Welcome Everyone

To this session in MT-04, Bld #02

v
 INTRODUCTION TO

PAINTING AND COATING INSPECTION

by

Madhusudan Lahane,
(Inspection Engineer, SEID)

v
 Introduction

PAINTING:
• Why painting of Piping & Equipment,
Structures is required.?

3
Painting is required :
• To protect the substrate (Piping, Equipments &
structural in plant) from corrosion & increase the
life of substrate.
• To make the product appealing to the eyes.
• To provide a surface finish which is part of the
functionality of the product.
• Paint type and means of application are dependent
upon what function the coating must perform.

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Surface preparation standards

National Association of corrosion

Engineers.( NACE)

 NACE 1- White metal Blast cleaning.

 NACE 2- Near -White Blast cleaning.

 NACE 3- Commercial Blast cleaning.

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Surface preparation standards
Steel Structures Painting Council (SSPC)
 SP-1 Solvent Cleaning.
 SP-2 Hand tool Cleaning.
 SP-3 Power Tool Cleaning.
 SP-4 Flame Cleaning.
 SP-5 White Metal Blast Cleaning.
 SP-6 Commercial Blast Cleaning.
 SP-7 Brush-Off Blast Cleaning.
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 Surface preparation standards
Steel Structures Painting Council ( SSPC)
 SP-8 Pickling.
 SP-9 Weathering Followed By Blast
Cleaning.
 SP-10 Near -White Blast Cleaning.

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Surface preparation standards
Swedish Standard ( St,Sa)
 St-2 Hand Tool Cleaning.
 St-3 Power Tool Cleaning.
 Sa 1 Brush –Off Blast Cleaning.
 Sa 2 Commercial Blast Cleaning.
 Sa 21/2- Near-White Blast Cleaning.
 Sa 3 White Metal Blast Cleaning.

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 Painting & Coating

Mainly activities involved are:-

• Surface preparation.
• Paint application.
• Drying of coating.
• Inspection &
Testing.(In process & Final)

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Activity

Inspection of Monitoring
Surface
surface environmental
preparation
prepared. condition.

Inspection of
Paint Paint Curing /
painted/coated
Application drying.
surface

10
 Surface Preparation Methods

 Power Tool Cleaning.

 Hand Tool Cleaning.
 Flame Cleaning.
 Pickling.
 Solvent Cleaning.
 Abrasive Blast Cleaning
• Dry Abrasive Blast Cleaning
• Wet Abrasive Blast cleaning.
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Surface Preparation

• HAND TOOLS

• POWER TOOLS

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Surface Preparation
Dry Abrasive Blast Cleaning Method

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Surface preparation

• Abrasive particles hitting the substrate

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Surface Preparation
Carbon steel surface

Surface before
abrasive Blasting.

Surface after abrasive

blasting.

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 Surface preparation

Wet abrasive/Hydro blast Cleaning Method.

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Surface preparation:

Abrasive Blast Cleaning Method

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 Abrasive blasting surface preparation method.

• In the field of anti-corrosion coatings

applied to steel structures, it is common for
the steel to be prepared for coating by blast
cleaning.
• In abrasive blast cleaning methods, The
work surface is bombarded by continuing
impact of abrasive particles propelled by
compressed air through a nozzle, or by
centrifugal force from an airless blast wheel.
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Abrasive blasting surface preparation method.

• Silica sand, Angular grit and rounded shot

are the most commonly used as a abrasive
media for blast cleaning.
• Old paint, rust, mill scales and other surface
contaminants are removed and a rough
profile is developed for good paint
adhesion.
• Blasting methods leaves a characteristic
profiled surface.
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Abrasive parameter
Abrasive
Four parametersParameters
determine the performance of
Abrasive
an abrasive: Parametersa
1)Shape
2)Hardness
3)Density
4)Size

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Angular Grits

21
Rounded Shots

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 Shape –Angular vs Round

• Angular particles are best suited for

Shape
removal of –Angular vsRound
soft surface contaminants such
as paint, rust and dirt. They produce an
angular, rough profile.
• Round particles are best suited for removal
of brittle contaminants such as mill scale.
They produce a peened, rounded profile.

