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1 REVISION QUESTIONS
Corrosion OP Monday
1 Is the electrical circuit in a corrosion reaction AC or DC?
D.C (Direct Current)
5 What is corrosion?
Degradation of a material by chemical or Electro-chemical means
14 Which of the two metals would corrode if steel and zinc were coupled?
Zinc
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19 In which environment would sulphate salts be found?
Industrial (Power stations etc) and Agricultural areas
21 What is an ion?
A positively or negatively charged particle or atom. Unstable atom
30 If corrosion occurs at anodic areas, why does steel corrode evenly all over the surface?
Trace alloying elements in the steel (Nickel, carbon, Aluminium etc) provides millions of anodic and
cathodic areas, (Bi-metallic contact) so the steel surface will corrode ( as it is both an anode and a cathode)
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PAGE # 23.2 Surface preparation - Monday
1 Which British standard would be used in determining the size of copper slag abrasive?
BS.410
2 Which British standard would be used in determining the size of metallic abrasives?
BS.410
7 What is a hackle?
A sliver, which has been deformed upright after blasting.
8 Name two other terms that could be used for anchor pattern?
Peak to trough, key, Surface Profile & Amplitude
9 What are the main advantages of using Testex papers for measuring profiles?
It provides a permanent record, and it can be used on curved surfaces
11 What are the main factors governing the grade of a blast finish?
Time spend, abrasive size, abrasive density, material density,
Shape of particle, hardness of abrasive, initial rust grade
12 Can the grade of a blast finish be determined by using the surface comparators to BS 7079 Pt C3?
No, only surface roughness
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19 What is the approximate speed of abrasives leaving a venturi nozzle?
720 Km/h 450 m.p.h. (Miles per hour)
26 In what situation would it be better to use steel grit in preference to copper slag abrasives?
Enclosed blast cabinets or Wheelabrators.
27 If cracks or laminations are found on a substrate after blasting what steps should be taken?
Stop the blasting operation and report it to the site Engineer for (ultrasonic lamination checks would
normally follow)
28 Using comparators to ISO 8503, what are the three main profile assessments?
Fine, Medium, Coarse
29 What are the other two assessments when the above three are not appropriate?
Finer then Fine, Coarser then Coarse
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PAGE # 23.3 Surface preparation Tuesday
1 What is the title of the BS 7079?
Preparation of steel substrate before application of paints and related products.
4 Name the gauge used for measuring pressure at the blast nozzle?
Hypodermic Needle Gauge.
8 Could you tell the difference between rust grades A and B blasted to Sa3?
No
9 Could you tell the difference between rust grades C and D blasted to Sa3?
Yes, possible heavy pitting.
15 How is pH measured?
Potential Hydrogen Litmus paper or pH indicator
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20 Which pH range covers alkalies?
7 to 14.
28 Two alloys are used to render wire brushes spark free, what are they?
Phosphor Bronze and Beryllium Bronze.
33 If an operator was blasting with a nozzle pressure of 80 psi. What would be his approximate
efficiency?
70% (80 psi = 20% x1.5efficiency drop = 30%)
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38 What is the main disadvantage of high pressure jetting compared to other systems?
Safety, huge volume of water, slurry, no profile, flash rusting.
40 What would be the typical temperature and concentration of Sulphuric Acid in the pickling process?
5-10% at 65% to 70% degrees
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PAGE # 23.5 Paint technology (1) - Wednesday
1 Name a third type of paint other than solvent free and solvent borne.
Powder
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19 What are the natural properties of a Resin?
Brittle & fast drying.
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PAGE # 23.6 Paint technology (2) Wednesday
2 What is polymerisation?
The joining together of a string or structure of repeated units.
8 Briefly describe the difference between saturated and unsaturated when referring to oils or
polymers.
Unsaturated oils will react with oxygen and solidify,
Saturated oils will not, so they are classed as non-drying oils.
16 If pigment was added way below the CPVC, how would it affect the film?
Low Opacity, Blistering, Low Cohesive Strength, High Gloss.
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19 If carbon was used as a pigment what would be the paint colour?
Black.
22 Which of the common extenders could not be used in whites and pastels?
Slate flour
23 How would the film be affected if pigment was added above the CPVC?
Permeable / porous, Low Cohesive strength, Low Gloss, Low Adhesion.
26 If chromium was used as a pigment, what colour would the paint be?
Greens, Yellows and Oranges
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Convertible
39 What type of polymerisation occurs in chemically curing paint?
Cross linked.
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58 Does a phenolic resin have an induction period?
