2 - 06 FROSIO Pre - Certification

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Team No.1 Module 2.06 CA Pre-certification
Level 2 / Module 2.06 CA Pre-certification Slide 1 of 168

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FROSIO certification
• In order to be certified by FROSIO, the candidates must participate
in an 80-hour long compulsory training course
• The certification is a confirmation that the person has the knowledge
and experience stipulated in Norwegian Standard NS 476 Paints
and coatings – Approval and certification of surface treatment
inspectors
• The curriculum for the compulsory training course is given by NS
476, and only training bodies approved by FROSIO are accepted to
run such courses
• Having completed the 10-days / 80-hours training course,
candidates must pass an exam conducted by FROSIO, consisting of
a theoretical and a practical part
• The amount of relevant experience a candidate possess will
determine which level of certification he / she may obtain

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Purpose
• Jotun’s approved FROSIO course consists of 17 training modules,

addressing all the requirements of NS 476
• The purpose of this Team No.1 module is to prepare candidates for
participating in the separate 10-days training course which is
compulsory before sitting the exam for FROSIO certification.
• A number of the subjects required by FROSIO were introduced in
some of the Level 1 modules (Basic 1, 2 & 3).
• This module continues to build on the Level 1 basic modules,
introducing additional topics and further details, but it will still only
give a superficial cover of the content in the 17 modules in the
FROSIO course, and will thus not qualify a candidate to sit the
FROSIO exam

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Content
1. The duties of an
inspector 8. Passive fire protection
2. Corrosion 9. Paint film defects
3. Surface preparation 10. Technical data &
4. Ambient conditions calculations
5. Paints and coatings 11. Inspection work &
equipment
6. Application
12. SHE
7. Metallic coatings
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The inspector’s role

• The paint inspector is a key person in the QA
system.
• He performs the practical QC work at the yard.
• However, the inspector’s prime role is to protect
his employer’s interests. The inspector must
never forget whom he works for (who pays his
salary)
• Usually the inspector has no formal authority in

relation to the yard and contractor

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The challenge for the paint inspector

• To ensure that the coating
specification is met
• To verify the quality of work
carried out by the
contractor/yard.
• To prepare written records of
the standard of the work
– Approval (Good enough?)
– Not acceptable (non-
conformance)
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A First Class Professional CA will:
• be one of the best assets a company can have in terms of

promoting its products and services
• be polite and respectful, calm and firm, reliable and honest, and
represent his employer in a diplomatic way
• communicate extensively with all parties in a project
• perform his duties in such a way that he contributes to constructive
measures to be taken (i.e. seek a solution), instead of taking an
indifferent (or negative) approach
• whenever circumstances force compromises to be the only
solution, he ensures that this is properly authorised, recorded and
reported

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ISO 12944 Paints and varnishes - Corrosion protection

of steel structures by protective paints systems.
Part 1 General introduction.

Part 2 Classification of environments.
Part 3 Design considerations.
Part 4 Types of surface and surface
preparation.
Part 5 Protective paint systems.
Part 6 Laboratory performance test methods.
Part 7 Execution and supervision of paint work.
Part 8 Development of specifications for new
work and maintenance.

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Extracts from ISO 12944 - 7
6.1 General
• The execution of the work shall be supervised at all stages. Supervision
shall be undertaken by suitable qualified and experienced people. The
contractor shall be responsible for carrying out this supervision himself,
but additional supervision by the client – even for corrosion protection in
the workshop – is advisable.
• When coating material with which the contractor is unfamiliar are to be
applied, the manufacturer of the coating material shall be consulted.
• The level of supervision will depend on the type and importance of the
project, the degree of difficulty of the work and local conditions, and on the
type of coating and its intended service life. This supervision will require
appropriate technical knowledge and experience.

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6.3 Checking the paint coating

• Coatings shall be checked for compliance with the
specification, for example:
– By visual assessment, e.g. for uniformity, colour, hiding power
and defects such as holidays, wrinkling, cratering, air bubbles,
flaking, cracks and curtains
– By means of instruments for compliance with the following
characteristics of the dry film, if required:
• DFT: generally by non-destructive methods
• Adhesion: by destructive methods
• Porosity: by low or high-voltage detectors

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6.3 Checking the paint coating (cont’d)
• For DFT measurements, the parties concerned shall agree on the
following:
– The method to be used (instrument, calibration, surface profile, etc.)
– The sampling plan (how and how many measurements)
– How the results are to be reported and how they are to be compared
with acceptance criteria
• Dry film thicknesses (including the nominal and maximum

thicknesses) shall be checked at each critical stage, and when the
complete system has been applied. A critical stage is, for example,
when there is a change in the responsibility for the paint work or
when a long time elapses between application of priming coats and
subsequent coats.
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The importance of reports
Purpose
• In cases where more than one inspector are assigned to
a project, the records provide a history of the work
• In case of premature failure of a coating, inspection
records can assist during the investigation of the cause
• Inspection records can ensure that deviations from the
spec (error) are corrected before final acceptance /
approval of the work.

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Typical content of the daily reports
• Steel temperature
• Air temperature • Area, m²
• % Relative Humidity
• Product name, place of
• Dew point production and batch no.
• Object no. and name
• Name of relevant personnel
• Exact specification
• What was discussed
• Pre-treatment, specified and
actually conducted • Non conformance report
• Film thickness (to be (remember signatures)
measured also at spot repair) • Other comments

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Example of daily log content for newbuilding
• Client and external company

• Drawing or part number
• Size of the object, procedure, references
• Rust grade, cleanliness (ISO8501-1) and
roughness (ISO8503-1) of the steel
• Type of abrasive and particle size
• Date and time of start / finish of surface preparation
and painting
• Type of paint, batch no., colour
• DFT measurement & requirement for each coat
• Signature of approval
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Content
1. The duties of an
equipment
6. Application
12. SHE
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Production and degradation of steel

Reaction between the material and
the surrounding environment takes place
Plates, pipes,
profiles, etc.
Raw material
Iron ore Rust
The presence of water / humidity
and Oxygen is a pre-requisite for
corrosion of steel

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Corrosion
Corrosion: Parameters influencing

• A chemical reaction the corrosion speed:
between a metal and its • Humidity
surrounding environment • Temperature
under the formation of • Concentration of salts
corrosion products • Amount of air pollution
including
– acid rain
– soot
– dust particles

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The corrosion process: A galvanic cell
• Metals exposed to seawater

will obtain different
electrochemical potentials
• If two differently charged
metals are brought in contact a
current will start to flow
between them
• Electrons will transport current
between the metals and ions in
the electrolyte
CP and corrosion: Corrosion_cell1

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Pre-requisites for corrosion
A galvanic cell consists of:
• A Cathode:
– The noble metal / alloy (or part of metal)
• An Anode:
– The less noble metal / alloy
• An electrical connection
– between the two metals, conducting electrical current (by
electrons)
• An electrolyte:
– Conducting electrical current (by ions)

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What happens at the anode

and the cathode?
• At the anode:
The metal is dissolved in the electrolyte
• At the cathode:
Usually, oxygen and water is absorbed, and alkali is
produced (OHˉ -ions)
(Electrons are involved, they go from the anode

to the cathode via the metallic conductor)

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Anode & Cathode
• Anode: metal surface (positively charged) where

corrosion take place. This is the electrode where
oxidation occurs. Electrons flow away from the anode in
the external circuit. Corrosion will occur at the anode
and metal ions enter solution.
• Cathode: metal surface (negatively charged) where

reduction take place. This is the electrode where
reduction occurs. Electrons flow toward the cathode in
the external circuit. Oxygen is reduced at the cathode
so it will not corrode