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Hardness –Hard vs Soft

• Hard, tough particles used where primary

objective is to remove surface contaminants. They
minimize dusting, leave less residue, and are
recyclable.
• Soft particles are used for removing grease, dirt,
and other deposits from motors, paint films, etc.

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 Density –Dense vs Light

• Generally, the greater the density of the particle,

the more effective it is as an abrasive. Remember,
kinetic energy is related to the mass of the particle,
so increasing the mass increases the amount of
work done by each particle.

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Size - Large vs Small

• Cleaning rate is affected by particle size in that

Size –Large
large particles vsSmall
will remove coarse contaminants,
while smaller particles will scour out the residual
fine, friable corrosion products or old paint.

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Abrasive blasting surface preparation
process.
Pre blasting preparations.

Blasting & Cleaning.

Final Surface Condition.

27
 Pre-blasting preparations

•Dry
Sharp edges, blasting
abrasive fillets, corners andpreparation
surface welds shall be
rounded or smoothened by grinding (minimum
process
radius 2 mm).
• Hard surface layers (e.g. resulting from flame
cutting) shall be removed by grinding prior to
blast cleaning.
• The surfaces shall be free from any foreign matter
such as weld flux, residue, sliver, oil, grease, salt
etc.

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Pre-blasting preparations

• All surfaces should be washed with clean fresh

water prior to blast cleaning.
• Any oil and grease contamination shall be
removed.
• Prior to blasting operations any major surface
defects harmful to the protective coating system
shall be removed by suitable dressing.
• Defects have been revealed during blast cleaning,
and dressing has been performed, the dressed area
shall be re-blasted.
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Blast cleaning

• Blasting abrasives shall be dry, clean and free from

contaminants, which will be unfavorable to the
performance of the coating.

Surface preparation
is the most important
part of a coating system,
because it affects the
performance of the coating
more than any other variable.

30
Blast cleaning
Steel, when it is abrasive
blasted, steel surface becomes
rough like sandpaper, with a
series of tiny peaks and valleys
called surface profile. Coatings
anchor themselves to the
valleys of the profile, and the
peaks are like teeth. This is why
surface profile created by
blasting is sometimes called an
"anchor pattern" or "mechanical
tooth."

31
Blast cleaning

• Size of abrasive particles for blast cleaning shall be such

that the prepared surface profile height (anchor pattern
profile) is in accordance with the requirements for the
applicable coating system.
• If the surface preparation is poor, coating performance is usually going
to be poor. If surface preparation is good, then the coating applied over
it is likely to perform well.

Anchor Pattern

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Blast cleaning
• PROFILE(ANCHOR PATTERN)

CORRECT

TOO DEEP

TOO ROUND

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Blast cleaning

• The surface profile shall be graded as per the

requirement as per ISO 8501 / SSPC Standards.
• Sa 1- Light blast cleaning.
• Sa 2 -Thorough blast cleaning.
• Sa 21/2- Very thorough blast cleaning.
• Sa 3 -Blast cleaning to visually clean steel.

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Blast cleaning

Comparator

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Blast cleaning abrasive

• Metallic Grits & Shots or Silica sand can be used

as blast medium.

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 Blast cleaning abrasive

• The grit shall be non metallic and free from

chlorides when used on stainless steel substrates.

Glass Beads. Silica sand

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Blast cleaning abrasive: Sand
Sand
• It is the natural abrasive of highest availability and
very low cost.
• It is historically "the abrasive", and gives the name
to all processes of preparation of surface by
projection of particles, commonly called
“sandblasting”.
• The type of sand that is used is silica not
calcareous, because it has the necessary hardness
for this type of work.
•
38
Blast cleaning abrasive: Sand

• As sand is a natural abrasive it must be subjected

to analysis, due to the pollutants that it can have
from its place of origin, dune, rivers, quarry, etc.
• Remove the fine sand , which does not perform a
good sandblasting on the surface.
• Sand should not be very thick that would seal off
the equipment.
• It should also be subjected to a drying process due
to its capacity to absorb humidity.

