Self-Analysis Paper

1. Describe why and how corrosion occurs?

Corrosion occurs when the material tries to revert back to its natural state by an
Electro-chemical process
2. Describe what is meant by Bi-metallic corrosion?
Bi-metallic corrosion is when one metal attached to another metal sacrifices itself
to protect the other
3. Describe the following
a) The galvanic series?
The galvanic series list metals, which are more or less noble than one another
and how they will affect each other when attached together i.e., zinc will
sacrifice itself over steel
b) Millscale?
Millscale is a thin iron oxide layer formed on the surface of the steel during
making
c) Rust grades to SIS 05-59-00?
A
Millscale
B
Light millscale and rust
C
Rust and Light pitting
D
Heavy rust and Heavy pitting
d) Blast cleaning grades to SIS 05-59-00?
S.A1 light blast clean
S.A.2 thorough blast clean
S.A.2
very thorough bast clean
S.A.3 Blasted to visually clean steel
4. Describe the difference between water blasting and pressure washing?
Water blasting uses pressures of approximately 60,000p.s.i and will take off paint,
rust etc.; pressure washing uses pressures of approximately 100p.s.i. and is used
for washing
5. Name two tests used to determine the presence of hygroscopic salts left on a
blast cleaned surface?
Two tests used to determine the presence of hygroscopic salts are Potassiumferrocyanaide and silver nitrate
6. Name four expendable abrasives and state the difference between an expendable
and a reusable abrasive?
Four expendable abrasives are
a) Copper slag
b) crushed ice
c) crushed walnut shells
d) sand (not recommended)
The difference between expendable and reusable abrasives is that expendable
abrasives explode upon impact and become useless reusable can be filtered and
used up to 3 times

7. Name the three basic constituents of a solvent carrying paint and the functions
that each performs in the paint?
a) Binder to hold the constituents together and give a flexible tough
impervious finish
b) Pigment - to give colour and opacity resistance to acids/alkalis
c) Solvent to evaporate in the drying process also to thin paint and degrease
8. Name six pigments and there respective colours?
a) Coal tar
black
b) Carbon
black
c) Titanium dioxide
white
d) Calcium plumbate
white
e) Red lead
red
f) Zinc phosphate
yellow
9

Describe what qualities a laminar pigment gives to a paint and name four laminar
pigments?
Qualities of a laminar pigment are the particles overlap and form a thick
impervious coating
a) Micacious iron oxide
b) Aluminum oxide
c) Glass flakes
d) Zinc oxide

10 Describe
a) A barrier paint system?
A barrier paint system is a coating that form a continuous even flexible
coating which is impervious
b) A sacrificial paint coating?
A sacrificial paint coating is a coating, which will protect but at the expense of
itself i.e. it will break down
11 Describe what a tie coat is and give three reasons why we may require one?
A tie coat is a coat of paint, which will tie to different systems together
a) Maintenance painting
b) Adhesion problems
c) Bleeding through of primer/undercoats
12 Describe a typical paint manufacturing process and give two types of paint mill,
which could be used?
a) Assemble ingredients together
b) Mill ingredients to right consistency and proper mix
c) Can and ware-house
d) Distribute
Two types of used mill are direct charge mill and ball mill
13 Describe what you know of viscosity and outline one method of testing?
Viscosity is the measurement of a paint resistance to flow and can be measured
in an able type cup
14 Describe what you know of density?
Density is the weight of paint per unit volume
15 Can you use a banana gauge over
a) An M.I.O coating?