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Electrolytes
• Consists of water or moisture which conducts electricity
by way of charged molecules: positively and negatively
charged ions
• Examples: Seawater, soil, acids, alkalis, concrete,

humid wood, salt solutions
A sugar solution is not an electrolyte
• The more ions in the electrolyte, the better the

conductivity

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Galvanic Series in Sea Water

Energy Metal / Alloy Potential Corrosion
(volts) *
Least energy Gold +0,500 Least corrosive

required Silver - 0,205
for refining Titanium - 0,225
Stainless steel (316) - 0,235
Ni-Al- Bronze - 0,380
Copper - 0,435
Carbon steel - 0,600
Aluminium (pure) - 0,800
Zinc (anode alloy) - 1,080
High energy Aluminium (anode alloy) - 1,140
required Magnesium (anode alloy - 1,550 Very corrosive
for refining
*) Potential in seawater measured versus a

Copper / Copper Sulphate reference electrode

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Information from the galvanic series
a) The degree of general corrosion
b) Prediction of galvanic corrosion:

• The ” more negative” metal will corrode
• The “more positive” metal will be protected
The corrosion rate depends on the driving force

( i.e. the difference in potential between the
two metals)
• Rule of thumb: Differences < 50 mV will not

give galvanic corrosion problems

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Types of corrosion
1. Uniform corrosion
2. Galvanic corrosion
3. Selective (preferential / dealloying) corrosion
4. Pitting corrosion
5. Crevice corrosion
6. Micro biological corrosion (bacteria)
7. Corrosion fatigue
8. Stress corrosion cracking
9. Erosion corrosion
10. Cavitation
11. Stray current corrosion

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General corrosion (Uniform corrosion)

 General corrosion is uniform by nature
 Deep pits or uneven areas can however be found

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Galvanic corrosion (Bimetallic corrosion)

Galvanic corrosion is an electrochemical reaction between two dissimilar
metals in the presence of an electrolyte and an electron-conductive path. It
occurs when dissimilar metals are in contact.
Pre-requisites:
• Water (Electrolyte)
• Two metals with different
potentials
• Electrical contacts between the
two metals
Important parameters:
• Anode - Cathode area ratio.
• Electrolyte conductivity
• Difference in galvanic potential of
the metals
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Galvanic corrosion
• Galvanic series: systematic ranging of metals’

inherent electrical potential from the highest potential
to the lowest
• Electrolyte : Electrically conductive liquid, such as
seawater
• Galvanic Series in Sea Water
Noble Ignoble
Gold  Silver  Titanium  Stainless steel  Ni-Al-Bronze  Copper  Carbon steel 
Aluminium (pure)  Zinc  Aluminium  Magnesium

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Pitting corrosion
• Pitting corrosion is a localised attack on
a material normally protected by a
passive film
• The passive film may be damaged
mechanically or by aggressive ions in an
electrolyte
• Weak points in the oxide film are
attacked and severe concentrated
corrosion may take place
• Happens both on steel and on metals
with a protective oxide film (e.g.
stainless steels and aluminium)
• Can perforate metal sheet in a short
time without notice

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Crevice corrosion
• Due to differences in
electrolyte composition
• Areas with stagnant water
with lack of oxygen will be
anodic
• Aerated water areas (i.e.
with dissolved oxygen) will
be cathodic
• Occurs often at stainless
steel flanges, under rivet
and bolt heads, under mud
and dirt etc

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Cavitation and erosion corrosion

• Cavitation: On ships’ propellers and rudder, caused by
repeated impact on the same spot of air bubbles or
vacuum bubbles
• Erosion: Inside copper pipes, typically where the fluid
velocity is high and combined with turbulence
Sharp corners and intrusions creates turbulence, leading to erosion

corrosion:

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The principle of cathodic protection
• In a corrosion cell steel will

corrode when coupled to a
more noble material
• The noble material is replaced
with a material being less
noble than steel: A sacrificial
anode
• The direction of the current will
change
• The steel will be protected
while the anode corrodes
Cp and corrosion \ CP_protection cell1

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Cathodic protection
• By using a more negative material in contact with the steel, the steel becomes
cathodic and is prevented from corroding
By sacrificial anodes By impressed current
• Zinc anodes and aluminium anodes • Permanent electrode more noble than
• Less noble metal than steel steel (platinum, graphite, etc.)
• The less noble metal sacrifices itself • Electrons from an electrical source is
for the steel pushed out through the permanent
electrode, making the steel cathodic
Cp and corrosion \ CP_protection cell1

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Content
1. The duties of an
equipment
6. Application
12. SHE
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Steel preparation
• Purpose is to assure good quality of a coating all over

• Sharp edges, fillets, corners and welds shall be
rounded or smoothened by grinding (min. R = 2mm).
• Hard surface layers e.g. resulting from flame cutting
shall be removed by grinding
• The surface shall be free from any foreign matter
such as weld flux, weld spatter, residues, slivers, oil,
grease, salt etc.
• Any oil and grease shall be removed in accordance
with SSPC-SP1

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Remaining weld beads after removal of supports welded on

to the structure
Prior to pre-treatment
these must be
ground smooth to
form an acceptable
substrate for the
paint system
Cd-4932-04

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Unacceptable weld. Too rough and full of pinholes / pores
• Weld spatters
close to weld
• Re-welding and
grinding must be
carried out prior to
re-blasting and
painting
Cd-4930-39

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Disc grinding of weld beads, sharp edges etc. by

means of a disc grinder.
• Other types of
discs are
available.
• Some of them
will reduce the
Cd-4932-06
amount of
sparks.

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ISO 8501-1 Evaluation of rust grades

Rust grade A Rust grade B
Rust grade C Rust grade D

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Rust grades
A. Steel surface largely covered with adhering mill

scale but little rust
B. Steel surface which has begun to rust and from
which the mill scale has begun to flake
C. Steel surface on which the mill scale has rusted
away or from which it can be scraped, but with
slight pitting under normal vision
D. Steel surface on which the mill scale has rusted
away and on which general pitting is visible under
normal vision

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ISO 8501 - 1
Types of preparation grades
Sa: Blast cleaning (grades 1, 2, 2 ½ and 3)
St: Hand and power tool cleaning

(grades 2 and 3)
Fl: Flame cleaning (one grade)

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Definitions of preparation grades
Hand and Power Tool Cleaning (St)

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

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Abrasive Blast Cleaning (Sa)
Sa 1 Light blast cleaning
When viewed without magnification, the surface shall be
free from visible oil, grease and dirt and from poorly
matter.
Sa 2 Thorough blast cleaning
free from visible oil, grease and dirt and from most of the
mill scale, rust, paint coatings and foreign matter. Any
residual contamination shall be firmly adhering.
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Sa 2½ Very thorough blast cleaning.
free from visible oil, grease and dirt and from poorly
matter. Any remaining traces of contamination shall
show only as slight stains in the form of spots or stripes.
Sa 3 Blast cleaning to visually clean steel.
free from visible oil, grease and dirt, and shall be free
from mill scale, rust, paint coatings and foreign matter. It
shall have a uniform metallic colour.
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Abrasive Shapes