39
Blast cleaning abrasive : Sand

• It is extremely fragile. It can only be used once

because more than 80% is transformed into dust
after the first impact.
• It creates great pollution in the working
environment by the fragility of its particles that,
after the impact, become dust in a high percentage,
with sizes below 300 Mesh.
Silica Sand

40
Blast cleaning abrasive : Sand

• Due to its composition, as it divides finely

releasing silica, it causes an irreversible illness
called Silicosis.
• Because of this the safety requirements must be
really strict, nevertheless the use of sand as an
abrasive has been banned in most of the
technologically advanced countries.

41
Blast cleaning abrasive : Steel Abrasive

• Shots & Grits.

• It is an abrasive that is obtained from steel through
a fusion process with controlled chemical
composition.
Steel Grits Steel Shots

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Blast cleaning abrasive : Steel Abrasive

• Rounded particles that constitute the steel shot are

obtained from the primary process of steel
manufacturing.
• These particles in the state of largest diameter are split
forming the angular steel grit.
• For those works where the use of the sand is replaced,
grit is exclusively used, in some cases with the
addition of a small percentage of shot.
• A particle of grit has edges and nibs and as it is
projected, works as a tool that fixes and drags on the
surface to process.
43
Blast cleaning abrasive : Steel Abrasive

• This abrasive can be selected according to the

work to be performed, not only by the size of the
particle, uniform in all of them, but also be the
hardness in certain range.
• It is highly recyclable, being able to be projected
from 700 to 5000 times according to the diameter,
type and hardness of the abrasive used.
• As they are particles of tempered and low
tempered steel, they do not cause any problem of
pollution.
44
Blast cleaning abrasive : Steel Abrasive

• The dust produced in the operation is just basically

the result of the materials, rust & mill scales
removed from the surface to be treated.
• Steel Shot does not absorb humidity so it does not
require a previous drying.
• As all the particles are of similar size, they
performed a totally uniform work.

45
Blast cleaning abrasive : Steel Abrasive

Steel abrasive is extremely advantageous with regard

to the sand.
• Higher productivity,
• Lower cost of abrasive by clean M2 (Area)
• Reduction of maintenance costs
• Better quality in terms of the work performed
(homogeneity, roughness, cleaning)
• Lower environmental pollution
• Lower residue and dust generation
• Better visibility for operators
• Lower risk for the health of the operators
• Lower investment in dust collecting systems

46
Final surface condition

• The surface to be coated shall be clean, dry, free

from oil/grease.
• Specified roughness and cleanliness until the first
coat is applied.
• Dust, blast abrasives etc. shall be removed from
the surface after blast cleaning .
• Fine dust can be removed by industrial vacuum
cleaner.

47
Paint Application
• Paint application can be done with various
methods like Spray method, by brush or by a roller
depending up on type of paint & paint
manufacturers recommendations.

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Methods of Paint Application

Spray gun

Roller
Brush

49
Methods of Paint Application

• The goal in applying a paint coating is to provide a

film which will give protection and decoration to
the surface being painted.
• The success of any paint application will be
governed by a number of parameters
Surface preparation.
Film thickness.
Climatic conditions prior to, during and after
application, and methods of application.

50
Film Thickness
Film Thickness
• An adequate film thickness is essential for the
success of any coating system.
• Low thickness application will generally result in
premature failure.
• Application of modern high technology paint
coatings can lead either to solvent entrapment and
subsequent loss of adhesion, or to splitting of
primer coats.

51
Film Thickness

• With the majority of coatings, the limits of

acceptable dry film thickness allow for reasonable
practical variation, but the correct film thickness
should always be the target during application.
• The actual dry film thickness recommended for a
particular surface will depend on the type of paint
system being used and the nature of the surface.
• Recommended dry film thicknesses for individual
products are given on the Product Data Sheets and
System Specification Sheets in this manual.
52
Paint Application Conditions

• When applying paints, the most important factors to

consider are -
 The Condition of the surface,
 Surface temperature
 Atmospheric conditions at the time of painting.
• During the night, steel temperatures fall. So condensation
on the steel surfaces is possible.
• During coating application, relative humidity should not be
more than 90% .
• Condensation should not be allowed to take place on the
surface being painted.

