one, which give a
result as accept/reject, pass/fail, go/no go, whereas a quantitative test is one,
which gives a result in known units eg milligrams/m2.

Test for soluble iron salts

This is a qualitative test, it will not even differentiate between the salts. It will
detect the presence of either sulphates or chlorides.

This test is known as the potassium ferricyanide test, although it is now under a
new universal naming system, known as potassium hexa-cyanoferrate, a name
more descriptive of its formula.

Test papers, usually Whatman No.3 laboratory filter papers are soaked in a 5-
10% solution of potassium ferricyanide and distilled water and left to dry. The
result is a lime green paper, fringed with an orange brim.

The area of blast to be tested is sprayed with a fine mist of distilled water, (any
other water is likely to contain dissolved salts) and left a few seconds to allow
the salts, if present, to dissolve and form a solution.

A potassium ferricyanide test paper is then applied to the area and by capillary
action draws up the solution like blotting paper.

If there are any dissolved salts they react with the potassium ferricyanide to
form potassium ferrocyanide. The ferrocyanide is Prussian blue and shows as
blue spots on a lime green background.

Test to detect soluble chlorides

The test for detecting chloride salts is known as the silver nitrate test.

As with the previous test a solution of silver nitrate, 2% with distilled water is
made and the Whatman papers cut into strips.

The strips are then soaked in the solution and pressed onto the area under test
for about 20 seconds, then washed in distilled water.

The reaction between silver nitrate and any chloride salts present produces
silver chloride, which remains on the strip after washing.

If the strip is then dipped into photographic developer the chlorides show up as
black/brown.

ATC88-40915
Surface Contaminants and
Tests for Detection 3-1 Copyright © TWI Ltd
 Other tests for salts
1 Merkoquant
A salts/distilled water solution is made and by swabbing an area of 150mm
x 150mm, using approximately 22.5ml. Merkoquant strips, which consist of
a small disposable plastic strip and a chemically impregnated cotton pad,
are then dipped into the solution and the resulting colour change is
compared to a master chart on the container. The concentration level of the
salt contamination is read directly from the chart.

2 Bresle sample patch

A test with a reported accuracy of approximately 95%. An adhesive patch
with a rubber diaphragm is firmly affixed to the substrate and distilled water
is injected by hypodermic needle through the side of the patch. The distilled
water is extracted and injected several times to produce a solution of any
salts present. By measuring the electrical conductivity change in the
solution, the level of salt contamination can be determined. It is a
quantitative test.

3 Salt contamination meters

Salt contamination meters measure the resistivity or conductivity of a given
sample and convert this value into a concentration (mg/m2).

With any of the above tests, if the amount of salts present is greater than
specified, the area should be washed down with copious amounts of clean
water, reblasted and retested.

Test to detect the presence of mill scale

Mill scale being cathodic in relation to steel can cause corrosion cells under a
paint film and subsequent early disbondment. Millscale in small quantities is
permitted on a SA2½ blast standard, but not on an SA3. Therefore the test
needs to be carried out only if the specification requires an SA3.

Blasted steel is dark grey in colour and mill scale is dark blue, so by naked eye
the contrast is difficult. However, if the surface is sprayed with a fine mist of
slightly acidic copper sulphate solution, the solution ionises and tints the steel
copper colour and blackens the mill scale, if present, thus providing a better
contrast.

If this test indicates mill scale presence then it should be reblasted and then
retested.

Test to detect the presence of dust on a substrate

Any dust on a blasted substrate will adversely affect the adhesion of a paint
film. In conditions of low relative humidity, dust and finings passing down a
blast hose become electrostatically charged and stick onto the substrate.
Brushing or air blowing the surface will not remove them, self-adhesive tape
however, will.
If a piece of self-adhesive tape is stuck onto the surface and snatched off, the
dust/finings sticks to the tape. By then sticking the tape onto white paper the
dust can easily be seen.

ATC88-40915
Surface Contaminants and
Tests for Detection 3-2 Copyright © TWI Ltd
 Test to detect the presence of moisture on a substrate
Presence of moisture, even in the teeniest amount, can affect the choice of
paints and if work can be done or otherwise.

A very simple test for the presence of moisture is to sprinkle with talc or
powdered chalk and then lightly blow away. The powder will stick to areas
where moisture is.

Test to detect the presence of oil or grease

Other than ultra violet light, oil and grease can be detected by dropping solvent
onto the suspect area and absorbing the solution on Whatman or blotting
paper. The solvent will evaporate and oil or grease will give a darker
appearance.

ATC88-40915
Surface Contaminants and
Tests for Detection 3-3 Copyright © TWI Ltd