assessment of coatings systems
TRANSCRIPT
SSPCPROTECTIVE COATING SPECIALIST COURSE ( PCS)
Assessment of coatings systems Development of coatings specifications Surface preparation and coatings applications Economics of coatings Contract planning and management Coating failure analysis Inspection
Exam InformationThe comprehensive certification examination and calculation questions consists of multiple choice, matching, essay, and material estimating questions. These questions are chosen primarily from the material covered in the C1 and C2 courses and from the suggested readings. Some of the questions can be answered from knowledge acquired by working in the coatings industry. Many of the questions require knowledge of several different subject areas:
Corrosion and Corrosion Control
Mechanisms of metal corrosion; common types of corrosion; methods of corrosion control.
Coating Types and Their Mechanisms of Protection
Mechanisms of corrosion control by coatings; desired film properties; coating components and their functions; mechanisms of coating film formation; comparison of generic coating types; selection of coating systems.
Surface Preparation for Painting
Preparing surfaces before cleaning; surface contaminants causing early coating deterioration; surface preparation methods; recommended removal methods for different contaminants; standards for cleaned steel surfaces; visual aids to surface cleanliness; level of cleanliness required for different coatings; air abrasive blasting equipment; centrifugal blasting equipment; surface profile and blasting abrasives; and blast cleaning procedures.
Application of Coatings
Brush, roller, and spray application; application of coatings that cure by fusion; handling of paints; application temperatures and humidities; achieving desired film thickness; recommended spraying procedures; coating application defects.
Coatings for Industrial Steel Structures
Selecting surface preparation for steel; coating systems appropriate for steel; selection of coating systems by environmental zone; coatings for atmospheric zones; coatings for
immersion and marine service; coatings for buried steel; coatings for high-temperature surfaces.
Coating of Concrete Surfaces
Components of concrete; similar features of all cementitious surfaces; placement of concrete; reasons for coating concrete; pre-coating materials applied to cementitious surfaces; coatings for cementitious surfaces; surface preparation for coating; inspection of coating application.
Inspection and Quality Control
The specification and its contents; responsibilities of the inspector; monitoring the ambient conditions; pre-surface preparation inspection; post-surface preparation inspection; pre-painting inspection; inspection of paint application.
Management of Coatings Projects
The corporate coatings program; planning for programmed painting; contracting for coatings work; specifying and testing coating materials; project roles and responsibilities; quality assurance: formal systems; quality control and coating inspection.
Standards and Specifications for Coatings Projects
Engineering standards for protective coatings; specifications for coatings systems; preparing a coatings specification.
Achieving Economic Protection by Coatings
Corrosion and its prevention; selection of construction materials; alternate construction materials; coatings and linings; economic considerations in coatings system selection.
New Construction and Planned Maintenance Painting
Coordinating and scheduling new construction projects; coating systems selection; shop and field painting; maintenance painting; facility condition survey and analysis; selecting coating systems for maintenance; implementation of the maintenance plan.
Contracts and Documentation for Coatings Projects
Contractor qualification; competitive bidding; project management and inspection.
Coating Failures
Causes of coating failures; consequences of coating failure; investigating the cause of failure; laboratory analysis of coating failures; responsibility for failure and repairs.
Regulations and Safety for Coatings Projects
Environmental regulations affecting the coatings industry; regulating hazardous materials; worker safety and health; OSHA general and construction industry standards; specifying and complying with regulation; hazard communication; hazards from toxic materials and operations; surface preparation hazards and safety requirements; paint
application hazards and safety requirements; hazards in high, confined, and remote places; personal protective equipment; other safety issues.
Sample PCS Examination QuestionsThe comprehensive certification examination and calculation questions consists of multiple choice, matching, essay, and material estimating questions. Questions are chosen primarily from the material covered in the C1 and C2 courses and from the suggested readings . Some of the questions can be answered from knowledge acquired by working in the coatings industry. Many of the questions require knowledge of several different subject areas.