No. (Phenolic resins paints are not chemically using.)
64 What is the term used for paints needing temperatures in excess of 65oc to cure?
Stove Drying.
73 When using a whirling hygrometer which bulb should be read first and why?
The Wet bulb should be read first, as it is artificially reduced and the temperature will gradually rise back to
ambient.
74 At what speed should the thermometer bulbs pass through the air?
4m/sec (four meters per second), or as fast as possible.
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77 When the air temperature rises does the airs capacity to hold water increase or decrease?
Increases
78 What is the stated criterion for acceptance, prior to calculations, on a whirling hygrometer?
2 Consecutive identical readings (within 0.2 degrees)
80 Is it possible for a wet bulb temperature to be higher than the dry bulb?
No, never.
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PAGE # 23.8 Paint testing Thursday
1 Define viscosity.
A fluids resistance to flow
12 What is the main difference between the rotathinner and Krebs Stomer?
Rotothinner is dynamic viscosity, kerbs stormer is Kinematics.
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19 What colour should the flame be at the flash point?
Blue
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38 What information could be obtained from a cold check test?
Contraction cracking.
48 Where could an inspector find information to determine if a 2 pack paint was mixed in the correct
proportions, using a density cup?
Manufacturers data sheet
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57 In a gloss paint what would be a typical degree of grind?
Occasionally 10 microns, but mainly 20 microns.
58 What percent reading would be expected when measuring gloss on a glass panel?
100%
60 If an aggregate size of 35 um was present in a paint of 30 um DFT what would be a likely result when
using a gloss meter?
Matt finish.
63 Inter coat adhesion and primer to substrate adhesion are two adhesion faults name the third?
Cohesion failure
73 What voltage would be used on a 250 um thick paint using a sponge type pinhole detector?
9 Volts
74 What voltage would be used on a 450 um thick coating with a sponge type pinhole detector?
67.5 Volts
75 When using a wet sponge, what other liquid is added to the water?
Detergent
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76 What function does the above additive perform?
Reduce surface tension, water softener
80 Other than the wet sponge, which other equipment could be used to determine the presence of
pinholes/holidays?
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PAGE # 23.10 Revision questions general Friday
1 Name two categories of paint mill.
Direct charge Mill, Premix mill, let down mill.
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16 What is cohesive failure in paint, give the main cause?
Solvent entrapment, incorrect mixing ratio, too high CPVC.
24 Other than pigment, base and curing agent name two other constituents of FBE powder paint.
Anti foaming agent, Wetting Agent.
26 Brush application has advantages over spray application, what are they?
Small area Works paints into substrate
Accuracy No overspray
Accessibility Very low waste
Environment friendly Thicker application
Cheaper Prevents pinholes
27 What is the main consideration when selecting a metallic pigment for a sacrificial paint?
Its position in the galvanic list.
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33 A colour has three properties, what are they?
Hue, Brightness and saturation.
42 What is flocculation?
Loosely clustered particles or aggregate often found in out of date paint.
45 How many depressions of the bellows are needed for the Drger test?
Varies according to the relevant crystals required for the solvent under test.
46 What are the hazard signs for Toxic, Very Toxic, Harmful and corrosive?
Black Skull & X bones, Black X, Dripping test tubes, steel block & hand
47 What is saponification?
The production of lead soap, when using basic primer with Natural Oil paints
50 What is padding?
Use of a pad, coated in fine natural hair, to apply paint
51 What air inlet pressure is needed to give 2500 psi delivery with 35:1 pump?
71 psi
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53 What is cissing and how is it caused?
Oil or grease contamination of the substrate, causing a local lack of adhesion
54 What is meant by the abbreviations: OES, OEL, MEL, UEL, LEL and RAQ?
OES, Occupational Exposure Standard
OEL, Occupational Exposure Limit
MEL, Maximum Exposure Limit
UEL, Upper Explosive Limit
LEL Lower Explosive Limit
RAQ Required Air Quantity
57 How can you tell the difference between blooming and chalking?
No
60 Why are manufacturers developing solvent free, water borne and powders?
Environmental impact, cost
Whiplash cables,
External coupling etc) should have site plan and documentation.
Administering adhesion tests
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64 Name five documents, which a painting inspector might need on a contract.