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Venturi nozzles increase the speed of the abrasives
Today mainly venturi nozzle is used. This increases the speed of

the abrasive out of the nozzle and covers a larger area with a
more even pattern than a straight bore nozzle of the same size
Standard nozzle abrasive speed: 300 Km/h at 7 bar
. . . .
. . .... . ....
. .
Venturi nozzle abrasive speed: 700 km/h at 7 bar
. . ..
. . . .... . ...
. .
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ISO 11127 - 6
Content of water soluble contaminants
The abrasives can be contaminated with: Water, oil and grease,
chlorides, sulphates
Conductivity measurements
• A sample of 100 g. of the abrasives
• 100 ml of water
• Shake for 5 minutes and let rest for 1 hour
• Shake again for another 5 minutes
• Measure the conductivity at a temperature of 10 oC
Typical requirement: Maximum conductivity of 25 mS/m

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How to check the abrasives

ASTM D 4940
• Mix 300 ml of abrasive and 300 ml water
• Stir for 1 min. let stand for 8 min., stir again for 1 min.
Conductivity Oil content

• Fill the liquid for test and • No presence of oil, either on top
measure the conductivity. or as an emulsion after 30 min.
Max 25 mS/m

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Checking blasting air (ASTM D4285)
Procedure
1. Use an absorbent or non absorbent paper or cloth
collector in a rigid backing
2. Adjust the air discharge so that it does not destroy the
paper or cloth - let the air flow through the cloth for 1
minute
3. Visually examine the paper or cloth for the presence of
oil or water

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Blasting air & pressure test
Determining the blast-cleaning air pressure

Equipment : Needle pressure gauge
(manometer)
Procedure
1. Start up the blast equipment without the abrasive
2. Insert the needle at a 45 angle through the blast
cleaning hose as close as possible to the nozzle into
the air stream
3. Read the blast cleaning air pressure

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ISO 8503 Surface roughness of blast-cleaned steel
Part 1: Specifications and definitions for ISO surface profile

comparators for the assessment of abrasive blast-cleaned
surfaces
Part 2: Method for the grading of surface profile of abrasive blast-
cleaned steel - Comparator procedure.
Part 3: Method for the calibration of ISO surface profile
comparators and for the determination of surface profile-
Focusing microscope procedure.
Part 4: Method for the calibration of ISO surface profile
comparators and for the determination of surface profile - Stylus
instrument procedure

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ISO 8503 Surface roughness
• Example of a reference
comparator
• Surface profile comparator
comprising four segments.
• Grit (G)
• Shot (S)
• Check if the profile is
according to specification and
the paint manufacturer’s
recommendation
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ISO 8503 – 1 Surface profile roughness
Comparators for steel. Comparators for steel.

Blast-cleaned with grit abrasives Blast-cleaned with shot abrasives
- Fine (G): Profiles equal to - Fine (G): Profiles equal to

segment 1 and up to, but segment 1 and up to, but
excluding segment 2 (25-50 mic) excluding segment 2 (25-35 mic)
- Medium (G): Profiles equal to - Medium (G): Profiles equal to

- Coarse (G): Profiles equal to - Coarse (G): Profiles equal to


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ISO 8501-4: Waterjetting
• Table 1 – Descriptions of initial surface conditions
A surface where the paint coating system has degraded to an extent

DC A
similar to that illustrated by ISO 4628-3, grade Ri3.
A surface where the paint coating system has degraded to an extent

DC B
similar to that illustrated by ISO 4628-3, grade Ri4.
A surface where the paint coating system has degraded to a major

DC C extent, as illustrated by ISO 4628-3, grade Ri5, or when completely
degraded as illustrated by ISO 8501-1, rust grade C.
An iron oxide epoxy prefabrication (shop) primer surface that has

DP I
degraded.
DP Z A zinc silicate prefabrication (shop) primer surface that had degraded.

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• Table 2 – Descriptions of the surface appearance after cleaning
Light high-pressure water jetting

Wa 1 When viewed without magnification, the surface shall be free from visible oil and
grease, loose or defective paint, loose rust and other foreign matter. Any residual
contamination shall be randomly dispersed and firmly adherent.
Thorough high-pressure water jetting
When viewed without magnification, the surface shall be free from visible oil, grease
Wa 2 and dirt and most of the rust, previous paint coatings and other foreign matter. Any
residual contamination shall be randomly dispersed and can consist of firmly adherent
coatings, firmly adherent foreign matter and stains of previously existent rust.
Very thorough high-pressure water jetting
When viewed without magnification, the surface shall be free from all visible rust, oil,
1 grease dirt, previous paint coatings and, except for slight traces, all other foreign
Wa 2 /2
matter. Discoloration of the surface can be present where the original coating was not
intact. The grey or brown/black discoloration observed on pitted and corroded steel
cannot be removed by further water jetting.

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• Table 3 – Descriptions of the surface appearance for three flash
rust grades
Light flash rust
A surface which, when viewed without magnification, exhibits small quantities of a
L yellow/brown rust layer through which the steel substrate can be seen. The rust
(seen as a discoloration) can be evenly distributed or present in patches, but it will
be tightly adherent and not easily removed by gentle wiping with a cloth.
Medium flash rust
A surface which, when viewed without magnification, exhibits a layer of
M yellow/brown rust that obscures the original steel surface. The rust layer can be
evenly distributed or present in patches, but it will be reasonably well adherent and
it will lightly mark a cloth that is gently wiped over the surface.
Heavy flash rust
A surface which, when viewed without magnification, exhibits a layer of re-
H yellow/brown rust that obscures the original steel surface and is loosely adherent.
The rust layer can be evenly distributed or present in patches and it will readily
mark a cloth that is gently wiped over the surface.

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Water cleaning and jetting prior to recoating

(NACE No. 5 / SSPC SP. 12)
• Low Pressure Water Cleaning (LPWC)

Less than 34 MPa (340 bar/5 000 p.s.i.)
• High Pressure Water Cleaning (HPWC)

From 34 to 70 MPa (340 to 680 bar/5 000 to 10 000 p.s.i.)
• High Pressure Water Jetting (HPWJ)

From 70 to 210 MPa (680 to 2 100 bar/10 000 to 30 000 p.s.i.)
• Ultra-High Pressure Water Jetting (UHPWJ)

Above 210 MPa (2 100 bar / 30 000 p.s.i.)

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ISO 8502 – 3 Assessment of dust

The dust on the surface may :
• Reduce the adhesion of coatings
• Absorb moisture
• Promote corrosion on the surface
Procedure:
1. Press 150mm of freshly exposed tape
on the surface
2. Rub the tape with your thumb at a firm
pressure
3. Remove the tape from the surface and place it on a board or a piece of
paper
4. Compare the tape with the photographic reference
5. Assess the quantity of the dust and the predominating particle size
• Large amounts of dust (5) – small amount (0)
• Large particles of dust (5) – small particles (0)
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ISO 12944
General standard for corrosion protection
ISO 12944-2 Classification of environments
Corrosivity category
C1 very low : school
C2 low : rural area, sports hall
C3 medium : urban, laundry
C4 high : industrial area, ship and boatyards
C5-I very high (industrial): high humidity and aggressive
atmosphere
C5-M very high (marine): coastal and offshore with high salinity
Category for water and soil
Im 1 Immersion in fresh water
Im 2 Immersion in sea or brackish water
Im 3 Buried in soil
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ISO 12944
General standard for corrosion protection
ISO 12944-5 Protective paint system, expected

durability
3 levels:
• Low (L) : 2 to 5 years
• Medium (M) : 5 to 15 years
• High (H) : more than 15 years

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ISO 4628 Evaluation of degradation of paint coatings
• Designation of intensity, quantity and size of common

types of defect
Part 1 General principles and rating schemes
Part 2 Designation of degree of blistering
Part 3 Designation of degree of rusting
Part 4 Designation of degree of cracking
Part 5 Designation of degree of flaking
Part 6 Designation of degree of chalking