No the coating is magnetic

b) An aluminium substrate?
No the substrate is non-magnetic
c) A galvanised surface?
Depending on the substrate, whether magnetic or non-magnetic and on the
thickness of the galvanising
16 Describe a destructive test for determining the dry film thickness of a paint?
Paint inspectors gauge (cut and measure)
17 Give four artificial weathering devices and describe what they simulate?
a) Salt spray box to simulate a marine environment
b) Cold check to check for brittle cracking and shrinkage in cold climates
c) Tropical box to check for high humidity
d) Alternating temperatures to check for elasticity of coating
18 What is the name of an instrument, which measures opacity and gives two
examples?
The instrument that measures opacity is a Cryptometer, examples are hiding
power charts and a pfund Cryptometer
19 Describe a dolly test for adhesion?
a) Paint and fully cure specimen
b) Roughen and degrease surface and attach dolly using regular araldite and
keep at 200c for even results
c) Let fully cure
d) Cut around dolly down to substrate using special tool
e) Attach puller and pull off note force at which dolly lets go
f) Check if failure is adhesive or cohesive
20 How do the following work
a) Conventional spray setup?
Paint is held in a can then pressurised and fed through a nozzle where it
atomises and the pressure propels it onto the surface being painted
b) Airless spray system?
Paint is held in a non-pressurised container and is then pumped to a nozzle
where it is propelled onto the surface at high pressure
c) Electrostatic spray system?
The item to be coated is negatively charged and the paint discharged from the
gun is positively charged and this attracts the paint onto all surfaces to ensure
full and complete coverage
21 How is B.S. 4800 used in the construction industry?
B.S. 4800 is used in the construction industry for selecting paint colours and types
for structural steelwork
22 What are the essential differences between a blister and an osmotic blister?
A blister is a dry bubble in the paint, which may be caused by adhesion problems,
or tapped air. An osmotic blister is caused by trapped salts or by water ingress
through the paint system.
23 What shall painting equipment comply with when used on a B.Gas site?
Painting shall comply with P9, Health and Safety at Act, C.O.S.H.H, and relevant
specifications and contract details

24 How do the following display their characteristics

a) Bleeding?
When an underlying coat comes through on the next coat i.e. red undercoat
bleeds through on white to give pink
b) Blooming?
Paint that has an pocked effect on the surface
c) Chalking?
When the pigment starts to breakdown and a white powder forms on the
surface
d) Cissing?
When the paint refuses to cure properly i.e. linseed oil based not properly
cured before overcoating
e) Grinning?
When an underlying coat comes through on the next coat because of poor
coverage
f) Flocculation?
When paints constituents in the can, separate and resist mixing together
g) Lifting?
When paint that has been applied does not adhere to the surface
h) Ropiness?
Any thing to do with being out the night before? I dont know!
i) Solvent stripping?
When solvent is used to soften and remove paint
j) Oxidation?
When the surface takes on an oxygen atom i.e. hot steel worked air cools and
millscale formed millscale is oxidised steel
k) Chemical curing?
When a chemical has to be added to a paint to allow it to cure i.e. two pack
paints
l) Overspray?
Overspray is when a light coating is noticed on adjacent items that do not
require painting only found when spraying may be cause by air blowing a fine
mist of paint away from surface being painted
25 Define the following
a) Dewpoint?
Dewpoint is the temperature that condensation will form on a surface
b) R.H.?
Relative humidity is an expression of the amount of water present in the air
c) Induction period?
The time a two-pack paint must be left to stand after mixing to allow for
chemical reactions
d) Pot life?
The time in which a two-pack paint must be used in after mixing
e) Flash point?
The lowest temperate at which solvent vapour will ignite
f) Shelf life?
The maximum time, which a paint can be stored without using according to,
manufactures recommendations
g) Batch number?
A unique number to a tin of paint which will allow the manufacturer to trace
the paint if problems arise
h) Masking out?
Covering an area which does not require painting with removable sheeting
i) A.G.I.?

j)
k)
l)
m)
n)
o)
p)

Above Ground Installation

Rust blooming?
Rust blooming is when small areas of rust start to appear though a coating
(like a rash)
Water borne coating?
A water borne coating is a water-based paint
B-SA2 ?
Rust grade B (Light millscale and rust) blast to the stated grade (thorough
blast clean)
Feathering?
Creating a smooth transition at an edge
A-ST3
Rust grade A (Millscale) Hand clean with mechanical wire brush (note millscale
is not allow to be taken off by this method only by blast cleaning)
P.a.9?
Method of painting items to Bgas specifications
P.a.10?
Method of testing paint to Bgas specifications

26 Give as much detail as you can for the following

a) S.P.A 1?
Painting of pipeline which operates below 1000c paint to have D.F.T of 275m
when finished
b) S.P.A.2 Standard of preparation and paint systems only?
c) S.P.A 3?
Painting of items which are above 5000c at works or on site
d) S.P.A 4?
e) S.P.A 6?
Maintenance painting
Dont know much on the last 7 specification questions (guessing) will read more on
the subject