Contract specification, inspection reports, Operator qualifications, COSHH
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PAGE # 23.12 Revision questions PA 10 specific
1 What is the specified course of action for grit inclusions?
Re-blast and re-coat
8 Two materials are specified for used on damp surfaces, what are they?
Moisture Curing Polyurethane, and solvent free epoxy
10 Some non-ferrous substrates are painted for aesthetics only, name four.
Stainless steel, Concrete, Fibre Glass, Aluminium
11 Which three non-ferrous substrates are painted for anti corrosion purposes?
New and weathered galvanized, aluminium
16 List four items needing masking off prior to blasting and painting.
Name plates, instrumentation, vents, monitoring panels
19 What differences are there in new and maintenance painting specifications for substrates below 100oc?
They are both covered by one specification = PA 10
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20 Toxic coatings need special considerations for removal from substrates, name two methods which
comply.
Needle gun, Water jetting, Water plus abrasive
29 What would be the specified surface preparation and coating system for Aluminium cladding?
Etch primer
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40 What is the first coat applied to galvanised substrates and why?
MIO, primer is not required
44 Give the criterion for when and when not, painting can take place.
Max. 90% Relative Humidity, Steel & Air Temperature to be 3c above Dew point
45 What should be the substrate reaction when T wash is applied to a newly galvanised substrate?
The substrate turns black
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PAGE # 23.14 B. Gas 3.2 Maths Exercises
WFT calculations
1 What WFT would need to be applied to give a DFT of 45 um using a paint of 56% vs?
80.35m
2 What WFT would need to be applied to give a DFT of 60 um using a paint of 40% vs?
150 m
3 A paint of 38% vs was used to give a DFT of 45 um what wad the WFT?
118.4 m
4 A DFT of 55 um was obtained from a paint of 55% vs, what was the WFT applied?
84.62 m
5 What WFT would be applied to leave a DFT of 65 um using a paint of 49% vs?
132.65 m
DFT calculations
1 What would be the DFT if 20 litres of paint, vs. 45% covered an area of 9m x 12m?
2 25 litres of paint, vs. 65% was used to cover a circular area of 10m diameter. What would be the
resulting DFT?
3 What DFT would be obtained if a paint vs content 42% was applied at a WFT of 84 um?
4 What would be the resulting DFT if a WFT of 130 um, what would be the resulting DFT?
5 A paint, vs 65% was applied at a WFT of 130 um, what would be the resulting DFT?
VS calculations
1 A DFT of 53 um was obtained from a WFT of 110 um, what was the vs% of the paint?
2 A paint was applied at 120 um WFT. The resulting DFT was 65 um, what was the vs%?
3 What would be the vs% of a paint if it was applied with a WFT of 120 um and a DFT of 68 um was
obtained?
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4 What was the vs% of a paint with a DFT of 36 um, when the WFT was 108 um?
5 A DFT of 62 um was measured, from a WFT application of 100 um, what would be the vs% of the
paint used?
Volume calculations
1 What volume of paint would be required to cover an area of 300 square metres, to a specified DFT of
65 um, using a paint of 45% vs?
2 How much paint would be required to coat a tank, roof and side sheets to a DFT of 100 um? The tank
is 5 metres diameter and 6 metres high. The paint to be used is solvent free.
3 How much paint would be needed to cover a circular area of 10 metres diameter, using a paint 65% vs
to a DFT of 60 um?
4 A circular area of 7 metres radius is to be coated to a DFT of 45 um. What volume of paint would be
required if the vs content was 48%?
5 How much paint would be needed, at 55% vs, to coat an area of 250 square metres to a DFT of 60 um?
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Density and SG exercise
4 If the weight of 25 litres of paint is 37.5 kg, what would be the SG?
5 A 2 pack epoxy should be mixed at one part base to one part activator, the base has a density of
1.4gm/cc and the activator 0.9 gm/cc. What would be the density of the mixed components?
6 A 2 pack paint is mixed at a ratio of six parts pack A (density 1.3gm/cc) to one part pack B (density
0.9gm/cc). What would be the density of the combined parts?
7 A mixed 2 pack paint has a density of 1.35gm/cc. The density of the base was 1.5gm/cc and the
activator 0.9gm/cc. The mixing ratio was 3:1. Has the paint been mixed correctly?
8 A mixed 2 pack paint has a density of 1.35gm/cc. Mixed at a ratio of 6:1, base density 1.45gm/cc,
activator density 0.95gm/cc. Has the paint been mixed correctly?
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RH and DP exercise
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Whirling hygrometer
Limpet Gauge ( Magnetic contact wait 15 min before reading)
Thermocouple (Electronic, contact, Immediate reading)
Density (The Density (SG) cup
Flash Point of solvent ( ABEL Closed Cup)
Higman Grind Gauge (for fineness of grind, Degree of dispersion)