Quality Control of

Industrial Painting
Operations
William D. Corbett
KTA-Tator, Inc.

Webinar Content

Industry standards for coating application QC

Developing a quality control plan for painting
Navigating a Technical (Product) Data Sheet
Measuring ambient conditions and surface temperature
Witnessing mixing, thinning and application procedures
Calculation and measurement of wet film thickness
Dry film thickness measurement
Post-application testing
Cure/hardness
Holiday/pinhole detection
Adhesion
Identifying application defects

Learning Objectives/Outcomes
Completion of this webinar will enable the participant
to:
Describe the industry standards that pertain to coating application
Prepare a Quality Control Plan for painting
Describe the content of a Technical (Product) Data Sheet
Measure environmental conditions and surface temperature prior to
coating mixing
Evaluate mixing, thinning and application procedures
Calculate and measure wet film thickness
Measure dry film thickness
Perform post-application testing

Industry Standards for Coating Application

SSPC-PA 1 Shop, Field and Maintenance Painting of Steel
SSPC-PA 2 (frequency and tolerance of coating thickness
measurements on steel)
SSPC-PA 9 (frequency and tolerance of coating thickness
measurements on concrete)
ASTM E337 (use of whirling/aspirating psychrometers)
ASTM D4414 (wet film thickness measurement)
ASTM D7091/D6132 (dry film thickness measurement)
ASTM D5402/D4752/D3363/D1640 (drying, curing, hardness)
ASTM D5162/D4787 (holiday/pinhole detection)
ASTM D3359/D6677/D4541/D7234 (adhesion)

SSPC Paint Application

Specification No. 1 (PA 1)
Shop, Field and Maintenance Painting of Steel
Common specification reference
Contains 14 Sections:
1.
2.
3.
4.
5.
6.
7.

Scope
Description
Referenced Standards
Definitions
Pre-application Procedures
Factors Affecting Application
Application Methods

8. Shop Coating
9. Field Coating
10. Repair of Damaged Coatings
11. Appl. Proc. For Coatings
12. Curing & Handling
13. Inspection
14. Safety & Environmental

Purpose of a Quality Control Plan

Provides QC Inspector with:
A systematic inspection and testing plan that
covers all phases of work in sequence
A written document that lists what to inspect, how
to inspect and the acceptance criteria
A tool to enable an inspector to navigate through
and extract inspection check points from the
specification

May be a required contract submittal

Benefits of a Quality Control Plan

Coating specifications can be complex documents
Specifications typically contain the quality
requirements for a coatings project
Good inspection doesnt happen by accident; it
requires planning
QC plans make specification compliance more
streamlined and complete
Provides a key communication tool between QA
and QC inspection personnel

Sample Quality Control

Plan
Inspection
Item

Technique/
Instrument

Frequency of
Tests

Standard
Test
Method
Reference

Spec.
Referenc
e
(mock)

Acceptance
Criteria
(mock)

Verify
ambient
conditions

Electronic
psychromete
r

Before mixing
and every 4
hours;
changing
conditions

SSPC-PA 1

3.4.1

Air: 50-100F
Surface: 50110F
RH: <85%
ST > 5F DP

Verify
installation
of protective
coverings

Visual

Prior to primer
application

SSPC-PA 1

3.4.2

Properly
installed &
maintained

Dry Film
Thickness of
Primer

Calibrated
Type 2 gage
verified for
accuracy

Area coated
during the
previous work
shift, per SSPC
PA2

ASTM D
7091
SSPC-PA2

3.4.7

3-5 mils

Holiday
Detection

Low voltage
wet sponge
detector

After topcoat
application

ASTM D5162

3.4.10

No pinholes or
holidays

Product Data Sheets

Prepared by the coating
manufacturer
An instruction manual for
the coating
Technical & marketing
information about the
coating
ASTM F 718 provides a
standard specification for
marine paints

Product Data Sheets, cont.

Typically contain:
Brand name of the product
Generic type of the coating
When/where the coating can be used
Compatible coatings
Product weight and volume solids content
Theoretical coverage rate

Product Data Sheets, cont.

Often contain:
Recommended level(s) of surface preparation
Recommended dry film thickness
VOC content of the coating (as manufactured)
Adjusted VOC content dependant on amount and type of thinner
Performance data (adhesion, abrasion resistance, etc.)
Recommended methods of application
Mixing and thinning instructions
Pot life, induction time
Drying times (dry to handle, dry to recoat)
Cure times
Recoat times
Method to verify cure

Product Data Sheets Vs.