Multiple Choice - give best answer
1. Which of the materials listed below is commonly used to make impressed current anodes for cathodic protection?A. High-purity zincB. High-silicon cast ironC. Electrolytic-grade magnesiumD. Titanium alloy
2. Which of the generic coating types listed below is recommended for service in sea water immersion?A. Epoxy polyamideB. Epoxy esterC. Silicone alkydD. Acrylic emulsion
3. What is the upper limit for shadows, streaks, or stains allowed on steel abrasive blast cleaned to a near-white condition?A. 0%B. 5%C. 33%D. 50%
4. Which if the following spray painting methods listed below has the highest transfer efficiency?A. Conventional air sprayB. Airless sprayC. High-volume low-pressure sprayD. Electrostatic spray
5. For what purpose is a plastic sheet test used?A. To prevent early flash rustingB. To test for coating cureC. To determine if concrete is dry enough for coatingD. To detect efflorescence
6. Which of the following is NOT a type of payment for coating contracts?A. Stage paymentB. Balloon payment
C. Incentive paymentD. Penalty payment
7. Who is normally responsible for preparation of a specification for a coating job?A. An independent inspectorB. The general contractorC. The ownerD. The coating contractor
8. Which of the following SSPC documents addresses maintenance painting?A. PA 1B. PA 3C. PA 4D. PA 5
9. Which of the following is a type of coating failure related to aging?A. BlushingB. UndercuttingC. CrateringD. Wrinkling
10. How often are proposed regulations published in the Federal Register?A. DailyB. WeeklyC. MonthlyD. Annually
Match the structure with a likely coating or treatment:1. Steel piping (atmospheric service)2. Bridge in a severe environment3. Lining for a chemical storage tank4. Ships, to prevent fouling5. New marine pilings
A. Three coats epoxy-polyamide; two coats coal tar epoxy B. FRP, vinyl ester; or epoxy resin, depending on specific product C. Petrolatum paste; microcrystalline wax, tape D. Organic zinc-rich primer; epoxy-polyamide midcoat; aliphatic polyurethane topcoat E. Copper oxide polymer
Essay:1. Discuss the differences in surface profiles produced by round steel shot and steel grit.
2. Briefly describe the capabilities of at least two (2) laboratory instruments in conducting a coating failure analysis.
3. State in writing at least six (6) technical problems resulting from specification deficiencies that could adversely effect a coatings project.
4. Facility management has decided to repair damaged coatings on a power plant structure before damage to the substrate occurs. What are at least six (6) basic factors involved in deciding between spot repair and full overcoating?
5. Discuss the advantages and limitations of abrasive blast cleaning, high-pressure water jetting, and power tool cleaning in the removal of existing coatings containing hazardous metals such as lead or cadmium. For each of these three cleaning systems, discuss at least two (2) advantages and at least two (2) disadvantages.
Calculate:1. A painter needs to apply a coating with 50% solids by volume at 4 mils dry-film-thickness. In order to do this, what should the wet-film-thickness measure be on his British wet-film-thickness gage? (answer in microns)
2. A manufacturer's data sheet indicates that when its coating is thinned by 10%, application at 5 mils WFT will result in 3.5 DFT. What is the % solids by volume of the coating?
3. A laboratory analysis of a new coating indicated that it had 75% total solids by weight and 35% pigment by weight. From these data, calculate the % of binder in the vehicle portion of the coating.
4. A painter is to coat the 20,000 square feet interior of a steel tank with a coating containing 80 % solids by volume at 4 mils dry film thickness. Assuming a 10% loss of coating during the work, how much coating would be required to complete the work?
5. A coating was found by laboratory analysis to contain 25% solvent by volume. What is its theoretical spreading rate at 4 mils DFT when thinned by 10%?