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ISO 4628 - 3 Designation of degree of rusting
Rating
Designate the degree of rust formation by reference to the pictorial
standards
Degree Area rusted %

Ri 0 0
Ri 1 0,05
Ri 2 0,5
Ri 3 1
Ri 4 8
Ri 5 40/50

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Content
1. The duties of an
equipment
6. Application
12. SHE
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Purpose of climatic evaluation (ambient conditions)
• Verify that the climatic conditions are suitable

for the product:
– Substrate Temperature (drying / curing)
– Relative Humidity (application)
• Evaluate the likelihood for the moisture in the

air to form condensation on a substrate

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Definition
• Absolute humidity (g/m3): The maximum content of

water vapour in the air at a given temperature
• Relative humidity (%):The amount of water vapour
present in air at a given temperature expressed as
percent of the absolute humidity (maximum amount of
water vapour which can be held) at that temperature
• Dew Point (°C): The temperature at which the air
becomes saturated with water vapour and
condensation starts

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Ambient conditions
General condition
Painting should not be started when:
• The relative humidity exceeds 85% (can vary depending on
products, ref. TDS)
• The substrate temperature is less than 3o C above the dew point
Measuring equipment
• Electronic multi-function gauge
• Electronic humidity gauge
• Sling Psychrometer (Sling Hygrometer, “Dry and Wet bulb”)
• Dew point calculator
• Steel thermometer

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Why Temperature & Humidity are important

Condensation follows the contours
of the double-bottom tank 
 Frozen overnight
condensation, follows
the frames of the ship

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Procedure of measuring R.H and dew point ISO 8502-4)
Procedure
1. Check the thermometers
2. Saturate wick with water
3. Whirl the sling hygrometer for 20~30 seconds
4. Note wet bulb temperature then the dry bulb temperature
5. Whirl the sling hygrometer for another 20~30 seconds
6. If the values are the same as the last reading STOP, if not
whirl again until there is no difference from the last reading
7. Determine RH and dew point from tables or IX diagram

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Ways to control the climatic conditions
• Dehumidifier, reduces the actual

humidity in the surroundings
• Heater, heat the objects
(surfaces) prior to application in
order to reduce the danger for
condensation.
• Forced ventilation is a must in
enclosed areas in order to
secure proper evaporation of the
solvents from the paint film.

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Content
1. The duties of an
equipment
6. Application
12. SHE
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Composition of paints
• Binder
• Pigment
• Extender
• Solvent
• Additive

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Binder
• Describes the type of paint / coating

• Determines the drying mechanism
• Bind pigments and extenders to a solid film
• Provides the adhesion to the substrate
• Determines cohesion and flexibility of the film
• Provides the water, chemical, solvent and UV
resistance

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Colour Pigments
• Natural or synthetic pigments

• Organic or inorganic pigments
• Gives colour to the film
• Hides the substrate (opacity)
• Almost all colours consist of a blend of pigments
• Individual colours can be changed or adjusted by
altering the pigment blend

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Active / Reactive Pigments
Takes an active role in ensuring that the paint

perform as expected:
• Anticorrosive (Red Lead, Zinc-chromate, Zinc-
phosphate, Zinc-dust)
• Antifouling (Cuprous oxide)
• Rheology or Anti-sagging (Bentonite clay)

Jotun Coatings
Barrier pigments
• Flake-shaped pigments
• Tend to align themselves parallel to the substrate
• Reinforce the film
• Increase the barrier effect of the film
• Often made from aluminium, glass, micaceous iron oxide (MIO or mica)
Water
Paint with glass or

aluminium flakes
Steel
Flake-shaped pigments make it more difficult for moisture to reach the
steel as the distance becomes longer.

Jotun Coatings
Extenders
• Naturally occurring minerals, e.g.:

– Dolomite
– Talc (Talcum powder)
– Chalk (Calcium Carbonate)
– Clay (China Clay)
• Reinforce and give body to the film
• Varying hardness
• White / grey in colour
• Very little influence on colour of the film (poor
opacity)

Jotun Coatings
Solvent / Diluent / Thinner
• Lowers the viscosity

• Gives application properties for
brush, roller, spray
• Once the paint has been applied, it
is no longer needed

Jotun Coatings
Additives
Many types: Examples:
• Production enhancers • Wetting agent
– Improve manufacturing
• Anti-foam
• Storage facilitators
• Anti-settling
– Storage stability
• Application aids • Anti-skin
– Easier application • Anti sagging
• Appearance improvers • Catalysts
– Better gloss • UV-absorbers
• Service life strengtheners • Etc.
– Resist fouling

Jotun Coatings
Physical drying
• The solvents
evaporate
• Molecules pack
and melt together
to form a paint film
• No chemical bonds Paint technology: Physical_drying1

Jotun Coatings
Curing (drying) by oxidation
• The solvents evaporate

• Oxygen enter the paint
and the reaction starts
• The binder molecules
link together through a
chemical reaction with Paint technology: Oxidation_drying1
oxygen

Jotun Coatings
Chemical curing
• The solvents evaporate

• Component A and
Component B molecules
moves towards each other
• They link together through a
chemical reaction
• A three dimensional network
Paint technology: Curing_good1
is formed which give the
solid paint film

Jotun Coatings
Corrosion protection by paints
For corrosion prevention with paints, three main principles are

employed:
• Barrier effect: keep out the water

ex. alkyds, chlorinated rubber, vinyl, epoxy, polyurethane, etc.
• Inhibition effect: obtained by anticorrosive pigment which creates a

passivation of the steel
ex. zinc phosphate, zinc chromate, red lead
• Cathodic protection : sacrificing metal pigment such as zinc

ex. zinc ethylsilicate, zinc-epoxy

Jotun Coatings
Corrosion protection by paints
Inhibitor effect
Barrier effect Galvanic effect

Jotun Coatings
Shopprimers
• Definition: A quick drying material applied as a thin film

to a metal surface after cleaning, e.g. by a blast
cleaning process, to give protection during the period
before and during fabrication.
• Requirement: Must not interfere with the speed or
quality of cutting and welding of the steel during
fabrication, so DFT must be limited to:
Iron oxide: 15 – 20 micr.
Zinc-rich: 10 – 15 micr.

Jotun Coatings
Antifoulings
Purpose:
 To prevent (or at least reduce) growth of marine organism
 To provide better fuel economy over the sailing period
 To avoid growth penetrating the coating and thereby extend
corrosion protection

Jotun Coatings
Conventional Antifoulings
• Soluble matrix paints

• Rosin as a binder
• Approximately 12 months protection
• Binders dissolves in water and biocide is
released
• Danger of cracking and flaking
• Needs to be quickly immersed in water
Example: A/F Supertropic (no more in assortment)

Jotun Coatings
Long-life Antifoulings
• Insoluble matrix paints

• Only biocides are released
• Effective protection is up to 24 months
• Leaves weak substrate for subsequent coat
(leached layer)
• Sealer coat normally required
• Binder: CR, Vinyl
Example: A/F Sargasso (no more in assortment)

Jotun Coatings
Self-polishing Antifoulings
• Predictable performance
• Extended dry docking period
• Control of roughness and smoothing
• Fouling control due to linear biocide release
• Lifetime directly proportioned with dry film
thickness
Example:
A/F SeaForce (hydrating)
A/F SeaQuantum (hydrolysing)

