inspections work and equiptment

8/12/2019 Inspections Work and Equiptment

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Frosio course hand-out: Section 17A Inspection work & equipment

1

Frosio 17A Inspection work & equipment slide # 1

Use of instruments


Utstyr utlagt

Inspection Equipment


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Inspection after application

Climatic conditions (Ventilation,Temperature and humidity)Curing / drying of the filmDry film thickness (DFT)

AdhesionHoliday detection (if required)

After applicationthe following must be checked


Wet paint

Steel

ISO 2808 - 97 Method No.1Wet film measuring comb

Microns250 225 200 175 150 125 100 75 50 25


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4932-81

0459-21

ISO 2808Wet film thickness gauge

Measure wet paint film Here: 25 microns between the teeth


Using PIG Universal on aships hull

PIG = PaintInspection Gauge

Destructive testmethod

Possible to verifythe number of coatsapplied

Possible to measurethe thickness ofeach individual coat

Cd-4932-100


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PIG Paint Inspection GaugeMainly for laboratory use

4932-100


ISO 2808 - 97

Determination of film thickness

Method No. 6: Magnetic method

Magnetic induction principle (Method 6 A) Permanent magnetic principle (Method 6 B)

Instruments for magnetic, metallic substrates Calibration must be done in accordance

with instructions from the manufacturer

Before testing the paint systemmust be properly cured.


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ISO 2808 - 97

Determination of film thickness

High frequency electromagneticinstrument

For non-magnetic substrates

Calibration in accordance with themanufacturers instruction

Method No. 7 - Eddy current method


Electromagnetic instruments Calibration on a smooth steel surface min. 1,2 mm

thick For DFT measurement, not less than 25 and

preferably above 50 microns Number of readings, as a guide:

1 reference area: At least 3 readings evenly 2 reference areas for every square meter for flat plates 4 reference areas for every length for a web 2 reference areas every metre length for a flange 2 reference areas every metre length for a pipe

ISO 2808 - 97Determination of film thickness

Method No. 10 - On blast cleaned steel substrates


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ISO 2808 - Magnetic and electromagneticDry film thickness gauges

Dry film thickness gauge Calibrate on smooth

surface to zero and tothickness similar to bemeasured

Check with yourcalibration foil frequently

Plastic material foils wear

easily. Replacefrequently. No internal memory in

gauge

Cd-4932-82


ISO 2808 - Magnetic and electromagneticDry film thickness gauges

Dry film thickness gauge Calibrate on smooth


Check with your calibration

foil frequently Plastic material foils wear

easily. Replace frequently. No internal memory in

gaugeInspection \ Dryfilmthickness1


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Trrfilm mlere Elektr.Magn.

Magnetic and ElectromagneticDry Film Thickness Gauges

ISO 2808 Dry film thickness gauge Calibrate on smooth


Check with yourcalibration foil frequently

Plastic material foilswear easily. Replacefrequently.

Some models haveinternal memory.


SSPC - PA 2Measuring DFT on small areas

1. Area of 10 m 2 : 5 spot measurements

2. Each spot measurement: The average of 3 individualreadings made on one small area

3. The average of 5 spot measurements must bewithin specified range of film thickness

4. Single spot measurements may be as low as 80% ofspecified minimum film thickness

5. Individual readings included in the spotmeasurements may be less than 80% of minimumthickness

Procedure


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SSPC - PA 2Number of film thickness measurements

1. 10 m 2 5 spots (on each spot: 3 measurements)

2. 30 m 2 As for case 1 for each 10 m 2

3. Up to100 m 2 Select 3 areas, each of 10 m 2

4. Above 100 m 2 The first 100 m 2 as for case 3For each following 100 m 2 selectrandomly one area of 10 m 2

Note: If measurements outside the specification for any 10 m 2 in case3 or 4 above are found, then each 10 m 2 shall be measured

Case Area Selection of Measurements


Instruments for measuringsurface roughness

Stylus instruments Elcometer Mod. 123 Testex Press-O-film Microscope Comparator

Rugotest No. 3 ISO 8503 etc.


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Clemco

Compartor

Surface Roughness acc. toISO 8503

Example of a referencecomparator: Clemco

Surface profile comparatorcomprising four segments.