Answers
Multiple Choice: 1) B, 2) A, 3) B, 4) D, 5) C, 6) B, 7) C, 8) C and/or D, 9) B, 10) A
Matching: 1) C, 2) D, 3) B, 4) E, 5) A
Essay: There are multiple ways to answer the essay questions.Calculations: 1) 200 microns, 2) 77%, 3) 61.5%, 4) 69 gallons, 5) 273 per gallon
Suggested Reading for the PCS Exam
The following SSPC publications may help you prepare for the PCS exam:
Steel Structures Painting Manual, Volume 1, Good Painting Practice, 4th Edition: A practical, comprehensive encyclopedia on methods, equipment, and systems for the painting of structural steel. Each chapter represents the best available technology and was subjected to a consensus peer review. Topics include surface preparation, application, inspection, specialized industrial and marine painting, and related issues. In addition to revised or updated chapters, tables and charts, an appendix of all referenced standards, and a revised glossary, the third edition contains new chapters on safety and
health in the protective coatings industry, and environmental regulations affecting protective coatings. The essential work for everyone concerned with good painting practice. [SSPC 02-14]
SSPC Painting Manual, Volume 2, Systems and Specifications, 8th Edition: Latest edition of SSPC's complete set of specifications, commentaries, guides and procedures for surface preparation, paint application, dry film thickness, safety, environmental protection, maintenance, paints and painting systems for structural steel. The authoritative product of many years of open consensus work by SSPC and leading specialists in the protective coatings industry. The 8th edition also features several recently developed performance-based paint specifications, new and revised guides for environmental protection, a guide for atmospheric testing of coatings in the field, and a new procedure for evaluating the qualifications of shop painting contractors. [SSPC 00-10]
Practical Math for the Protective Coatings Industry This handy new book presents an essential review of basic mathematical principles, then applies these principles to formulas and calculations commonly used in the protective coatings field. The book begins with easy-to-follow rules, tips, and formulas for simple arithmetic, equation solving, dimensional analysis, geometry, computations, and statistics. It then provides specific formulas for calculating dew point, relative humidity, spreading rate, wet and dry film thickness, pigment volume concentration, transfer efficiency, and other important figures. Although it has something to offer coatings personnel at all levels of experience, it is written especially for those who seek to improve their math skills and advance in their profession through training and education. [SSPC 03-05]
The Fundamentals of Cleaning and Coating Concrete: Presents a thorough examination of concrete's physical and chemical properties; procedures for mixing, placement, consolidation, finishing, and curing; and the causes and prevention of concrete deterioration. It also provides detailed information on surface cleaning, repair, and preparation; the selection, application, and performance capabilities of protective coating and lining systems; inspection and failure analysis; and other relevant subjects. [SSPC 01-10]
Corrosion and Coatings: An Introduction to Corrosion for Coatings Personnel: This new book examines the various mechanisms and forms of corrosion, the prevention and control of corrosion through the use of protective coatings, and other methods and considerations for corrosion control. Although written for those with a limited technical background, Corrosion and Coatings can also provide the more seasoned professional with a handy overview of basic principles and can be useful as a guide for the development of a total corrosion control program. [SSPC 98-08]
The Inspection of Coatings an Linings: A Handbook of Basic Practice for Inspectors, Owners and Specifiers 2cnd Edition: This handbook is a comprehensive compilation of information, procedures, standards, and practices needed for effective inspection of coatings and linings applied to industrial structures. Its primary purpose is to provide coatings inspectors with the resources and guidance to effectively perform the work of inspection. This forms an important part of SSPC's mission to advance the technology and promote the use of coatings to preserve industrial structures. [SSPC 03-14]
Shop Painting of Steel: A new report on current surface preparation and coating practices in shop painting facilities. It identifies and describes the different types of industrial and light industrial/commercial paint shops, discusses their methods of operation, and compares the relative advantages and limitations of shop painting versus painting in the field. It also contains over one dozen SSPC guides and standards for the selection and performance of shop primers and coating systems. [SSPC 02- 01]
Protective Coatings: Fundamentals of Chemistry and Composition , Clive HHare: Discusses the basics of paint compositions and polymer design, and describes the properties and function of nearly every resin, binder, pigment, solvent and additive used in the formulation of protective coatings. Its accessible, straightforward text provides both the beginner and the more advanced coatings formulator with an essential overview of basic coatings technology. [SSPC 94-17]
