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Coating Inspection 2
Quality Control is a necessary function if coatings are to be
successfully applied. Their long-term performance is much
more likely to meet expectations if the factors that affect
performance can be improved. Experience shows that
inspection is a significant element in achieving desired
quality levels.
Coating Inspection 2
Index
Non-destructive Test Instruments and Methods .................... 4
Surface Preparation ................................................................ 5
pH Measurement.............................................................. 5
The pH Meter................................................................... 6
Magnifiers ........................................................................ 6
Visual Standards for Evaluation of Coating Defects .......... 7
Evaluation of Checking ................................................... 8
Evaluation of Cracking .................................................... 9
Evaluation of Erosion ...................................................... 9
Evaluation of Blistering ................................................... 9
Evaluation of Flaking..................................................... 11
Rusting Standard............................................................ 12
Detection of Moisture—Indicators and Tests................... 12
Moisture Meters for Wood, Plaster, and Concrete ........ 13
Other Tests for Moisture in Concrete ............................ 15
Tests for Water-Soluble Chemical Salts........................... 16
Origin of surface salts .................................................... 16
Qualitative Test for Water-Soluble Ferrous Salts.......... 18
Semi-quantitative Tests.................................................. 19
Tests for sulfate ions & nitrous ions .............................. 25
Conductivity Testing...................................................... 25
Applicable Limits .......................................................... 26
Dry Film Thickness Measurements .................................. 28
Magnetic Pull-Off Gauges ............................................. 28
Electromagnetic DFT Gauges........................................ 29
Accuracy ........................................................................ 30
Eddy current DFT gauges .............................................. 32
Destructive Instruments and Tests ....................................... 35
Solvent Sensitivity Testing ............................................ 36
Paint Inspection (Tooke) Gauge .................................... 39
Precision Groove Grinder .............................................. 42
Saberg Drill.................................................................... 43
Adhesion Tests.................................................................. 44
Measuring Adhesion by Tape Test ................................ 45
Adhesion Testing Using Portable Pull-Off Tensile
Testers ............................................................................ 48
Other Tensile (Adhesion) Testers .................................. 53
Reporting Tensile Test Results ...................................... 53
Non-Destructive Adhesion Testing ............................... 56
o The pH meter
o Magnifiers
Surface Preparation
When coatings are applied, surface preparation is considered
to be the single most influential factor that determines the
potential performance of the coating system. Quality control
of surface preparation includes:
o Cleaning operations
o The pH meter
o Magnifiers
o Moisture measurement
pH Measurement
Measurement of the pH level provides an indication of the
acidity or alkalinity of an aqueous solution. The pH scale
ranges from 0 to 14; the range 0 to 7.0 is acidic, and the
range from 7.0 to 14 is alkaline, with a pH of 7.0 being
neutral.
The pH Meter
A pH meter is an electronic gauge, often pocket size, with a
scale that provides a numerical value for pH. The probe of
the pH meter is placed in the aqueous solution to be tested.
Magnifiers
Magnifiers may sometimes be useful to the coating inspector.
These devices may be used for examining a blast-cleaned or
coated surface for:
o Contamination
o Rust
o Mill scale
o Blisters
o And pinholes
Surface Microscope
A surface microscope may be used for the same purpose as a
magnifier, but generally provides more magnification, and
perhaps better optics. Various magnifications are available
in simple (and cheap) pocket microscopes. A microscope
that provides 20 times magnification is probably the best for
general purposes, and anything more than 30 times is
unlikely to provide an adequate view of any defects.
Binocular Microscope
Binocular microscopes, also called stereo microscopes,
provide a three-dimensional image. These microscopes are
laboratory grade instruments with superior optics, and are
available with magnifications up to 500 times. Many can be
fitted with a camera or a digital image capture device, and
are widely used in laboratory testing of paints.
Evaluation of Checking
ASTM D 660 Standard Test Method for Evaluating Degree of
Checking of Exterior Paints defines checking as ‘slight
breaks in the film that do not penetrate the film’. It lists 8
types of checking, including:
Evaluation of Cracking
ASTM D 661 is the Standard Test Method for Evaluating the
Degree of Cracking of Exterior Paints and defines cracking
as ‘breaks in the film that penetrate the film’. It lists 3 types
of cracking, which are:
o Line type
o Sigmoid type
Evaluation of Erosion
ASTM D 662 is the Standard Test Method for Evaluating the
Degree of Erosion of Exterior Paints and defines erosion as
‘wearing away of the finish to expose the substrate or
undercoat’. Only one type of erosion is recognized.
