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Main Topic: Quality Control

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Problem Solving Forum (39)

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Does the presence of non-burst blisters in a coating system always mean that the coating requires replacement?

Question posted September 1 to September 5, 2014


How do you measure wet film thickness on shop-applied organic zinc-rich primers to accurately predict dry film thickness? Our shop applies a great deal of OZ primer, and we have found that WFT readings with a standard gauge are not accurate predictors.

Question posted August 18 to August 22, 2014


What is the maximum number of holidays that should be permitted for linings in immersion service, and why?

Question posted August 11 to August 15, 2014


What is the best way to assure compliance with specified dry film coating thickness requirements on vertical concrete?

Question posted July 7 to July 20, 2014


As a facility owner, how can I justify the cost of quality control measures, such as third-party inspection, to upper management in my company?

Question posted June 30 to July 4, 2014


When we use field splice plate connections on structural steel projects, how do we prevent rust and rust staining at bolt heads and at the splice plate/steel interface?

Question posted May 12 to May 16, 2014


When performing maintenance surveys on structures that require coatings under insulation, how do you inspect the condition of the coatings?

Question posted May 5 to May 9, 2014


What do you do when the surface profile is higher than the dry film thickness of the specified primer?

Question posted March 10 to March 14, 2014


What’s the best way to determine if a cementitious-based mortar used to repair exterior concrete is ready to be coated?

Question posted February 17 to February 21, 2014


Under what circumstances is third-party inspection justified on commercial coating work?

Question posted February 10 to February 14, 2014


Is it practical to use black light to check for dirt or other foreign matter during surface preparation inspection?

Question posted January 20 to January 24, 2014


What is the difference between a damp-surface tolerant and a wet-surface tolerant paint? How can we determine when a surface is damp or wet?

Question posted January 2 to January 12, 2014


What is the risk of damaging a paint film by inspecting a repaired area more than twice with a high-voltage holiday detector?

Question posted December 16 to December 23, 2013


I have galvanized steel in direct contact with powder-coated aluminum in an outdoor exposure. The galvanized steel is corroding. What is the best way to remedy the situation?

Question posted November 11 to November 15, 2013


During a week of heavy rain, we painted the interior walls of a heated concrete building. On the interior of walls that had an outside exposure, the paint blistered badly a week after the rain subsided. Could the rain have caused the blistering and, if so, how?

Question posted October 28 to November 1, 2013


Where are errors most likely to occur when measuring dry film thickness on steel, and how can they be avoided?

Question posted August 19 to August 25, 2013


How does the concave or convex curvature of a surface affect a coating's shore hardness reading?

Question posted August 12 to August 18, 2013


Why would a pull-off adhesion test give a high value (no failure) for a solventless epoxy that later showed poor adhesion in service?

Question posted July 1 to July 7, 2013


How does the concave or convex curvature of a surface affect the WFT reading?

Question posted June 24 to June 30, 2013


How do you accurately measure the adhesion of inorganic zinc?

Question posted June 10 to June 16, 2013


How can I determine when concrete has cured sufficiently to be coated, besides waiting the 28 days typically specified?

Question posted June 3 to June 9, 2013


How does one accurately measure coating thickness on the inside and outside of a small-diameter (~50mm) pipe?

Question posted May 27 to June 2, 2013


How does the concave or convex curvature of a surface affect the dry film thickness reading?

Question posted May 6 to May 12, 2013


What is the best way to repair localized coating breakdown on steel?

Question posted March 11 to March 17, 2013


Is the MEK rub test a conclusive test to check the cure of IOZ coatings?

Question posted January 14 to January 20, 2013


As an engineer in a moderate-sized chemical plant, how can I justify the cost of third-party inspection to upper management?

Question posted December 3 to December 9, 2012


When should the adhesion of an applied coating or lining multi-coat system be tested?

Question posted November 26 to December 2, 2012


What’s the best way to prevent corrosion of reinforcing bar in concrete?

Question posted November 19 to November 25, 2012


Under what conditions should small-diameter blisters (<1.5 inches) in a water tank lining be repaired/repainted? Should the blisters be broken and the substrate examined?

Question posted October 22 to October 28, 2012


What are the advantages and disadvantages of using mechanical equipment inspectors or welding inspectors, instead of certified coating inspectors, to perform coating inspection duties?

Question posted August 13 to August 19, 2012


What coating problems are likely in storage tanks that have dissimilar metal sides and floors?

Question posted June 25 to July 1, 2012


How do you measure the DFT or WFT of a film-forming sealer applied to a metallized coating (e.g., flame-sprayed zinc)?

Question posted November 21 to December 4, 2011


How do you calibrate a DFT gauge in the magnetic field of a live power plant to measure coatings on steel substrates?

Question posted September 26 to October 2, 2011


Is it necessary to holiday test the interior lining in the vapor phase (roof) of water storage tanks after coating?

Question posted September 5 to September 11, 2011


Which DFT statistics should be recorded in a daily inspection report, and why are they relevant to a good coating QC record?

Question posted June 20 to June 26, 2011


What percentage of deterioration is acceptable at a one-year warranty inspection of water tank linings before a contractor must repair the coating job?

Question posted May 23 to May 29, 2011


A specification requires Manufacturer X’s system “or equivalent.” What does “or equivalent” mean, and who decides what’s “equivalent?”

Question posted May 2 to May 8, 2011


How does rapid depressurization affect lining performance in vessels and line pipe, and how can you identify any failure that might result?

Question posted March 21 to March 27, 2011


What is the maximum number of holidays that should be permitted for linings used in immersion service, and why?

Question posted February 14 to February 20, 2011


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