Jotun Coatings
Primer, Intermediate and Topcoats
• Primer coats: supply good adhesion to the steel surface
• Intermediate coats: increase the film thickness and assure good

adhesion of the top coat
• Top coats: withstand weather and give the desired

colour and gloss

Jotun Coatings
Curing agents for two-pack paints
• Polyamides:
– Normal epoxy paints (e.g. Penguard)
• Amine and amine adduct:

– Solvent free epoxy, Tankcoating, EpoxyMastic
• Isocyanates:
– Polyurethane
– Can be used for low temperature curing of epoxy
(not by Jotun)

Jotun Coatings
Content
1. The duties of an
equipment
6. Application
12. SHE
Jotun Coatings
Application by brush
Benefits
• Good wetting of the substrate
• Forces the paint into the surface
• Better than roller on the first coat
• Good on areas with poor
accessibility
Limitations
• Gives low film thickness, many
coats required
• Creates an uneven film
• Application speed is slow

Jotun Coatings
Application by roller
Benefits
• Application speed is faster than
with paint brush
• Good on areas with poor
accessibility
Limitations
• Poor wetting of the substrate
• Never use for the first coat
• May incorporate air and pinholes
in the paint film
• Gives low film thickness, many
coats required

Jotun Coatings
Stripe coating prior to each full coat
Stripe coat with paint brush:

• Where difficult access
with spray
• Profiles
• Inside edges
• Holes, notches
• Corners, angles
• Sharp edges
• Manual welding seams

Jotun Coatings
Application by airless spray

Paint pump delivers paint at high pressure. The pump may be driven by
electric motor, petrol engine or (most commonly) by compressed air
motor
Benefits
• High production rates
• High viscosity paints can be applied
• Lower loss of paint
• Skilled operators
Limitations
• Over spray / dry spray
• Rebounce coating corners, hollows etc
• Worn-out nozzle

Jotun Coatings
Airless spray pump: How it works.

Compressed
air
Piston direction
Piston direction
Pressurized
Paint

Jotun Coatings
Application fault: Sags and runs
Appearance
• Paint running or hanging like curtains
on vertical surfaces
Caused by
• Too high wet film thickness
• Too much thinner added to the paint
• Airless spray gun too close to surface
Repair
• Avoid above
• Use paint brush to smoothen or
remove excessive paint

Jotun Coatings
Application fault: Orange Peel

Appearance
• Paint surface is rough, like orange peel
Caused by:
• Poor flow / levelling properties of the paint
(Paint too thick or too low temperature)
• Poor atomisation of the paint
• Too fast evaporation of the thinner
• Airless spray gun too close to surface
Repair:
• Improve application technique
• Use correct thinner
• Grind surface and apply new paint

Jotun Coatings
Application fault: Dry spray

Appearance
• Porous, sandpaper like surface of the paint
Caused by
• Poor atomisation of the paint
• Spray gun too far away from the object
• Strong wind during application
• High air temperature and low relative
humidity resulting in too fast evaporation of
the solvents
Repair
• Inorganic Zinc: Re-blast and apply new
paint
• Physically drying paints: Apply thinner on
the painted surface and apply a new coat
• Oxidatively drying paints: Remove loose
dust and apply topcoat
• Two-pack paints: Remove loose dust,
sandpaper to smooth surface, apply topcoat
Jotun Coatings
Application fault: Pinholes

Appearance
• Tiny holes through one or more coats,
or even down to the substrate, as if
perforated by a needle
Caused by
• Dry spraying
• Entrapped solvents or air
• Porosity of previous coat
• Incorrect application technique or viscosity of the paint
Repair
• Grind top layer of the paint
• Recoat

Jotun Coatings
Application fault: Formation of vacuoles
Appearance
• A weakness in the paint system that, in most cases, is not visible
to the naked eye. When examining a cross-cut of the film, voids
can be seen
Caused by
• Very high thixotrophy in the paint film
• Far to high film thickness of the coats
• Solvent trapped within the film
Repair
• Remove old paint system
• Apply new suitable paint system

Jotun Coatings
Application fault: Popping

Appearance
• Solvents or air try to escape through the upper
part of the film, which has already nearly dried,
leaving small bubbles / craters on the surface
Caused by
• Very porous substrate (e.g. Zinc silicate primer)
• Entrapped solvents or air in the paint film
• Usually in connection with too high film
thickness, too long application distance or too
strong ventilation.
Repair
• Reduce film thickness or ventilation and adjust
application technique (Tie coat / mist coat
technique.)
• Remove paint on painted surfaces and repaint

Jotun Coatings
Application fault: Holidays
Appearance
• Primer/undercoat shining through
topcoat
Caused by
• Uneven film thickness of the last
applied coat
Repair
• Apply another coat

Jotun Coatings
Time Aspects
• Shelf Life: acceptable storage time “on the shelf” in the

paint store
• Pot Life: how long you can continue to apply a two-pack
paint after the two components have been mixed
• Induction Time: pre-reaction of the two components in
the tin prior to application
• Drying Times: time required from application and until
the paint becomes Surface dry/ Hard dry / Fully Cured
• Re-coating Interval: minimum / maximum time between
applying subsequent coats
Jotun Coatings
Content
1. The duties of an
equipment
6. Application
12. SHE
Jotun Coatings
Metallic coatings
• Steel can be protected against corrosion through use of a
metallic coating (a thin layer of another metal on the surface of
the steel)
• Various metals can be used to form such metallic coatings, such
as chrome, aluminium, copper and zinc, even noble metals like
gold and silver can be used
• When correctly applied, the metallic coating may form an alloy
with the steel substrate on its interface, providing a metallurgical
bonding between the two
• The metallic coating forms an impervious barrier between the
steel and the environment, preventing oxygen and moisture to
reach the steel, and thereby eliminating corrosion of the steel

Jotun Coatings
Metallic coatings
• Can be carried out with metals which are less noble than steel
(e.g. zinc and aluminium), or more noble than steel (e.g.
chromium and nickel)
• May form a galvanic couple with the underlying metal:
– As anode: Zinc and Aluminium coatings
– As Cathode: Chromium and Nickel coatings
• Anodic coatings protect the steel against corrosion by acting as
sacrificial anode (galvanic protection)
• Cathodic coatings protect against corrosion only as long as they
are intact (barrier protection). If damaged, they can cause
accelerated corrosion (pittings)
• Cathodic coatings are used to provide a permanent and shiny
surface

Jotun Coatings
Metallic coatings
• The surface of the steel needs to be prepared before a metallic

coating is applied, either chemically (e.g. acid treatment) or
mechanically (blast cleaning)
• When correctly applied, the metal in the coating will fuse with
the steel in the contact zone, providing a chemical adhesion
(metallurgical bond) rather than a physical adhesion (as is the
case with most organic paints)
• When applying paint on top of metallic coatings, one must treat
the substrate in accordance with the particular metal in the
coating, not as a normal steel substrate
• The most frequently used metallic coating on steel is zinc,
commonly referred to as galvanised steel, but aluminium is also
used

Jotun Coatings
Types of metallic coatings
Application:
• Hot dip galvanizing
• Electro-plating
• Metal-spray (Thermally sprayed Aluminium and Zinc)
Types:
• Noble metal coatings: Chromium, Nickel, etc
• Ignoble coatings: zinc, aluminium, etc.
• For canned food: Tin coated steel canisters
Metallic coatings may be coated by paint for increased

protection

Jotun Coatings
Process of Hot-dip galvanising
1. Alkaline degreasing : oil, old paint on the steel is removed