Paint Film Degradation, Clive H. Hare: This new 631-page hardcover presents a scientific approach to the analysis and prevention of common paint and coating failures on industrial, commercial, and residential structures.It stresses the importance of good formulation, storage, mixing, handling, and application, as well the selection of materials suitable for a given substrate and service environment. Although the information it contains can assist in identifying or correcting existing failures, the book is not specifically designed for this purpose. Instead, it is meant to provide an approach to help avoid failures before they occur. [SSPC 01-14]
Generic Coating Types: An Introduction to Industrial Maintenance Coating Materials, Lloyd M. Smith, Ph. D., General Editor: Outlines and defines major generic classifications of coating materials. Includes an overview of basic coatings technology; a directory of coatings, linings, and floor toppings; and a directory of coatings manufacturers. [SSPC 95-08]
Surface Preparation and Coatings Handbook:
Prepared for the National Shipbuilding Research Program (NSRP), this compact yet comprehensive new handbook provides information on the maintenance of marine vessels with protective coatings. Topics include surface preparation methods and standards, coating materials, application methods, housekeeping requirements, safety and fire prevention, environmental issues, and more. [SSPC 95-07]
Industrial Lead Paint Removal Handbook, Volume I, Kenneth A. Trimber: An indispensable guide for managing lead paint removal operations. The second edition contains revised and updated sections on worker protection, containment systems, lead paint removal methods, preparing specifications, and verifying compliance with regulations. Its appendices contain relevant excerpts from the Code of Federal Regulations and the entire OSHA interim final standard on lead exposure in construction (29 CFR 1926.62). Those who already own the Handbook rely on it as the most comprehensive resource on industrial lead paint removal. Second Edition, 1993. [SSPC 93-02]
Project Design: Industrial Lead Paint Removal Handbook, Volume 2, Kenneth A. Trimber and Daniel P. Adley: Applying the fundamental information form Kenneth A. Trimber's Industrial Lead Paint Removal Handbook, this book addresses the specific job of designing and specifying industrial lead paint removal projects. Project Design gives specifiers, applicators, and facility owners an organized approach to collecting and analyzing data for appropriate decision making. This approach is organized into 11 methodical phases, including identifying lead or other toxic metals in coatings; determining a painting strategy; conductive risk assessment; establishing requirements for worker protection, waste management, and project closeout; preparing cost estimates; and writing a specification. In each phase, appropriate test methods are presented. Along with sample checklist forms that the reader can incorporate directly into his or her plan. [SSPC 95-06]
SSPC-VIS 1, Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning: The revised SSPC-VIS 1 features new photographs of previously painted blast cleaned steel, new photographs of industrial blast finishes, and other images and text not found in the previous version. [SSPC 02-12]
SSPC-VIS 3 Visual Standard for Power- and Hand-Tool Cleaned Steel: Shows a total of seven (four uncoated and three previously coated) steel surfaces before and after hand tool cleaning (SSPC-SP 2); power tool cleaning (SSPC-SP 3) with power wire brushes, needle guns, and sanding discs; and power tool cleaning to bare metal (SSPC-SP 11). Also contains photos that depict SP 11 surfaces on which the profile has been restored; a written guide to the use of reference photographs; and additional explanatory notes. [SSPC 93-04]
SSPC-VIS 4/NACE VIS 7, Guide and Reference Photographs for Steel Surfaces Prepared by Waterjetting: Shows a total of six (two uncoated and four previously coated) steel surfaces before and after waterjetting. Photographs illustrate four separate degrees of cleaning (WJ 1, WJ 2, WJ 3, and WJ 4) for each initial condition. Also contains photos that depict the appearance light, moderate, and heavy flash rust after cleaning; a written guide to the use of reference photographs; and additional explanatory notes. [SSPC 01-05]
SSPC-VIS 5/NACE VIS 9, Guide and Reference Photographs for Steel Surfaces Prepared by Wet Abrasive Blast Cleaning: Shows two uncoated, rusted steel surfaces before and after wet abrasive blast cleaning. Photographs illustrate two degrees of cleaning (WAB 6 and WAB 10) for each initial condition. Also contains photos that depict the appearance light, moderate, and heavy flash rust after cleaning; a written guide to the use of reference photographs; and additional explanatory notes. [SSPC 01-06]
PCS Program & Exam PoliciesGrading SSPC staff will grade the exams. Candidates will be notified in writing of their pass/fail results within sixty days after the exam date. Passing score for the exam is seventy percent or better.
Validation Exam results are subject to validation by at least one member of the certification panel at the discretion of the program administrator. (Between 65% and 75%)
Appeals A candidate has the right to appeal the exam results. The certification panel will resolve any disputes, which arise from the grading of the exams. The results of the panel's review by majority vote of the exam's grade shall be considered final and binding.
RevisionsThe exam is revised periodically. Revisions may affect the format of the exam or the % balance of subject areas covered by the exam.