Specification Requirements
Product data sheets contain recommendations
When the PDS and the project specification differ, the
specification is the governing document (contract)
The specification may invoke the PDS
QC inspector should note discrepancies/vague
information and advise the owner at the bidding stage
and at the pre-job meeting

Environmental Conditions for

Coating Application
Air Temperature (min. &
max.)
Relative Humidity (min. or
max)
Dew Point Temperature
Surface Temperature [min.
5 F (3C)] above Dew
Point Temperature
Wind Speed (max.)

Significance of Conditions
Air Temperature
Too cold or too hot can affect coating application & curing

Relative Humidity
Too damp or too dry can affect coating application &
curing

Surface Temperature
Too cold or too hot can affect application & curing

Surface temperature at or below dew point

temperature will result in condensation

Significance of Conditions, cont.

Wind Speed
Too windy can affect application (dry spray) and cause
overspray damage

Mixing/application of coatings under adverse

weather conditions can void the manufacturers
warranty and is considered a specification nonconformance

Ambient Conditions & Surface

Temperature

Measuring Instruments

Sling Psychrometers*
Battery-powered
Psychrometers*
Electronic Psychrometers
Analog, Thermocoupletype & Non-contact
Surface Thermometers
* Used in conjunction with
psychrometric charts or calculators

Sling Psychrometer

Using Sling Psychrometers

ASTM E337
Verify wick cleanliness
Saturate wick and/or fill
reservoir with DI water
Whirl 20-30 second intervals
until wet bulb stabilizes (2
readings within 0.5o)
Record wet & dry bulb
temperatures

Using Psychrometric Charts

Locate Chart (relative
humidity or dew point)
Verify Barometric Pressure
(e.g., 30.0 in.)
Intersect air temperature
with wet bulb depression
(Ta-Tw)
Calculators (bottom image)
can also be used

Electronic Psychrometers
Measure/Record:

Air Temperature
Surface Temperature (ST)
Relative Humidity
Dew Point Temperature (DP)
Spread between
DP and ST

Features
Auto-logging allows for automatic
data collection
Magnetic surface probe
Data graphing and Blue Tooth
uploading
Audio/visual alarm

Measuring Surface Temperature

Dial-Type Thermometer
Position & stabilize for
minimum of 2 minutes

Thermocouple-Type
Thermometers
Stabilize quickly

Infrared (non-contact)
thermometers
Watch distance

Assessing Wind Speed

Analog wind meters
Digital wind meters
Rotating Vane
Anemometers
Air flow inside
containment
Wind speed

Documenting Ambient Conditions and

Surface Temperature
Condition

Data

Date

2/15/12

Time

0900 hours

Dry Bulb Temperature (DB)

16oC (60oF)

Wet Bulb Temperature (WB)

13oC (55oF)

Depression (DB-WB)
Relative Humidity

3oC (5oF)
73%

Dew Point Temperature

11oC (51oF)

Surface Temperature

15oC (59oF)

Wind Speed
Measurement Location

11 km/Hr (7 mph)
West side of tank, ground level

Significance of 5F (3C)
Theoretically, a small (<1F)
increase (surface temperature
over dew point) will preclude
moisture formation
Minimum increase of 5F (3C)
compensates for:
Instrument tolerances
Varying conditions
Changing conditions

Location and Frequency of Data

Acquisition
Location
Dictated by where the
work is being performed
(e.g., inside vs. outside of
a containment; balcony of
elevated storage tank vs.
ground level)
If interior, with
ventilation in operation
Shops: Blast or Paint bay
area

Frequency
Prior to mixing of
coatings
Four-hour data collection
intervals is common
More frequent
measurement if conditions
are changing

Inspecting Mixing Procedures

1. Verify components are within
the manufacturers shelf life
(and stored properly)
2. Check PDS for mixing
instructions
3. Measure coating temperature
after all components are
thoroughly blended
4. Straining required?
5. Thinning required/allowed?
6. Induction time required?
7. Pot life monitoring

Inspecting Thinning Procedures

Verify:
Correct type of thinner is
used
Calculation of thinner
quantity is accurate
Graduated containers are
used to measure thinner

Consider impact on local

VOC regulations

Calculating the Target

Wet Film Thickness
Sometimes the wet film thickness will be listed
on the PDS (many times it is not)
Arriving at the target wet film thickness is
necessary to arrive at the specified dry film
thickness
Must be adjusted based on the amount of
thinner added