2. Water rinsing : hot or cold water
3. Pickling in HCl (14~16%) : scale and rust are removed
4. Water rinsing
5. Fluxing in zinc-ammonium chloride solution
6. Drying 70~120℃
7. Immersion in molten zinc at 460℃, DFT <100 microns,
depends on dipping time
8. Cooling in air or water
9. Inspection

Jotun Coatings
Hot-Dip Galvanising
Advantages Disadvantages
• Low price • Stationary zinc bath

• Long life time • A Max. size of the structure
• Good overall quality • Heat affected
• Good cathodic protection • Deviation from normal welding
• Few defects procedures
• Easy to inspect • Grayish colour

Jotun Coatings
Metal-spray: Flame (Gas) spray
Powder feed
• A single continuously moving
wire is passed through a
pistol and melted by a conical
jet of burning oxy-fuel gas.
The molten wire tip enters
the cone, atomises and is
propelled onto the substrate.
• Alternatively, metal powder

may be fed into the flame
from a powder cup or hopper. Wire
feed
• Flame temperature typically
2,700 – 3,100 oC

Jotun Coatings
Metal-spray: Arc spray
• A pair of metal wires are

electrically charged so an arc
is struck across the tips when
brought close in the nozzle of a
pistol.
• The electrical arc melts the
auto-fed wire ends.
• Compressed air is blown
across the arc to atomise and
propel the molten metal wire
particles onto the prepared
work piece
• Temperature in the electric arc
is approx. 5,500 oC

Jotun Coatings
Content
1. The duties of an
equipment
6. Application
12. SHE
Jotun Coatings
The purpose of passive fire protection
• To protect human lives

– Gain time to evacuate a building /
structure
– Prevent the structure from collapsing on
rescue personnel & fire fighters
• To protect assets
– Prevent the fire from spreading outside
the affected fire cell

Jotun Coatings
Variables
Protection of structure is based on:

• Critical steel core temperature of the
structure
• Ratio between the heated surface and the
mass of material which will be heated
(Hp/A)
• Duration (time / length) of protection

Jotun Coatings
Passive fire protection materials
Organic coatings:
• Epoxy coatings
• Thickness 3-30 mm (3,000 – 30,000 micr.)
• Swells when subjected to high temperature and
creates an insulating layer, which will slow down the
otherwise rapidly increasing substrate temperature
• Products:
– Chartec,
– Pitt-Char,
– Thermolag,
– Firetex

Jotun Coatings
Example of intumescent coating (organic thin-film)
Before After

Jotun Coatings
Passive fire protection materials
Inorganic coatings:
• Cement-based coatings
• Thickness 20-40 mm
• Liberates water when subjected to high
temperature, which will have a cooling
effect and slow down the otherwise
rapidly increasing substrate temperature
• Products:
– Mandolite,
– Pyrocrete

Jotun Coatings
Expectations
• Requirements relating to
protection of fire divisions
• Ensure stability
• Ensure integrity i.e. prevent
penetration of fuel, flames
and fumes
• Maintain insulation
requirements

Jotun Coatings
Examples of critical core temperatures:
• Temperatures at which
construction materials loose
their strength:
– Structural steel 400C
– Reinforcement bars, ordinary
500C
– Reinforcement bars, pre-stressed
350C
– Aluminum 200-250C

Jotun Coatings
Temperature during a fire
• Cellulose fire (wood, paper, other solid fuel)

– Temperature after 5 minutes: 556C
– Temperature after 1 hour: 945C
• Hydrocarbon fire (oil, paint, solvent, etc.)

– Temperature after 5 minutes: 926C
– Temperature after 1 hour: 1,145C

Jotun Coatings
Typical PFP benefits

• Materials will always function
• Independent of signals / remote
controls
• Reliable
• Durable
• No test requirement in situ
• Well proven
• Low cost
Jotun Coatings
Content
1. The duties of an
equipment
6. Application
12. SHE
Jotun Coatings
Lifting
Appearance
• Small wrinkles through the paint film
Caused by
• Softening and raising or swelling of a
previous coat by the application of an
additional coat
• Normally when overcoating Alkyd
• Lifting often caused because the
solvents in the new coat is too strong
for the previous coat
Repair
• Remove the paint
• Recoat

Jotun Coatings
Fisheyes
Appearance
• Spots of paint on the surface with no wetting
of the surface around the spots.
Appearance of a fisheye.
Caused by
• Paint applied on oil, silicone or other
contaminants
• Painted on incompatible paint (Glossy paint
giving poor wetting)
Repair
• Recoat
Jotun Coatings
Sweating & carbonisation (Amine blooming)

Appearance
• Tacky and sweating film, often with white
stains
Caused by
• High humidity, particularly on Epoxies during
curing
• Poor ventilation
• The Amines react with CO2 and humidity
and form Amine carbamate.
• Too low temperature
Repair
• Wash with warm water or thinner, using rags
Preventive measure
• Induction time before application start

Jotun Coatings
Bloom & Blush (Blushing)
Appearance
• Surface looks milky
Caused by
• Condensation on cold steel surfaces
at high humidity
• Air pollution, sulphur dioxide (SO2)
and ammonia forming ammonium
sulphate on the paint film.
• “Fast “ thinners
Repair
• Recoat

Jotun Coatings
Osmotic blistering
• Appearance
• Smaller or bigger blisters in the paint
film
Caused by
• Salt and other water soluble
contamination on the metal surface or
between coats
Repair
• Remove existing system
• Fresh water clean
• Apply new paint system

Jotun Coatings
Pinpoint rust penetration
Appearance
• Points of rust
Caused by
• Small pores (pinholes), openings or
• defects in the paint film down to bare
steel
• Holidays due to overspray, dry spraying
etc.
• Too high substrate roughness
Repair
• Grind down to bare steel
• Recoat

Jotun Coatings
Checking / cracking
Appearance
• From fine cracks in the topcoat to
more severe cracks down to the
substrate.
Caused by
• Stress in the paint film
• Entrapment of solvent
• Too soft primer compared to the
softness of the topcoat
• Too high thickness
Repair
• Abrade to remove cracked paint
• Apply new suitable coating system

Jotun Coatings
Alligatoring / crocodiling
Appearance
• Very large cracks (looks like the skin of
an alligator) that may penetrate down to
the substrate
Caused by
• Too soft primer compared to the
softness of the topcoat
• Limited flexibility in the paint film
• Too fast drying of the topcoat
Repair
• Depending upon extent, abrade or
remove all affected coats
• Apply new suitable paint system

Jotun Coatings
Mud-cracking
Appearance
• Cracks occurring during the drying
process of the paint
• Appearance of the surface of
cracked mud
Caused by
• Particularly for inorganic Zinc
applied at a too high film thickness
Repair
• Re-blast to Sa 2½ or grind off
• Apply the inorganic Zinc

Jotun Coatings
Delamination (Adhesion failure)

Appearance
• Loss of adhesion:
• Intercoat delamination: Between coats
• Substrate delamination : Between primer and
substrate
Caused by
• Primer not compatible with subsequent coat
• Contamination of substrate or between coats
• Recoating interval too long
• Blooming / sweating
Repair
• Remove loose paint layer or down to substrate
• Recoat

Jotun Coatings
Chalking
Appearance
• Almost like dust on top of the coat
• The gloss will be reduced
Caused by
Pigments and extenders exposed on
the paint surface, due to
• Exposure to sun / UV light
• Degradation of the binder
• Weathering of the paint
• Insufficient mixing of the paint
Repair
• Grind and/or wash top layer of the paint
• Recoat
Jotun Coatings
Bleeding
Appearance
• Discolouration of a paint, particularly in
topcoats
Caused by
• Coloured ingredients in a previous coat
or on the substrate is dissolved by
solvents in the subsequent coat, e.g.
– Soluble pigments (Poor solvent
resistance)
– Tar, Bitumen, etc.
– Surface contaminants (coloured)
Repair
• Re-blasting and re-application