PCS EmeritusPCS individuals who are retired from the coating industry may qualify for the status of PCS Emeritus. Contact [email protected].
Renewal PoliciesCertification is valid for four years, subject to verification of current status as a practicing industrial protective coatings professional. To re-certify for each four-year period, you must comply with the certification renewal policy.
SSPC Protective Coatings Specialists are required to demonstrate significant, continuing involvement in the protective coatings industry. Such involvement is demonstrated through continuing education and professional work experience.
PCS 4th year recertification requires that the Protective Coatings Specialists satisfy the Recertification Process. This is met by accumulating a minimum of 32 Recertification Units (RU) during the four-year term of certification (from issue date to expiration date) by following PCS Recertification Track 1 or PCS Recertification Track 2 . Recertification Units (RU) are defined as continuing employment and involvement in industry events which provide additional coatings training or activities which demonstrate your commitment to keep up-to-date on coatings technology. In order to make it easy for a PCS to track the Recertification Units SSPC has developed a Recertification Spreadsheet to fill out during the 4 year term. The spreadsheet is available at the following websitehttp://www.sspc.org/files/. Click on the file (PCSrecert.zip) and open the spreadsheet.
Failure to return a completed renewal form, attestation, or pay fees, will result in loss of PCS certification.
Renewal at the Four-Year TermRenewal notices are mailed to the last known address of each individual at least 90 days before the certification's expiration date. (The certified individual is responsible for updating SSPC of any change in personal or contact information. SSPC cannot be held responsible for de-certifications resulting from incorrect addresses, etc.)
Renewal Application Form: Click here for Application
SSPC PCS ADMINISTRATION: Recertification will occur at the 4th year renewal of a PCSís certification. ï SSPC will provide PCSís reminders about completing the forms via online emails every six months.Paperwork required at the 4th year renewal:
1. Attestation that the individual is in compliance with the standards of professional practice and has not been subject to disciplinary action. 2. Recertification Worksheet. 3. Fee of $250 (member rate) every four years. Non-member fee is $450. 4. Submit a photo ID
SSPC will provide a photo wallet card and a certificate upon completion of the 4th year recertification process. If you have any questions on the new recertification process, please contact PCS Certification Administration at 1-877-281-7772 ext 2201 or email at [email protected] .
Failure to return a completed renewal form, attestation, or pay fees, will result in loss of PCS certification.
Continuing Education Requirement PCS certification renewal requires that the Protective Coating Specialist satisfy a Recertification Units Requirement. This is met by accumulating a minimum of 32 points during the four-year term of certification (from issue date to expiration date).
Standards of Professional Practice To maintain the high standard of skills and practice in the protective coatings industry, SSPC Protective Coatings Specialists are required to:
Be objective, thorough, and factual in any report or statement pertaining to the protective coatings industry
Avoid involvement in any dishonest venture Act in all ways with complete integrity in professional matters Undertake assignments only when qualified by training, experience, and capability.
Disciplinary ActionDocumented infractions in professional conduct may result in suspension or revocation of certification.
Disciplinary actions may include issuance of a reprimand, suspension, or revocation of certification for up to one year. Recommendations for disciplinary actions are initiated by the SSPC program administrator, followed by concurrence by a majority of the certification panel or oversight body (such as SSPC Board of Governors).
De-certificationDecertified individuals are no longer permitted to use the title of Protective Coatings Specialist or their certification ID number. This includes, but not limited to: business cards, letterhead, correspondence, etc. No Exceptions.
The formerly certified individual's name and information will be removed from the SSPC web site. A de-certified individual is not eligible for any benefit of the certification, present or future.
Reinstatement of CertificationAn individual, who has been de-certified due to a failure to submit the annual maintenance paperwork and/or fees before the certification expiration, must take the following steps to reinstate:
Reinstatement within 90 days after expiration
Pay reinstatement fee in addition to renewal feeReinstatement greater than 90 days after expiration, but before end of original 4-year certification term
Complete another application and pay reinstatement fee in addition to the renewal feeReinstatement after the original 4-year term has expired
Reapply as a new applicant, pay all associated fees, and re-take and pass the certification exam.
Requests for reinstatements for individuals de-certified due to other reasons defined in this policy, must be in writing and will be reviewed by the certification panel.
A final determination will be made on a case by case basis.