Calculating a Target Wet Film

Thickness
Calculating Target Wet Film Thickness
WFT = Target DFT
% solids by volume
Example: 5 mils DFT
68% solids by volume (0.68)
Target wet film thickness: 7-8 mils

Calculating a Target Wet Film

Thickness
Effect of Thinner Addition on WFT Target
WFT =

Target DFT

% solids by volume
100% + % thinner

Calculating a Target Wet Film

Thickness
Effect of Thinner Addition, continued
WFT =

5 mils DFT

0.68
100% + 20% thinner

5 mils DFT

68
120

5 mils DFT

0.57

= 9 mils WFT

Measuring Wet Film Thickness

ASTM D 4414 Practice for
Measurement of Wet Film
Thickness by Notch Gages
Place gage into wet coating
immediately
Withdraw gage and read highest
wetted step (e.g., 5 mils)
Immediately clean coating from
gage

Measuring Dry Film Thickness

Three common standards that address the
nondestructive measurement of coating
thickness :
Ferrous and nonferrous metals: ASTM D 7091
Steel only: SSPC-PA 2 (2004)
2012 version will address ferrous and nonferrous metals

Non-metal surfaces
ASTM D 6132
SSPC-PA 9

Measuring Dry Film Thickness

Standards provide procedures for:
Calibration (gage manufacturer/approved lab)
Frequency of verifying gage accuracy (user)
Frequency of measurements (number of
measurements to obtain based on the size of the
structure)

SSPC-PA 2 places limits on spot and area

readings vs. specified thickness

Measuring Dry Film Thickness

(SSPC-PA 2)
Requires calibration by manufacturer (typically
annual)
Certificate of calibration traceable to a National
Metrology Institute required
Verification of accuracy (by user) before and after
each period of use
Two types of nondestructive coating thickness gages
Magnetic pull-off (Type 1)
Electronic (Type 2)

Verifying Type 1 Gage Accuracy

Use calibration blocks
NIST Traceable
Proprietary from gage
manufacturers

Verify accuracy:
In range of use
Before and after each period of
use

Must correct for surface

roughness (BMR)

Verifying Type 2 Gage Accuracy

Use calibration blocks
or shims
Verify accuracy in
range of use
Most can be adjusted
Follow gage
manufacturers
instructions (vary)

Verification of Type 2 Gage

Accuracy
If smooth reference
standards are used
(A), user must correct*
for surface roughness
If shims (foils) are
used (over the
prepared steel; B), no
correction is needed
A

*Via Base Metal Reading (BMR)

Measurement Frequency
Terminology:
Gage Reading: A single reading at one location
Spot Measurement: The average of at least 3 gage readings
made within a 1.5 diameter circle

Area Measurement: The average of 5 spot measurements

made within a 100 square foot area

Measurement Frequency

Dividing Structures into Test Areas

If the structure is less than 300 square feet, each 100

square feet is measured
If the structure is between 300 and 1000 square feet,
select 3 random 100 square foot test areas and measure
For structures exceeding 1000 square feet, select 3
random 100 square feet testing areas for the first 1000
square feet, and select 1 random 100 square foot
testing area for each additional 1000 square feet

Example:
Structure Size: 55,000 square feet
No. of Areas: 3 + 54 = 57 areas
No. of Spots: 57 Areas x 5 Spots/Area = 285
Spots
No. of Gage Readings:
285 Spots x 3 Readings/Spot =
855 Gage Readings

Coating Thickness Tolerance

(SSPC-PA 2)
Individual readings (averaged to create a spot
measurement) are unrestricted
Non-repeating low or high readings can be discarded

The spot measurement (the average of 3) must be

within 80% of the minimum thickness and 120% of
the maximum
Area measurement must be within specified range

Assessing Intercoat Cleanliness

Airborne dust and/or abrasive may be
deposited on coated surfaces
Problematic if surface is to be recoated
Requires visual or tactical (touch) examination
of the surface

Verifying Recoat Times and

Temperatures
Coating materials may have a minimum and/or
a maximum recoat time
Verify:
Coating has been allowed to dry or cure the
minimum amount of time
The next coat is applied before the maximum
recoat time has been exceeded

Detecting Pinholes and Holidays

Definitions:
Holidays skips or misses in the coating/lining system
Pinholes tiny voids in the coating or lining