Clemco - grit Clemco shot also available Check if the profile is

according to specificationand the paint manufacturersrecommendation


Jan, speil, lykt

Using Inspection Tools: Mirror andFlash light

Visual inspection Important tools to

be able to inspectareas difficult toaccess


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1. Air temperature2. % Relative humidity3. Steel temperature

4. Dew point

ISO 8502 4 Humidity

Guidance on the estimation of the probabilityof condensation prior to paint application

Steel temperature min. 3 oC above the dew point


Steel temperature

Contact Thermometer

Electronic instrumentfor measuring the steeltemperature

Steel temperaturemust be min. 3 oC

above the dew point Other types of

thermometers are alsoavailable. E.g.magneticthermometers


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Measuring the Relative Humidity

ISO 8502 - 4 Photo: Sling hygrometer

for measuring:- Dry temperature- Wet temperature

Measure the temperaturein the vicinity of the work

Calculate the relativehumidity

Use together with dewpoint calculator


Dew Point Calculator

ISO 8502 - 4 For calculation of dew

point To be used together with

surface temperaturethermometer and slinghygrometer.

Use this frequently duringpre-treatment, applicationand drying of the paint.

Recommendation: Every 6hours and when weatherconditions are changing


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Bresle sett

Salt Test Equipment - Bresle Test

ISO 8502 - 6(Sampling)

ISO 8502 - 9(Conductivity)

Equipment forsampling andmeasuring content of

water soluble salt onsubstrate Bresle method


How to measure the salt level ona surface

Water soluble salts will beremoved by water jetting

Here: The substrate iscleaned at a pressure of2000 bar

Salt level is measured bythe Bresle method

Dissolve the salt insidethe frame of the patch

Measure the conductivityof the water sample

Pre-treatment: Wj_saltlevel1

For 15 ml sample size, multiplyconductivity measured in S by afactor of 6 to get mg salt per m 2


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Calculating salt level on thesubstrate

Formula: (L2 L 1) x 6 = mg salt per m 2

L2 = S after cleaning

L1 = S before cleaning

Water sample, ml: 10 15 20 50

Constant in formula: 4 6 8 20


ApprovedNot approved

Tape Blast cleaned steel

Assessment of Dust on Steel SurfacesPrepared for Painting. ISO 8502-3


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Glove RagMEK

Rubbing 50 x

No Zinc on the Rag:CuredApproved

ASTM D 4752-87Curing test of Zinc - ethylsilicate with MEK.

A lot of Zinc on Rag: Not curedFurther curing / Reblasting


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ASTM D 4752-87MEK curing test of zinc ethyl silicate

Left: One cured and uncured test plate Right: Uncured zinc over coated. Result: Delamination

A-40807-2


Glove

Rag

MEK

ASTM D 4752 ASTM D 4752 --8787Curing test of ZincCuring test of Zinc ethyl silicate with MEK.ethyl silicate with MEK.

Inspection / Zincsilicate_curing1


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ASTM D 3359-87Adhesion testing by knife and adhesive tape

There are two test methods The method to select depends on the DFT

Method A: DFT above 125 micronsMethod B: DFT below 125 microns

(Above 125 if wider cuts are used)

Method A: X - cut. Tape testMethod B: Cross - cut. Tape test


ASTM 3359-87. Method BAdhesion testing

< 50 microns = 1 mm apart (11 cuts) 50 - 125 microns = 2 mm apart (6 cuts) > 125 microns = Method A

1. Cuts: 20 mm long2. Brush with a soft brush

3. Examine4. Cuts: 20 mm long at 90 o on the original cuts5. Brush with...6. Tape 75 mm7. Within 90 + 30 sec. remove tape


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5B The edges of the cuts are completelysmooth; none of the lattice is detached

4B Small flakes of the coating is detached atintersections: 5% of the area is affected

3B Small flakes of the coating are detachedalong edges and at intersections of cuts.The area affected is 5 to 15% of thelattice.

2B The coating has flaked along the edgesand on parts of the squares. The area

affected is 15 to 35% of the lattice.1B The coating has flaked along the edges of

cuts in large ribbons and whole squareshave detached. The area affected is 35 to65 % of the lattice.

0B Flaking and detachment worse than Grade1B.

Classification of adhesion test results.Method B. (Example for six parallel cuts).

5B None4B

3B

2B

1B

0B Greater than 65%


ISO 2409Cross-cut testCutting tool

Single bladed knifeor

Multi-blade cutting tool with 6 cuttingedges spaced 1 mm or 2 mm apart

Spacing of cuts0 - 60 microns: 1 mm spacing, hard substrates0 - 60 microns: 2 mm spacing, soft substrates

60 - 120 microns: 3 mm spacing, hard/soft substrates121 - 250 microns: 3 mm spacing, hard/soft substrates


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Procedure: Make 6 parallel cuts with defined space in the

coating. Repeat operation, crossing original cuts at 90 o

so that a grid pattern is formed. Brush with soft brush. Apply adhesive tape and pull off. Classify results in accordance with table 1.