53
Paint Application Conditions

• Paint application should not take place when steel

temperature is less than 3°C (5°F) above the dew
point.
(DEW POINT: The temperature at which moisture
will condense. )
• Paints should not be applied when surfaces are
affected by rain or atmospheric condensate.
• Some two pack paints (certain epoxies for
example) should not be applied at low
temperatures as curing may be retarded.
54
Painting systems

• Various painting system can be developed

depending upon the requirement or suitability of
application.
• Painting systems defines number of coats / layer to
be applied or thickness of paint.
• Number of paint layers may include primer paint
coat, intermediate coat & top coat.
• Time interval between two coat is important when
ever more number of coat are specified.

55
Paints
• Paint manufacturer generally provide brand name to their
paint products & paint technical name.
• Paint manufactures will provide paint data & certain
recommendation.
Storage :
 Shelf life- -- year , Sheltered storage @ ----°C max.
Mixing
 No. of Components : 1,2,3 etc.
 Mixing Ratio :By Volume or By weight.
 Thinner : Recommended Thinner.

56
Paints
Mixing
 Thinning Requirements : By percentage or by volume .
 Induction Time :
 Pot Life (mixture) : @ 25°C @ 40°C @ 60°C
Application
 Maximum Allowable Substrate Temperature : 60°C
 Typical Wet Film Thickness Per Coat : microns
 Typical Dry Film Thickness Per Coat : micron
 Theoretical Coverage @ 25 Micrometers : M²/L
 Dry Film Thickness – In Microns.
 Minimum Number of Coats (spray application ) : 1,2,3 etc.
57
Paints

Drying Time.

Substrate To Handle Recoat Interval To Immersion

Temperature Minimum Maximum

10°C Hours ----Hours ------Hours -----Days ----Hours

30°C Hours ----Hours ------Hours -----Days ----Hours

50°C Hours ----Hours ------Hours -----Days ----Hours

60°C Hours --Minutes -- Minutes -----Days ----Hours

58
Paints
Recommended Equipments.
 Airless Spray : Tip size: ----- to ----- inch Nozzle.
Pressure: --------- psi
 Conventional Spray : Tip size: --- to --- inch Nozzle
Press: --------- psi
 Brush/Roller : For touch-up only
Technical Properties.
 Volume Solids (ASTM D2697) : -----%
 Product Weight (ASTM D1475) : ----- Kg/L
 Viscosity (ASTM D562) : --------
 Flash Point (ASTM D93 or D56) : ------°C
59
Inspection

• The potential life of a coating system can be

realized if it is correctly applied to a suitably
prepared surface, under the correct environmental
condition.
• Inspection is an important requirement to ensure
the success of the coating operation.

60
Inspection
Surface Preparation Inspection
• Before any preparation operations commence, the
surface must be free of oil and grease, substrate
defects and where possible, sharp edges removed.

61
Inspection
After the cleaning operation the procedures for
inspection are
Mainly visual.
Degree of cleanliness and
Surface character evaluated with standards or
comparators.

62
Inspection
• Standards of Cleanliness
Most common method is visual comparison of
the steel surface with the photographic standards included in
 Swedish Standard SIS 05 5900 (1967), and the Steel
Structures Painting Council Guide to Visual Std No. 1.
 To carry out the comparison, the reference disc.
should be placed on the surface and examined with an
illuminated magnifier.
 The reference section most closely matching the profile of
the surface being tested is selected.

63
Inspection
Rust grade book. Dust tape test

64
Inspection
• The ISO 8501(-1) standard is an important tool to inspect
steel work and surface preparation. It gives four rust grades
which are used to assess the steel surfaces.
• These are given the designations A, B, C and D.
Photographs are used to illustrate the four rust grades of
the steel.
• Photographs of dissimilar rust grades A, B, C and D, the
standard also contains 24 pictures which show the visual
cleanliness after mechanical pre-treatment by wire-
brushing, blast cleaning and flame cleaning on steel
substrates originating from the four different rust grades.