Evaluation of Blistering
ASTM D-714 is the Standard Test Method for Evaluating
Degree of Blistering of Paint and provides a method and
photographs to standardize evaluation of blistering. This test
is often used to evaluate the degree of blistering which
results from testing coatings under laboratory conditions,
such as in an “Atlas Cell Test”, or to evaluate blistering that
occurs in the field.
1
Pictorial Standards of Coating Defects Handbook, published by the Federation
of Societies for Coatings Technology, 492 Norristown Road, Blue
Bell, PA, 1942, USA
o Dense (D)
o Medium (M)
o Few (F)
o Size - from 0 to 10
o Solvent entrapment
o Chemical attack
Evaluation of Flaking
ASTM D 772 is the Standard Test Method for Evaluating
Degree of Flaking (Scaling) of Exterior Paints defines
flaking as ‘detachment of pieces of the film from the
substrate or from paint previously applied’. Only one type of
flaking is recognized
Rusting Standard
ASTM D 610 is the Standard Test Method for Evaluating
Degree of Rusting on Panted Steel Surfaces provides a
pictorial guide to help judge the quantity of rust. Ten grades
are defined, ranging from Rust Grade 10 – no rusting – to
Rust Grade 0 – approximately 100% of the surface being
rusted.
Detection of Moisture—Indicators
and Tests
As indicated previously, moisture in porous surfaces may
lead to poor adhesion and blistering of coatings. This effect
is particularly likely if the moisture is present when coatings
are applied.
Test Procedures
For the specific instrument shown The Delmhorst moisture
meter, first, check calibration by pushing “Cal Check.” The
needle pointer should move to “20” on the scale. If it does
Tests for soluble salts are most often performed after surface
preparation, and before the application of coatings. Tests
may also be performed prior to any surface preparation work,
when decisions regarding the work may be influenced by the
results. For example, tests for the presence of chlorides may
be performed on pipe delivered to a pipe coating plant as
deck cargo on a ship or barge. If levels are found to exceed
10 micrograms per sq. cm, pipe should receive extra acid
Test Procedure
A qualitative test for water-soluble ferrous salts was first
described in Appendix G of British Standard BS 5493, and is
now included in ISO 8502-1, Annex A. The method
includes:
Semi-quantitative Tests
Quantitative measurement of chemical salts generally
requires accurate laboratory test methods. The most
Sample Collection
For most quantitative or semi-quantitative chemical tests, the
first stage is collection of a representative sample. The
sample is then tested using pre-prepared indicator strips, test
solutions or other test method. Alternatively, samples can be
sent to a laboratory for analysis.
Use the wetted cotton wool ball to wash the surface of the
test area, being cautious to keep the water within the
inscribed area. Return the cotton wool ball to the beaker
containing the wash solution.
Use a new, dry cotton ball to dry up the test area. Return the
second ball to the beaker containing the test solution, and
repeat the drying process with new cotton balls until the
surface is dry.
Stir the contents of the beaker, which contains all the cotton
balls used, for 20 seconds.
Bresle Patch
The Bresle patch is a self-adhesive patch about 5cm - 2inch
square, with a latex center that allows injection of test
solution through the surround section, using a hypodermic
needle and syringe. The test solution is most commonly 5-
ml of de-ionized or distilled water.
Chlor-Test Kit
Using a similar principle to the Bresle patch, the self-
adhesive Chlor-Test sampler provides a bigger sample
pouch, and therefore allows a larger test sample. The test
Indicator Papers
Indicator papers are available for a wide variety of
substances. Of particular interest in the context of surface
preparation for coatings are those used for the detection of:
o Water-soluble ferrous salts
Kitagawa Tubes
Sealed tubes with reagents that are specific to the salts to be
measured are probably more accurate, particularly after
storage, than most other indicators. Kitagawa tubes are
similar in appearance to Draeger tubes.
After sample collection, the tubes are made ready for use by
breaking the sealed ends. When placed in the test solution,
the fluid is drawn up through the tube by capillary action.