Jotun Coatings
Overpainting Grit or Foreign Matters
• Surface has not been well

cleaned
• Weak point in paint film
• Entrapped air
• Less adhesion
• Corrosion will develop
rapidly

Jotun Coatings
Content
1. The duties of an
equipment
6. Application
12. SHE
Jotun Coatings
Calculations : Abbreviations
• WFT = Wet Film Thickness

• DFT = Dry Film Thickness
• % VS = Percent Volume Solids
• LF = Loss Factor
• DV = Dead Volume
Link to calculator

Jotun Coatings
Wet Film calculations
• 1 litre covers 1 m2 in 1000 microns wet
• 1 litre covers 10 m2 in 100 microns wet
• RATIO:
1 : 1 : 1000
litre sq.meter wet film thickness
Meaning: sq.m./ltr x WFT = 1000

Jotun Coatings
Formula for calculation
DFT = WFT x % VS
100
WFT = DFT x (100 % + % thinner)

% VS
Spreading rate = % VS x 10 = m2/litre

DFT
Area, m2 x DFT
Consumption of Paint with loss =
10 x % VS x LF

Jotun Coatings
Dead Volume increases the volume of paint required
The dead volume is the amount of paint needed to fill up the

anchor profile (roughness) in a blast cleaned surface
Specified thickness Dead volume (ltr/m2)
Smooth (polished) steel surface

Even film thickness
Steel
Uneven steel surface (profile)

Steel Paint will fill the valleys

Jotun Coatings
Consumption of paint with loss including Dead Volume
A certain roughness will give a certain dead volume:

Roughness Dead volume
micr. l/ m2
30 0.02
45 0.03
60 0.04
75 0.05
90 0.06
105 0.07
Area (m2) x DV x 100

Total Dead volume, litre = % VS x LF

Jotun Coatings
Calculation exercise
• How much paint is required for 900 m2 when:

• 320 micr DFT
• 79 %VS
• 35% loss
• 60 micr roughness
Area (m2) x DV x 100 900 x 0.04 x 100 = 70.1 ltr

Dead volume = =
VS x LF 79 x 0.65
2
Consumption w/ loss = Area, m x DFT = 900 x 320 = 560.8 ltr
10 x % VS x LF 10 x 79 x 0.65
Link to TOTAL PAINT REQUIREMENT = 630.9 ltr
calculator

Jotun Coatings
Content
1. The duties of an
equipment
6. Application
12. SHE
Jotun Coatings
ISO 2808 Determination of film thickness
Wet film
• Comb gauge
– Firmly grasp the wet gauge and
place it perpendicular into the fresh,
wet coating
– Remove the wet film gauge
– Record the wet film thickness at the
last tooth covered with paint and the
next not covered with paint
• Wheel gauge
– Rolling over a wet film and reading
thickness of wetted central rim

Jotun Coatings
ISO 2808 - Determination of film thickness
Dry film
• Magnetic gauge
• Electronic gauge
Procedure for calibration

1. Place the probe onto the mooth /
polished steel and adjust to zero
2. Select a foil close to the thickness
you plan to measure
3. Place the foil onto the mooth /
polished steel and adjust the
instrument so that the DFT of the foil
is read on the instrument
4. Recheck above step
Jotun Coatings
ASTM D4138 Measurement of DFT of protective coatings

by destructive means
Measures the total DFT and

the DFT of each coats
Procedure:
1. Mark a reference benchmark on
the surface with a marker pen
2. Cut with the knife of the gauge
through the paint film
3. Use the microscope and take the
readings at the edge of the
marker line
4. Limitations : only for organic
coatings (paints)
5. DFT from 0 ~ 2000 microns,
problem on hard paints

Jotun Coatings
P.I.G.
Measure on the smooth side of the cut, from the cut-away edge of the
marker-pen to the exposed substrate. Count the number of divisions across a
single coat or a system, multiply by factor to get DFT
Black
marker
pen
Rough Smooth
edge edge
Measure this side

Jotun Coatings
ISO 8502-6 Extraction of soluble contaminants for analysis

- The Bresle method
Procedure
1. Remove the protective paper and the punched
out material, place the patch on the surface
2. Fill the beaker with 15ml of distilled water
3. Record the conductivity (µS/cm)
4. Retrieve 3ml of the water using the syringe
w/needle
5. Inject the water through the outer edge of the patch
6. Retrieve the water into the syringe, repeat this 4
times
7. Retrieve and transfer the water from the patch to a
suitable vessel for analysis
8. Subtract the initial conductivity from the measured
and multiply by 6 to obtain the value in mg/m2

Jotun Coatings
Determining the presence of non-visible grease or

oil contamination
Water break test

1. Spray a mist of atomized distilled water onto
the surface to be tested
2. Observe what happens to the film as follows
3. If the water gathers in lenses that last about 25
seconds before flowing out, the surface is
clean
4. If the water gathers in droplets (form a water
break) within 25 seconds, the surface is likely
to be contaminated with grease, oil or other
water insoluble matters

Jotun Coatings

oil contamination
UV light test
1. Shine an UV lamp (either short or long
wavelength) onto the surface
2. In daylight conduct the test using a shield
(e.g. Black cloth) to avoid sunlight
3. Observe the surface for florescence as
follows:
4. A bright yellow or lime green florescence
indicates contamination by grease or oil
5. An absence of florescence indicates that the
surface is not likely to be contaminated by
grease or oil

Jotun Coatings

oil contamination
Chalk test
1. Run the chalk over an area where there is
likely to be contamination of grease or oil
2. Observe the surface for florescence as
follows:
3. A sudden break of the chalk on the surface
indicates the presence of grease or oil
4. An absence of the break indicates that
surface is not likely to be contaminated by
grease or oil

Jotun Coatings
ASTM D4752 Measuring MEK resistance of ethyl silicate

(inorganic) zinc rich primers by solvent rub
Test procedure
1. Measure DFT
2. Clean the surface for loose zinc
dust using water
3. Fold cheesecloth and saturate
cloth with MEK
4. Rub test area with cloth stroke 50
mm
5. Rub until material is exposed or
50 double rubs have been
completed (also do this without
MEK)
6. Evaluate according to standard,
5 to 0
Jotun Coatings
ASTM D 3359 Adhesion testing by knife and adhesive tape
Test method A
X-cut, tape test : Ranking 5A to 0A , for DFT above 250 microns
30 – 45o
Test method B
Cross-cut, tape test: DFT is less than 125 microns, Ranking 5B to
0B
- 11 cuts, 1 mm apart : 0 ~ 50 microns of DFT
- 6 cuts, 2mm apart : 51~ 125 microns of DFT

Jotun Coatings
ISO 2409 Cross-cut test

Cutting tool
Single bladed knife or multi-blade cutting tool with
6 knives, edges spaced 1 mm or 2 mm apart
Spacing of cuts
• 0 - 60 microns: 1 mm spacing, hard substrates
• 0 - 60 microns: 2 mm spacing, soft substrates
• 60 - 120 microns: 3 mm spacing, hard/soft substrates
• 121 - 250 microns: 3 mm spacing, hard/soft substrates
Procedure
1. Make 6 parallel cuts with defined space in the coating.
2. Repeat operation, crossing original cuts at 90o so that a grid pattern is
formed.
3. Brush with soft brush.
4. Apply adhesive tape and pull off.
5. Classify results in accordance with table.
Jotun Coatings
ISO 4624 Pull-off test for adhesion
1. Procedure
2. Lightly abrade dolly and substrate
3. Clean dolly and substrate with a
dry tissue
4. Mix adhesive / apply to dolly
5. Press the dolly firmly to the
substrate
6. Tape the dolly
7. Cut around the dolly
8. Record type of break and MPa