65
Inspection
• A- Steel surface with abundant presence of
adherent rolling scales but little or no rust.
Before blasting After Blasting

Rust Grade -A

66
Inspection
• B -Steel surface that has begun to rust and with
rolling scales beginning to flake off.
Before blasting After Blasting

Rust grade -B

67
Inspection
• C- Steel surface where rolling scales have been
removed by rusting or that can be scraped off, but
with slight dimpling visible to the naked eye.
Before blasting After Blasting

Rust Grade -C

68
Inspection
• D Steel surface where rolling scales have been
removed by rusting and with abundant dimpling
visible to the naked eye.

69
Inspection
Digital Surface Profile Gauge
Surface Profile
Gauge -Analog
Type

70
Inspection
Roughness gauge
Thickness
Gauge issued
to measure the
peak-to-valley
height of a
surface profile
formed in the
Testex Tape.
Surface Profile Gauges :
Testex Profile Tape

71
 Inspection
Roughness Gauge. Comparator.

72
Inspection

Surface Contamination

• Visual testing is to ensure that dust or dirt has

been removed from the surface.
• Use can also be made of adhesive tapes, especially
on blast cleaned surfaces, which will pick up any
contamination from the profile.

73
Inspection
The meter digitally indicates the presence of surface
salt contamination.
Simple and easy to use for any surface. Kit comes with,
Indicator, Pad holder and 100 test pads.

74
Inspection
Residual Mill Scale.
• Visual examination will normally indicate the
presence of residual mill scale.
• If necessary, A copper sulfate test can be carried
out on new steel that has been blast cleaned.
The copper sulfate will plate out with a bronze
deposit on steel, but not on mill scale. Good test
on new steel, but not effective on old, well rusted
steel.

75
Inspection
Steel Temperature
• Various types of coating have differing minimum
curing/drying or film forming temperatures.
• In each case, the surface temperature should be
above the minimum at the time of application.
• If the steel temperature is below the specified
minimum problems can occur with solvent entrapment,
retardation of the cure with two component products, etc.
• With low temperature the minimum and maximum re-coat
intervals will be extended.

76
Inspection
• High temperatures of surface creates different problems
such as dry spray, solvent boiling, etc., however, these can
often be solved at site.
• It must be noted that minimum and maximum re-coat
intervals will be reduced when steel temperature is high.
• Two methods are commonly used to measure steel
temperature.
(A)Battery operated thermocouple
(B)Contact thermometer that is simply clamped to the surface with a
magnet.
It is important that time must be allowed for the device to reach a stable
temperature. This could be up to 15 minutes for the contact type. Also a
representative area should be selected.
77
Inspection
Temperature Probe
Ranger Non Contact K Type Surface/Air
Thermometer Thermometer -
Temperature Heavy Duty
Probe K Type
Rolling Surfaces
Extension

78
Inspection
Temperature Probe K Type Surface Small Tip
Fast Response small area, suitable for welds, steel
hot plates etc. Suits all K Type Digital
Thermometers and temperature Data loggers.
Temperature range -50C to 600°C

79
Inspection
Relative Humidity and Dew Point.
There is a variable amount of water vapor in the
atmosphere. The maximum amount air can hold
before precipitation occurs is dependent on
temperature and atmospheric pressure.
The warmer the air, the more water it can
hold. Relative humidity takes into account these
factors, although from a practical view point
atmospheric pressure is taken as a constant.
80
Inspection
Relative Humidity Meter-. The RH% Dew point Meter
measures both relative humidity and air temperature and computes and
displays the dew point temperature

Hygrometer

81
Inspection
If the substrate is of a lower temperature than the air,
the air in contact with the substrate will be cooled.
A point can be reached where the air in contact with
the substrate is at such a low temperature that it
cannot hold its water vapor. This temperature is
known as the dew point temperature.