ISO 2409Cross-cut test


ISO 2409Cross cut adhesion test

Cross cut adhesiontest

Cut vertical andhorizontal lines toform a grid

Apply a strong tape Pull off the tape Evaluate according to

the standard

Cd-4932-91


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ISO 2409Cross-cut adhesion test

Left: A good type of cross-cut tool Right: Evaluation of performed test

0002-001

0002-002


5B The edges of the cuts are completelysmooth; none of the lattice is detached

4B Small flakes of the coating is detached atintersections: 5% of the area is affected

3B Small flakes of the coating are detachedalong edges and at intersections of cuts.The area affected is 5 to 15% of thelattice.

2B The coating has flaked along the edgesand on parts of the squares. The areaaffected is 15 to 35% of the lattice.

1B The coating has flaked along the edges ofcuts in large ribbons and whole squareshave detached. The area affected is 35 to65 % of the lattice.

0B Flaking and detachment worse than Grade1B.

Classification of Adhesion Test Results.(Example for six parallel cuts).

5B None4B

3B

2B

1B

0B Greater than 65%


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ISO 2409Classification of Cross-cut testClassi-fication

Description Appearance of surfaceSix parallel cuts

0 Completely smooth: none of the squares detached1 Small flakes at the Intersections. Area affected 5 %

2 Flaked along the edges and/or at theIntersections. Area affected: 5-15%

3

Flaked along the edges, wholly in large ribbons,

and/or partly or wholly on different parts ofthe squares. Area affected: 15-35%

4Flaked along the edges in large ribbons and/or some squares have detached partly or wholly.Area affected: 35-65%

5 Any degree of flaking that cannot even be classified by 4.


ISO 2409Cross cut adhesion test

Cross cut adhesion test Cut vertical and

horizontal lines to forma grid

Apply a strong tape

Pull off the tape Evaluate according to

the standard

Inspection / Adhesion_crosscut1


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Instruments: Elcometer Adhesion Tester Saeberg Adhesion Tester (pneumatic) Hate Adhesion Tester (hydraulic) PAT Other

ISO 4624Pull-off test for adhesion

Failure:Adhesion failure: Between coats or between or substrate and 1st coatCohesion failure: Inside a coat


ISO 4624Pull-off test for adhesion

Procedure : Test dollies glued onto the coating Adhesive: Cyano-acrylate or solvent free epoxy Remove adhesive and coating around the dollies Pull off test-dollies vertical to the surface

Read adhesion value and report the type of fracture

Fractures: Adhesion failure - fracture between coats or substrate and 1.

coat Cohesion failure - fracture within a coat


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ISO 4624Pull-off dollies glued to the structure

Pull off adhesiontest

Dollies are glued tothe structure with astrong glue

Prior to pull-off:

Cut around thedolly, through thepaint film and downto the substratematerial

Cd-4932-102


ISO 4624Pull-off testing of paint on a structure

Pull off adhesion test. Destructive test method Here, connecting of the

device for pulling off thedollies

Read and note the value Several types of

instruments areavailable

Cd-4932-101


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ISO 4624Area after pull-off testing

Pull off adhesion test The adhesiveadhesive failure -

fracture between coats -or between coating andsubstrate must beevaluated

Note adhesion failure, % The cohesivecohesive failure -

fracture within thecoating- must beevaluated.

Note cohesion failure, % Also: Note glue failure, %

Cd-4932-103


ISO 4624Pull-off dollies glued to thestructure Pull off adhesion test Dollies are glued to the

structure with a strongglue

Prior to pull-off:

Cut around the dolly,through the paint filmand down to thesubstrate material

Record the pull-offvalue

Evaluate the failureInspection / Adhesion_pulloff1


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ASTM G-62-85, method ALow voltage pinhole detector

Photo: Low voltage pinholedetector

Detecting pinholes, voidsor metal particles in paintfilm up to 250 microns

Non destructive testmethod

Will only detect defectsdown to bare metal The sponge must be

wetted Do not use excessive water

0002-004


ASTM G-62-85, method ALow voltage pinhole detector

Detecting pinholes,voids or metalparticles in paint filmup to 250 microns

Non destructive test

method Will only detect defects

down to bare metal The sponge must be

wetted Do not use excessive

waterInspection / Pore_detection1


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ASTM G 62 Method BHoliday detection. High voltage.

High voltage: 900 - 20.000 V

Used to detect pinholes, voids andareas with thin paint films

This is a destructive test.