Color changes within the reagent crystals indicate the
quantity of salts, for example, chlorides, in the test solution.
Conductivity Testing
A measure that includes some consideration of the total
soluble salts present on the surface, without specifically
identifying any salt, is conductivity.
Applicable Limits
As mentioned earlier, there is no conclusive or definitive
level of salt contamination that can be used to specify
acceptable limits for coating purposes. Some levels are
defined by the Water-Jetting standards, NACE 5/SSPC-SP
12, as follows:
2
“Substrate Contamination by Non-Visible Soluble Salts, Acceptance Levels
Immediately Prior To Coating, Test Schedules and Preparation of
Specifications to Mitigate the Effects of Soluble Salts.”
Accuracy
Factors that affect the accuracy of DFT gauges, both
magnetic and electro-magnetic types, include:
o Substrate thickness
o Edges
o Curved surfaces
o Magnetic coatings
o Configuration of substrate
o Substrate thickness
o Edges
o Curved surfaces
o Conductivity of coatings
Calibration
In every case, the specific instructions and recommendations
of the instrument manufacturer should be carefully studied .
Where specifications provide a reference standard for the use
of DFT measuring equipment, or provide specific
instructions, the methods specified should be followed. Any
conflict between specified methods and the instrument
manufacturer’s instructions for calibration or use should be
resolved before the project starts.
o Tape pull-off
o Dolly pull-off
o Hardness
o Pencil
o Impressor, or indentation
o Cathodic disbondment
Test Procedure
The rub-test for inorganic zinc silicate is generally performed
as follows:
3
ASTM D-4138-94, Measurement of Dry Film Thickness of Protective Coating
Systems by Destructive Means [Method A]
One side of the gauge, at right angles to the side with the
guide studs, is equipped with an illuminated 50 power
microscope.
Note:
o A 1x 45-degree angle tip is used for coatings of 20 to
50 mils, or 500 to 1250 µm thick. When using the 1x
tip, each line on the reticle scale represents one mil or
25.4 µm.
Gauge Calibration
The Tooke gauge cannot be “field calibrated”.
o It is portable
Saberg Drill
The Saberg drill, - turned by hand - cuts a hole through the
coating with angled sides, like the counter-sunk section of a
normal drilled hole. The hole is cut at 90° to the surface,
until the substrate is reached. The various coatings within
the system can then be seen as layers within the angled hole.
Adhesion Tests
Most coatings properly applied to a well-prepared surface
develop good adhesion to the substrate. When coatings do
not develop good adhesion, this is a likely indication that
some element of the surface preparation and coating process
was defective. Many users elect to conduct adhesion tests to
determine the quality of the coating bond to the substrate, or
between coats.
Knife/Micrometer
A pocket knife or a very sharp putty knife or scraper may be
used to perform a quick, but informal, adhesion test. The
knife is used to cut through the coating, and an attempt is
made to peel the coating from the substrate.
Method A
Two cuts are made through the coating, approximately 2
inches, 5-cm long and intersecting at the mid-point to form
an ‘X’-cut. The cut should be a single stroke, completely
cutting through the coating to the substrate.
After the cuts have been made, the area is lightly brushed, to
remove any dislodged coating. Tape, of an agreed type, is
then stuck to the surface
From the roll of tape, two complete laps of tape are removed.
The tape is placed over the cuts and smoothed firmly with an
eraser to ensure good contact. The tape should be removed
within 60 – 120 seconds of application, and ideally at 90
seconds, by seizing the free end and rapidly pulling it off ,
but not jerking, as close to an angle of 180 degrees as
possible.
Rating Description
5A No peeling or removal
4A Trace peeling or removal along incisions or at their
intersectaions
3A Jagged removal along incisions up to 1/16 in. (1.6 mm) on
either side
Method B
A series of cuts through the coating are made at right angles
to each other, forming a series of squares. The number of
cuts depends on the thickness of the coating, as follows:
Again, the agreed tape is used. From the roll of tape, two
complete laps of tape are removed. The tape is placed over
the cuts and smoothed firmly with an eraser to ensure good
contact. The tape should be removed within The tape should
be removed within 60 – 120 seconds of application, and
ideally at 90 seconds, by seizing the free end and rapidly
pulling it off , but not jerking, as close to an angle of 180
degrees as possible.