Standards:
ASTM D5162 and D4787; NACE RP01-88

Conducted:
After final coat has been applied, but before it has achieved complete cure (touch-up)
Specifications may require holiday testing after the application of each coat
May cause intercoat contamination

Rules for Holiday Detection

Coating must be nonconductive
Substrate must be conductive
High voltage (spark) testing requires voltage
setting
100 to 125 volts/mil of coating
Obtain recommended test voltage from coating
manufacturer
Excessive voltage can damage coating film

Holiday Detectors
Low voltage (wetted sponge)
coatings that are less than 20
mils thick
High voltage (spark tester)
coatings that are greater than 20
mils thick
Move wand/electrode maximum
of one foot/second

Inspecting OAP Coating Systems

Visual pinhole/holiday
detection
Optically Active Pigments
(OAP) added to coatings
during formulation
Inspection performed using
UVA-340 light
Process described in SSPC
TU 11
Inspector training
recommended if inspections
not previously performed

Assessing Coating Drying/Cure

Pencil Hardness (ASTM D3363)
Solvent Resistance (Solvent Rubs; ASTM D5402) for
convertible coatings
Solvent Resistance (Solvent Rubs; ASTM D4752) for
ethyl silicate inorganic zinc primers
Impressor Hardness
Barcol Hardness (ASTM D2583)
Durometer Hardness (ASTM D2240)

Dry Time Testing (ASTM D1640)

Measuring Adhesion
Adhesion is destructive testing
Testing should not be conducted unless
required
Types of coating adhesion:
The adhesion of the coating to the substrate
The adhesion of the coating layers to each other
The inner-strength of each coating layer (cohesion)

Adhesion Test Methods

Standard

Title

D 3359 A

Adhesion by Tape Test (>5 mils DFT)

D 3359 B

Adhesion by Tape Test (5 mils DFT)

D 6677

Knife Adhesion

D 4541

Pull-off Strength of Coatings Using Portable

Adhesion Testers

D 7234

Pull-off Strength of Coatings on Concrete

Using Portable Adhesion Testers

Tape Adhesion (D 3359) Method A

(> 5 mils)

SCRIBE AN X
INTO COATING
TO SUBSTRATE
APPLY TAPE AND
RUB ONTO SURFACE

REMOVE TAPE
QUICKLY

Tape Adhesion (D 3359) Method A

(> 5 mils)
Rating

Description

5A

No peeling or removal

4A

Trace peeling or removal along the incisions

3A

Jagged removal along the incisions up to 1/16 on

either side

2A

Jagged removal along the incisions up to 1/8 on either

side

1A

Removal of most of the coating from the area of the

X under the tape

0A

Removal of coating beyond the area of the X

Tape Adhesion (D 3359) Method B

(< 5 mils)

SCRIBE A CROSSCUT PATTERN

INTO COATING TO
SUBSTRATE
APPLY TAPE AND
RUB ONTO SURFACE

REMOVE TAPE
QUICKLY

Tape Adhesion (D 3359) Method B

(< 5 mils)
Ratin
g

Description

5B

0%

Edges of cuts completely

smooth

4B

<5%

Small flakes of coating

detached at intersections

3B

615%

Small flakes of coating

detached along edges & at
intersections

2B

1635%

Coating flaked along edges

and parts of squares

1B

3665%

Coating flaked along edges in

large ribbons and whole
squares detached

0B

>65
%

Flaking & detaching worse

than 1B

Tensile (pull-off) Adhesion Testing

ASTM D 4541 measures the
resistance to a perpendicular
pull
Requires the attachment of
loading fixtures
Pulling mechanisms include:
Spring
Pneumatic
Hydraulic (shown)

Record psi (Mpa) and

location of break

Illustrations of Various Locations of

Break
1

Identifying Coating Application

Defects
Multitude of defect types
Identifying type, causes
and remedies is
challenging
Acquire a pictorial
reference guide
Sources:
ASTM standards
Fitzs Atlas 2 (shown)

Summary
During this webinar, we have described :
Industry standards for coating application
Developing a quality control plan for painting
Navigating a Technical (Product) Data Sheet
Measuring ambient conditions and surface temperature
Witnessing mixing, thinning and application procedures
Calculating and measuring wet film thickness
Dry film thickness measurement
Post-application testing
Identifying application defects

Quality Control of
Industrial Painting
Operations
THE END
William D. Corbett
KTA-Tator, Inc.