82
Inspection
• Dew point Calculator- Easy to use, for the dew point, slide the known
wet bulb temperature under the depression (i.e. the dry bulb minus the wet
bulb) and read the dew point under the arrow at zero. For the relative
humidity, slide the dry bulb reading over the known dew point and read
the relative humidity against the arrow.

83
Inspection

As the dew point is a temperature where water is

spontaneously deposited, the substrate temperature
must always be a minimum of 3°C (5°F) above the
dew point if paint is to be applied to a dry surface.

This even refers to coating with moisture tolerant

properties, because these materials displace moisture
at the time of application, and then lose it to the
atmosphere.
84
Inspection

• Wet Film Thickness

• Dry film thickness can be estimated & can be
controlled by measuring the wet film thickness of
paint during painting operation.
• Wet film measurement is most commonly carried
out using a comb gauge. The gauge consists of a
number of calibrated teeth.

85
Inspection
• Wet Film Thickness Combs. These wet film
combs are used to measure the thickness of a wet
coating prior to it curing, drying or solvents
flashing off. These wet film combs will determine
the wet film thickness (WFT), from this, the dry
film thickness can be calculated

86
Inspection
• Sheen Wet Film Wheel 0031 Stainless steel
wheel with eccentric rim rolled across the wet
paint film to determine the wet film thickness,
from this the dry film thickness can be calculated.
Ranges: 100, 200, 500 and 1500µm.

87
Inspection
• Dry Film Thickness
• After the film is sufficiently dry or cured for
inspection the dry film should be examined.
• Visual inspection will also reveal application
defects such as over spray, misses, dirt inclusion,
blisters, sags, runs or other defects.

88
Inspection
• The dry film thickness Meter.

Calibration Film.

Zero Plate

89
Inspection

• DFT check.

90
Inspection
• Dry thickness meter

91
Inspection
Painting defects
The most common coating defects and failures are:
• Orange peel/ Tiger stripping
• Blistering
• Pinholes
• Cratering
• Peeling or lifting
• Paint running /Sagging.
• Cracks
92
Inspection
• Orange peel and Tiger striping.
Painter training can eliminate or dramatically reduce
orange peel and tiger striping. These two coating failures
or coating defects are strictly in the hands of the painter.

93
Inspection
Blistering
Blistering is the formation of round 'bubbles' of paint
film. The cause is always moisture related:
• Excessive moisture coming through the substrate.
This can happen when humidity seeps from a
room with very high humidity, such as a bathroom
or laundry, or
• Exterior paint is applied over a damp or wet
surface. If paint is still in the drying phase, blisters
may appear during periods of rain or heavy dew.

94
Inspection
• Blistering

95
Inspection
• Pin holing can be reduced by painter training, but
for the most part is a function of the solvents that
are used in the paint formulation.

96
Inspection
• Cratering is almost always a function of surface
preparation, or the deposition of aerosol
siliconized particles from certain aerosol sprays on
the metal surface.

97
Inspection
• Peeling, lifting or flaking are also usually a function of
surface preparation. In some cases, peeling results when
too many coats of paint are applied too soon after each
other preventing solvents from escaping from the paint or
coating.
Lifting is a raising of the
undercoat. It is caused by a
stronger solvent in the
topcoat attacking the
previously applied film. The
result is a wrinkled surface.

98
Inspection
Delaminating /peeling
• Loss of adhesion to the substrate or between coats of paint
is delaminating or peeling.
The causes are:
• Unsatisfactory surface preparation
• Incompatible primer or undercoat
• Substrate or inter-coat contamination
• Excessive cure time between coats
• The way to repair the surface, is to remove paint down to
sound paint or to the substrate, and recoat.

99
Inspection
• Peel off.

100
Inspection
Sagging occurs when:
• Paint is applied in excess of the DFT specified
• Too much thinner has been added to the paint
• The gun is held too close to the surface.
• Sags are recognized as "curtains" on the painted
surfaces. If the wet film thickness is too high,
excessive sagging can result in pools of paints
forming on horizontal surfaces or in corners.
After curing, the paint may crack all the way to the substrate in
such areas and reveal unprotected steel. If sagging is noticed at
the spraying stage, it should be brushed out while the paint film
is still wet. Repairs after drying consists of abrasion (sanding)
and re-coating.
101
Inspection

• Holiday Detection
When protective coatings are applied there is a
possibility that flaws have occurred due to the
presence of trapped air, or voids and pinholes. Of
these defects only the largest can be detected
visually. A series of battery operated field
instruments are available.