ASTM G-62-85, method BHigh voltage holiday detector

Destructive test methodfor detecting pinholes,voids and thin spots inpaint film

Adjust voltage according to

the film thickness or thepaint manufacturersrecommendation

Gives a light or signal whenpinhole or weak point isdetected

Cd-4932-93


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0002-005

ASTM G-62-85, method BHigh voltage holiday detector

Destructive test methodfor detecting pinholes,voids and thin spots inpaint film

Adjust voltage according tothe film thickness or thepaint manufacturersrecommendation

Gives a light or signal whenpinhole or weak point isdetected


ASTM G 62 Method BHoliday detection. High voltage.

High voltage: 900 - 20.000V

Used to detect pinholes,voids and

areas with thin paint films

This is a destructive test.

Inspection / Holiday_detection1


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ISO 8504

Surface preparation methods:

Part 1: General principles.Part 2: Abrasive blast-cleaning.Part 3: Hand- and power-tool

cleaning.


Methods Effectiveness Fields of

application

ISO 8504 - 2

Abrasive blast-cleaning


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Methods Equipment to be used Procedure to be followed

ISO 8504 - 3Hand and Power-tool Cleaning


Steel

Rag soakedwith solvent

No reaction:Chemically curing

Paint dissolves:Physically drying

Using solvents to determinegeneric type of paint

2 coat paintLifting/Wrinkling:Oxidatively curing


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Use a rag soakedwith solvent

No reaction:Chemically curing

Paint dissolves:

Physically drying

Using solvents to determinegeneric type of paint

Lifting/Wrinkling:Oxidatively curing

Inspection / Determine_generic1


Standards relating to mechanical properties

Property Standard / Test methodAdhesion (Cross cut) ISO 2409, DIN 53251, BS 3900-E6, ASTM 3359Adhesion (Pull-off) ISO 4624, ASTM 4541, BS 3900 - E10Adhesion(Shear strength)

ASTM D 1002 (Specified for Chartek)

Hardness ISO 2815 (Buchholz - methode)Hardness ISO 1522 (Knig - pendel)

Hardness BarcholElasticiy ISO 1520 (Cupping test)Flexibility ISO 6860 ASTM D 522

BS 3900 - E11 (Conical mandrel)

Impact resistance ISO/TR 6272 - 79E ASTM D 2794 - 84DIN 55669 BS 3900 - E3


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Testing and evaluation.marine atmosphere (1 of 2)Test method Standards Comments

Physical testingAdhesionAdhesionFlexibilityElasticityHardnessImpact resistanceGlossAbrasion resistance

ISO 2409ISO 4624ISO 1510ISO 1520ISO 2815ISO 6272ISO 2813ASTM D 4060

Before and after exposureBefore and after exposureBefore and after exposureBefore and after exposure

Exposure conditions:SaltsprayProhesion testUV-cabinetCondensation chamber Humidity chamber WeatheringResistance to liquids

ISO 7253 or ASTM B 117

ASTM G 53ISO 6270BS 3900ISO 2810ISO 2812 Oil, petroleum , etc.


Test method Standards Comments

Evaluation of paint filmsBlisteringRustCrackingFlakingChalking

Scribe

ISO 4628/2ISO 4628/3ISO 4628/4ISO 4628/5ISO 4628/6

ASTM D 1654

Evaluation of the liquid paint

Appearance in tin

Application properties

ISO 2431

ISO 2884

Flow time

Viscosity

Testing and evaluation.marine atmosphere (2 of 2)


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Abrasion resistance

Weigh the paintedsample

Install it in the apparatusand run 1000 cycles

Measure the weight loss

Testing paints \ Abrasion resistance1


Flexibility test

Use a thin test panel Measure the paint film

thickness Carry out the impact test

on the rear side of thetest panel

Determine the highestlevel of impact loadbefore any crack ordefect in the paint filmoccurs

Testing paints \ Flexibility_test1


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Impact test

Use a thick test panel Measure the paint film

thickness Carry out the impact test

on the painted side of thetest panel

Determine the highestlevel of impact loadbefore any crack ordefect in the paint filmoccurs

Testing paints \ Impact_test1


Reference area should:

be representative to the remainingarea coated with the same system.

be available for inspection at any time. be marked thoroughly to indicate

"ref.area" not be overcoated


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Controlled application

Inspection of: steelwork cleaning surface preparation (blastcleaning) painting curing

completed system


Number of reference areas

2000,29>50000

1000,2925000 to 50000

750,3710000 to 25000500,575000 to 10000

250,552000 to 5000

120,63< 2000

Recommended maximumtotal area of referenceareas

m 2

Recommended maximumpercentage of referencearea relative to total areaof structure

Recommended maximumNumber of referenceareas

Size of structure(painted area)

m 2

inspections work and equiptment

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