Rating Description
5A The edges of the cuts are completely smooth; none of
the squares of the lattice is detached.
4B Small flakes of the coating are detached at
intersections; less than 5% of the area is affected.
3B Small flakes of the coating are detached along the edges
and at the intersections of the cuts. The area affected is
5% to 15% of the lattice.
2B The coating has flaked along the edges and 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 squares have detached. The area
affected is 35% to 65% of the lattice.
0B Flaking and detachment worse than Grade 1.
o Coating to substrate
Testing
The test is performed as follows:
o Substrate = A
o Second coat = C
o Glue or adhesive = Y
o Fixture or dolly = Z
Note: Location of adhesive or cohesive failure may be described using ASTM D4451 convention, as key below:
A = substrate B = First Coat C = Second Coat D = Third Coat (etc.) Y = Adhesive Z = fixture (dolly)
1000
Instrument reading (psi)
800
600
Series1
400
200
0
0 200 400 600 800 1000 1200
True Value (psi)
Hardness Testing
The hardness of a coating may be regarded as an indication
of its successful cure, and therefore, to some extent, its
‘normal’ expected performance. There are several laboratory
methods for determining hardness of a coating film, but only
two methods suitable for field use will be explored in this
module. These are:
o Pencil hardness
Pencil Hardness
The rapid determination of the film hardness of an organic
coating by the pencil hardness test is useful in coatings
development work, and in establishing performance criteria
for various coatings. This hardness test may be performed
under laboratory conditions or may be performed in the field.
Test Procedure
The pencil hardness test is a procedure that tries to mark or
mar a coating by pushing pencil leads of varying hardness
along the surface of the coating. The test is performed,
according to ASTM D 3363, as follows:
Calibration
Hard and soft aluminum alloy disks are supplied as standards
used to verify calibration of the instrument. Each has a range
of measurements, for example, 87-89 Barcol units, that
should be measured when the gauge is impressed on the disk.
If measurements made in this way fall outside the noted
range, adjustments must be made to any measurements
subsequently made.
Test Procedure
The test specimen should be at least 0.0625 in. (1.5 mm [63
mils]) thick and large enough to ensure a distance of 0.125
in. or 3 mm, in any direction from the indenter point to the
edge of the specimen.
o State of cure
Hardness Scales
Indentation hardness measurements are numeric, and based
on arbitrary scales created by the manufacturer of the
equipment. Manufacturers of commonly used hardness
testers, include:
o Rockwell
o Vickers
o Brinell
o Barcol, Barber-Colman
Boroscopes
Boroscopes are optical instruments used to observe the
interior of enclosed spaces. They may be rigid or flexible,
and are generally used for inaccessible interiors such as:
o boiler tubes
o hazardous environments
o Permeability
o Hardness
o Penetration
o Melting point
o Adhesion
o Abrasion resistance
o Color retention
o Gloss retention
o Bend
o Salt spray
Inspectors should analyze the duties that they are being asked
to perform. There are many similarities between coating
inspection performed on various structures, and the
techniques of measurement are essentially similar. If owners
require specific industry knowledge and experience,
inspectors are duty bound to examine their work experience
and determine whether they are sufficiently qualified to
perform the work.
Conflict of Interest
Coating inspectors are often employed by contractors or by
coatings manufacturers. Many owners write the requirement
into the specification in this way, effectively hoping to gain
true inspection while avoiding the need to write another
Instrument Calibration
Calibration might be described as validation of accuracy for
a particular instrument. Measurements made with an
instrument (or instruments) that are not calibrated are not
reliable, and are likely to be misleading.
Test frequency
The frequency at which inspection measurements are made is
often not defined in specifications. Inspectors are required to
make measurements of such properties as anchor profile
(surface profile), Wet Film Thickness (WFT), Dry Film
Thickness (DFT) or adhesion, but the number of
measurements is not stated.
Quality Assurance
Quality Assurance is a management system, based on ISO
9000 (or the comparable national standard) that defines a
total quality program. Formal, written procedures attempt to
define all of the actions that companies take to ensure their
products comply with a consistent standard of quality.
o Calibration process
o Measurement technique
o Measurement frequency
o Reporting system
Calibration