102
Inspection
1. Low Voltage Detectors
The wet sponge method is most commonly used.
This is suitable for coatings up to approximately
375μ (15 mils).
The method of operation is to draw the
moistened sponge over the surface. Where a
defect has occurred a small current will flow and
activate an audible alarm. Excessive wetting of
the sponge should be avoided.

103
Inspection

• Paint holiday tester

104
Inspection
2. High Voltage (Spark) Detectors
For thicker film a higher voltage is required for flaw
detection. Two types are used, either with AC or DC
voltages.
Care must be taken with high voltage (spark) detectors to
ensure that the test voltage selected is not excessive for
the coating thickness.
It is possible to destroy the coating and is some cases the
retained solvent is conductive enough to provide a current
flow through the paint film.

105
Inspection
• This Holiday Detector is fully adjustable, has regulated
'pulsed' output up to 20kV, 40kV or 60kV.
• It can be used for porosity and holiday testing of carbon
impregnated coatings such as carbonated rubber, thick
coatings such as rubber linings and on ‘plastic’/fibreglass
type coatings likely to become electrostatically charged.
• The Pulse 20kV & 40kV models are ideal for use in moist
conditions, on wet and contaminated coating surfaces.

106
Inspection
• This Holiday detector uses the low voltage wet sponge
method to detect pinholes in coatings.
Large sponge head & telescopic handle which extends to
1.2m. We highly recommend high voltage holiday and
porosity testing in lieu of wet sponge testing when working
with coatings over 150µm, or coatings in corrosive
environments.

107
Inspection

Degree of Cure
• An indication regarding the cure of two
component materials can be obtained by solvent
swabbing(cleaning/ scrubbing), If no coating is
removed after scrubbing the surface with
relatively strong solvents, the cure will be well
advanced. swab

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Inspection

• Adhesion Tester
• For testing adhesion of a wide range of coatings,
including films, varnishes and paints. For testing
coatings applied to substrates or intercoat adhesion
of multi-coat applications. Using the Cross Hatch
Cutters to do an adhesion test, will give a better
result than using a knife

109
Inspection

(Adhesion Test using Cross Hatch Cutters) -

Peel-off

110
Safety & Hazards- in painting & coating

• Hazards of abrasive blasting

• Hazards of protective coating

• General Hazards.

111
Hazards of abrasive blasting

• Dusts
• Noise
• Particulate matter
• Abrasive plant & equipment.

112
Dust Hazards

Dust hazards.
• Abrasive blasting can generate large quantities of dust,
which may be toxic.
There are a number of factors that affect the degree of risk
associated with dust produced in abrasive blasting work.
These factors include:
• The abrasive medium used.
• The surface being treated.
• The concentration of airborne dust in the breathing zone of
the worker.
• The size of the dust particles generated.
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Dust Hazards

• Whether dust particles are inspirable or respirable.

• Whether blasting is carried out in a confined
space.
• How easily the abrasive material breaks down.
• The duration of exposure and the individual
responses to exposure - some individuals may be
more affected than others due to differences in
their biology or lifestyle.
• Inspirable dust is any dust which can be inhaled.

114
Dust Hazards

• Respirable dust is only that dust which is small

enough to be inhaled into the lungs. This sort of
dust can result in permanent scarring of the lung
tissue. Abrasive blasting results in high
concentrations of respirable dust.

115
Dust Hazards control

Some control measures to reduce the exposure of

workers to risk from dust include:
• Substituting a less hazardous abrasive material.
• Substituting a less hazardous surface preparation
method.
• Isolation controls.
• Personal protective equipment.- Respiratory mask.
(Person carrying abrasive blast cleaning should use PPE
such as Goggles, Helmet, Safety Shoes, protective
clothing etc.)