Jotun Coatings
ISO 4624 Pull-off test for adhesion

Three types of failure
1. Cohesive failure (within a coat)
2. Adhesive failure (between coats)
3. Glue failure
• Adhesion failure: coating separates from the substrate or
between coats
• Cohesion failure: coating breaks within itself

Jotun Coatings
ASTM D5162 Discontinuity (Holiday) testing of non-conductive

protective coating on metallic substrates
Low voltage wet sponge testing

• • Voltage range : 5 to 90 V DC
• • DFT should not exceed 500 microns
Procedure
1. Check the DFT
(should not exceed 500 microns)
2. Check that the instrument works
(wet sponge to ground)
3. Attach the earth wire from the instrument to
the substrate to ensure good electrical
contact
4. Saturate the sponge with tap water
5. Move the sponge over the coating (max.
0.3 m/s)
6. Wipe surface to avoid telegraphing

Jotun Coatings
ASTM D5162 Discontinuity (Holiday) testing of ion

conductive protective coating on metallic substrates
High voltage spark testing
• Increase the voltage by 100 V DC per
every 25 microns of DFT
• DFT should exceed 500 microns
Procedure
1. Check the DFT ( should exceed 500
microns)
2. Adjust proper voltage
3. Check the instrument (electrode to
ground)
4. Check the earth (electrode to steel)
5. Move the electrode over the coating
(max. 0.3m/s)

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Content
1. The duties of an
equipment
6. Application
12. SHE
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How flammable is a paint ?
The “Flash point” tells how flammable a paint is.

• The flash point is the lowest temperature at which the fumes
from the solvents ignite or explode when exposed to a spark or
naked flame
Classification:
 Extremely flammable: Flash point below 0 °C
 Highly flammable: Flash point between 0 and 21°C
 Flammable: Flash point between 21 and 55 °C
This information can be found in the Safety Data Sheet

Jotun Coatings
Abbreviation
• LEL (Lower Explosion Limit)
– is the minimum vol % of vapor from a flammable liquid that can
cause an explosion
• UEL (Upper Explosion Limit)
– is the maximum vol % of vapor from a flammable liquid that can
cause an explosion
• OEL (Occupational Exposure Limits)
– is the average concentration to which nearly all workers may be
exposed without adverse effects
• OAR (Occupational Air Requirements)
– is the amount of ventilation necessary for keeping the solvent
vapours below the OEL

Jotun Coatings
The hazards of dust

Dust entering the lungs may cause severe health problems:
• Silicosis (Inhalation of silica from abrasives and quartz)
• Asbestosis (From dust of asbestos)
• Siderosis (From dust of iron oxide)
• Lung cancer (quarts)
Small particles (< 5 microns) are most dangerous and can
enter the narrow parts of the lungs
Protection against dust and gas
• Dust: Filter P1 - P3 (P3: highest protection)
• Gas from organic solvents: Filter A1 - A3 (A3: highest protection)
• Combination-filters (P and A) are recommended, e.g. A2-P2

Jotun Coatings
Health hazards when using paints.
Binders
• Skin contact
• Particularly Epoxy, Amines and Isocyanates may cause skin
irritation, burns and allergic reactions
Solvents
May enter the body in three ways:
• By inhalation
• Skin contact
• Ingestion
Other harmful / dangerous constituents:

• Tar, Heavy metals

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Health hazards from solvent exposure
Acute effects
• Headache Long term effects
• Abnormal • Irritability
tiredness
• Loss of memory
• Dizziness
• Organ damages (kidneys, liver,
• Nausea CNS)
Skin irritations • Reduced reaction ability
• Reduced evaluation ability
• Eczema
• Dry and cracked
skin

Jotun Coatings
Explosion and fire triangle

Oxygen
• Explosion triangle: • Fire triangle:

– Flammable gas
– Temperature
– Oxygen
– Oxygen
– Ignition source
– Fuel
Eliminate one
of the three,
and the
hazard is
eliminated
Fuel / Gas Ignition /
temperature
Remember: Solvent-vapours are heavier than air!


2 - 06 FROSIO Pre - Certification

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Team No.1 Module 2.06 CA Pre-certification

Level 2 / Module 2.06 CA Pre-certification Slide 1 of 168

Level 2 / Module 2.06 CA Pre-certification Slide 2 of 168

• Jotun’s approved FROSIO course consists of 17 training modules,

Level 2 / Module 2.06 CA Pre-certification Slide 3 of 168

The inspector’s role

• Usually the inspector has no formal authority in

Level 2 / Module 2.06 CA Pre-certification Slide 5 of 168

The challenge for the paint inspector

A First Class Professional CA will:

• be one of the best assets a company can have in terms of

Level 2 / Module 2.06 CA Pre-certification Slide 7 of 168

ISO 12944 Paints and varnishes - Corrosion protection

Part 1 General introduction.

Level 2 / Module 2.06 CA Pre-certification Slide 8 of 168

Extracts from ISO 12944 - 7

Level 2 / Module 2.06 CA Pre-certification Slide 9 of 168

Extracts from ISO 12944 - 7

6.3 Checking the paint coating

Level 2 / Module 2.06 CA Pre-certification Slide 10 of 168

Extracts from ISO 12944 - 7

• Dry film thicknesses (including the nominal and maximum

The importance of reports

Level 2 / Module 2.06 CA Pre-certification Slide 12 of 168

Typical content of the daily reports

Level 2 / Module 2.06 CA Pre-certification Slide 13 of 168

Example of daily log content for newbuilding

• Client and external company

Production and degradation of steel

Level 2 / Module 2.06 CA Pre-certification Slide 16 of 168

Corrosion: Parameters influencing

Level 2 / Module 2.06 CA Pre-certification Slide 17 of 168

The corrosion process: A galvanic cell

• Metals exposed to seawater

CP and corrosion: Corrosion_cell1

Level 2 / Module 2.06 CA Pre-certification Slide 18 of 168

Pre-requisites for corrosion

A galvanic cell consists of:

Level 2 / Module 2.06 CA Pre-certification Slide 19 of 168

What happens at the anode

(Electrons are involved, they go from the anode

Level 2 / Module 2.06 CA Pre-certification Slide 20 of 168

Anode & Cathode

• Anode: metal surface (positively charged) where

• Cathode: metal surface (negatively charged) where

Level 2 / Module 2.06 CA Pre-certification Slide 21 of 168

• Examples: Seawater, soil, acids, alkalis, concrete,

A sugar solution is not an electrolyte

• The more ions in the electrolyte, the better the

Level 2 / Module 2.06 CA Pre-certification Slide 22 of 168

Galvanic Series in Sea Water

Least energy Gold +0,500 Least corrosive

*) Potential in seawater measured versus a

Level 2 / Module 2.06 CA Pre-certification Slide 23 of 168

Information from the galvanic series

a) The degree of general corrosion

b) Prediction of galvanic corrosion:

The corrosion rate depends on the driving force

• Rule of thumb: Differences < 50 mV will not

Level 2 / Module 2.06 CA Pre-certification Slide 24 of 168

Level 2 / Module 2.06 CA Pre-certification Slide 25 of 168