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Problem Solving Forum (81)


Should pull-off adhesion tests be carried out on a zinc-rich primer alone, or only on a complete system?


What is the best way to remedy over-thickness of a topcoat after it has dried and cured?


How do you gauge the remaining service life of an aging FBE system on a buried transmission pipeline?


Is there any method to take accurate wet film thickness readings when applying zinc rich primers?


How do concrete admixtures such as hardeners and anti-dust compounds affect coating adhesion? What can be done to minimize negative effects?


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


After applying a thermal spray coating on a petrochemical industry live line that operates at 48 degrees Celsius (118 degrees Fahrenheit), the coating sustained a brown discoloration on the bottom of the pipe. What would cause this discoloration of a TSA coating?


In reviewing the testing data for adhesion, some manufacturers indicate ASTM D4541 results while others show ASTM C3359 results. Is it possible to compare one against the other? For example, does 1037 psi provide better adhesion than 4A?


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


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


What errors are most likely to occur when measuring dry film thickness on steel, and how can I avoid them?


What tests and criteria can a coatings user specify to assure consistent lot-to-lot performance of supplied coatings?


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


For coatings with a high-solids content (95 percent or more), what kinds of defects, such as holidays or micropores, are possible or likely to occur in the applied film? How can these be prevented or remedied?


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


How do you accurately measure the adhesion of inorganic zinc?


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


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


When and how should ambiguities between a coating spec, data sheets and responsibilities be clarified?


If you’re performing a QA inspection as a part-time consultant and the surface in question was blasted and painted two days before you arrived on-site, should you sign off on the work if the owner asks you to?


Some specifications may have requirements that the inspector may know to be extraneous or may be more restrictive than necessary to obtain a quality coating application. What is the ethical responsibility of the inspector to reject non-conforming coatings that they know will perform as intended, particularly where attempted repairs may degrade the coating system?


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?


What are the most effective procedures for protecting steel and adjacent concrete together?


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


How do I minimize corrosion at the splash zone on sheet pile and piping in brackish water?


What tests should be run to determine if an existing concrete bridge pier needs rehabilitation or repair before cleaning and coating?


How do you determine whether a lead-bearing coating can be overcoated or removed and replaced?


How can active corrosion be determined on a live pipeline?


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


How do you adequately assess the adhesion of a newly applied coating?


When and why would I need to stripe coat if I am using an edge-retention primer?


When performing maintenance painting of tank coatings, what are the pros and cons of overcoating an existing lining that appears to be in good condition?


What can be done to prevent rust bleed in crevices when applying a zinc/epoxy/urethane system?


When applying a 100% solids, fast-curing polyurea coating on concrete, what is the best method for verifying that the proper thickness has been applied?


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


What are the common moisture tests for vertical, below-grade concrete structures scheduled to receive a high-build, protective lining system?


How do you assess salts and other non-visible contaminants on concrete surfaces?


How do you assess salts and other non-visible contaminants on concrete surfaces?


How do you assess vertical concrete surface pH after surface preparation of existing concrete?


How do you gauge the remaining service life of an aging FBE system on a buried transmission pipeline?


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


How do concrete admixtures such as hardeners and anti-dust compounds affect coating adhesion? What can be done to minimize negative effects?


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


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.


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


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


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?


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?


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


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


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


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


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


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?


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


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?


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?


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


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


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


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


How do you accurately measure the adhesion of inorganic zinc?


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


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


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


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


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


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


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


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


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?


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


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


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


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


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


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


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


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


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


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


 
 
   

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