116
Noise hazards.

• Noise is unwanted sound that may damage a

person's hearing. The amount of damage caused
by noise depends on the total amount received
over time. The degree of risk is affected by the
intensity (loudness) and the frequency (pitch) of
the noise, as well as the duration and pattern of
exposure and the individual's susceptibility to
hearing impairment.
• Employers must prevent risks to their workers
from exposure to excessive noise.

117
Noise hazards.

• Excessive noise- means a level of noise above:

• LAeq, 8h of 85 dB(A) - that is, an 8 hour
equivalent continuous A-weighted sound pressure
level of 85 dB
A- referenced to 20 micropascals.
• Lc peak of 140 dB(C) - that is, a C-weighted peak
sound pressure level of 140 dB
C- referenced to 20 micropascals.

118
Noise hazards.

An indication of the level of noise experienced in

abrasive blasting processes can be obtained from the
following noise readings taken at operator ear level.
• Air discharge from blast nozzle - 112 to 119
dB(A)
• Feed air inside helmet - 94 to 102 dB(A)
• Blast cabinets - 90 to 101 dB(A)
• Air compressors - 85 to 88 dB(A)

119
Noise hazards.- Control Measures.

Noise Control Measures.

• Isolate the blasting zone.
• Provide PPE.
• Engineering controls such as
 Improved mufflers on blast pots;
 Silencers on intake and exhaust systems;
 Baffles and muffling materials in air supply hoses for blast
helmets;
 Sound attenuating material on walls and ceilings.
 Sound transmission barriers around compressors.
120
Particulate matter

Serious injuries or death can result from being

struck by particulate matter discharged under
high pressure. Common injuries include-
• Eye damage
• Severe lacerations burns.
• Skin penetration.

121
Particulate matter control measures.

Personal protective equipment

• Workers exposed to high velocity particulate matter should
wear suitable personal protective equipment to protect
against ricocheting abrasive. This may include:
• Eye protection.
• Protective gloves (canvas or leather).
• Protective footwear
• Respiratory equipment
• Protective clothing (overalls, long trousers, blast suits,
aprons).

122
PPE FOR SAFETY

• PPE ( OVEERALL, SAFETY SHOES, GOGGLES, HAND GLOVES, EAR PLUG, HALF
MASK,

123
Abrasive blasting plant and equipment hazards

Abrasive blasting plant and equipment

• Related to Air compressors, Blast pot, Nozzle,
Blast Hose, supplied respiratory air etc.
• Hazards related to above can be controlled by
periodic inspection & maintenance.

124
Protective Coatings Hazards.

The major hazards in protective coating processes

are associated with:
• Hazardous substances in protective coatings and
solvents.
• Misuse and poor maintenance of spray painting
plant and equipment.
• Explosion of flammable substances.

125
Protective Coatings Hazards.

Other hazards are similar to those encountered in

abrasive blasting, and may include:
• Manual handling slips, trips and falls.
• Working in confined spaces;
• Working on elevated work platforms and heat.

126
Protective Coatings Hazards.-Control

• Development of safe working practices and

procedures that should be used in combination
with other control measures such as ventilation
• Not pointing the spray gun at any part of the
human body.
• Not eating, drinking or smoking in a spray
painting zone.
• Storage and disposal of waste and solvent soaked
cleaning rags

127
Protective Coatings Hazards.-Control

• Maintenance checks for spray painting equipment.

• Minimizing the risk of inhaling vapors through
the use of smaller containers of paints and
solvents.
• Recapping immediately after use and prompt clean
up of spills.
• Mixing of protective coatings only in authorised
areas, for example, mixing room with exhaust
ventilation.

128
 Protective Coatings Hazards.-Control

• Following paint manufacturers' recommendations

to reduce overspray.
• Training workers in safe work practices, including
the use and maintenance of personal protective
equipment.

129
 Protective Coatings General Hazards.& Control

• Manual tasks.
• Working in confined spaces.
• working at heights.
• Slips, trips and falls.
• Vibration
• Heat.

130
Q &A Discussion

131
Painting & coating

132