QA QC Manual 2008

Quality Assurance /
QualityControl
Field Manual
1-877-234-5268
www.ceilcotecc.com
TABLE OF CONTENTS
Chapter 1 ……………………………………………………..Introduction
Chapter 2 ............Field Quality Control/Quality Assurance Program
Chapter 3 ……..………………………………………..Inspection Forms
Chapter 4 …………………………………………...Pre-Work Inspection
Chapter 5 …….…………………….Surface Preparation Verifications
Chapter 6 …………....………..………..Lining Application Verification
Chapter 7 ………………..………..Lining/Coating Testing Verification
Chapter 8 ………………...…………………….Quality Control Records
Chapter 9 ………….…………Instrumentation Calibration Standards
Chapter 10 .Technical Bulletins, Installation Specifications, Details

CHAPTER 1
1. INTRODUCTION
1.1. SCOPE
1.1.1. This Quality Control Manual outlines the functions and duties of QC personnel at
lining/coating jobsites where a Quality Control Program is established to monitor
field activities. Information contained within this manual describes the reporting,
inspection, documentation and testing procedures established to adequately
promote an effective Quality Control/Quality Assurance Program.
1.2. OBJECTIVE
The objective of this Quality Control Manual is to provide a reference of

established minimum standards and guidelines for an effective field QC/QA
Program which is uniform in functions and duties, efficient and reliable in
performance of its’ work, yet independent of the production process. References
to specific industry standards have been made, whenever possible, to promote a
comprehensive program.
CHAPTER 2
2. FIELD QUALITY CONTROL/QUALITY ASSURANCE PROGRAM
2.1 QUALIFICATION
Field QC/QA personnel will be approved by Ceilcote. They shall be experienced and
knowledgeable of the standard installation and testing practices in the corrosion
resistant lining/coating industry.
2.2 REPORTING
Field QC/QA personnel shall report directly to the Ceilcote Quality Control Supervisor.
2.3 RESPONSIBILITIES
Field QC/QA personnel will perform all visual and physical tests and inspections as
required by the appropriate Ceilcote Bulletins, Specifications and Quality Control
Procedures. These tests and inspections will be conducted in a thorough professional
manner to insure installation compliance. Responsibility for the acceptance or the
rejection of any work is a QC/QA function. Conflicts regarding the interpretation or
determination of work quality, environmental conditions, acceptability of substrates,
application methods and techniques, materials and record keeping will be reported
directly to the Field Foreman/Superintendent and Ceilcote’s Quality Control Supervisor.
Ceilcote’s Management and R&D Department must approve in writing all deviations
from procedures, methods, interpretations, testing and standard practices prior to their
implementation. Field QC/QA will remain independent of the installation crew in the
performance of their duties.
2.4 QUALITY ASSURANCE/MATERIALS

Quality assurance procedures are in place for both the material manufacturing process
as well as at the jobsite to insure the maximum reliability of both the products and
application services.
Manufacturing Quality Control is the responsibility of the R&D Department. They

establish specifications and procedures to ensure product purity and consistency and
their QC personnel have the obligatory authority to reject any material which is not
within specification.
CHAPTER 3
3. INSPECTION FORMS
3.1 NON-CONFORMANCE REPORT
This form is used to document conditions, work or areas that are unacceptable to any
work process. The discrepancy noted on the report should specify the exact procedure,
specification or other governing data that supports the stated non-conformance. Non-
Conformance Reports should be preceded with an inspection report that lists a
discrepancy. The Non-Conformance Report is issued if the discrepancy is not
adequately corrected after a sufficient amount of time has been allowed for the
correction. A copy of this form is contained within this Chapter as Supplement “A”.
3.2 EQUIPMENT ACCEPTANCE REPORTS
This form is used to note the date, acceptance and exceptions, if applicable, for the
release of equipment for lining/coating application. Parameters of work and the
appropriate Drawing Numbers should be stated on the form. Equipment Inspection
Reports and/or Non-Conformance Reports could be incorporated into this report or
separate reports should be used to supplement this form to indicate appropriate
information. A copy of this form is contained within this Chapter as Supplement “B”.
3.3 INSPECTION FORMS – GENERAL
Reports should include inspector’s name, customer’s name, appropriate dates,

designated equipment identification names and/or numbers and reference drawing
numbers. Retention of reports is discussed in Chapter 8.
NON-CONFORMANCE REPORT
CEILCOTE Job No. _______________________ Location: _____________________
The item(s) listed below are in non0conformance to (specifications) (procedures) (other) ____
Equipment: ____________________________ Contractor: _____________________
Non-Conformance noted: _____________________________________________________
Date: _________________________________ By: __________________________
Corrective Action Required: ________________________________________________
Date: ______________ Corrected by: ______________ Verified by: ______________
Comments:
cc:
EQUIPMENT ACCEPTANCE REPORT
DATE: _________________________ CEILCOTE JOB NO.: ________________________
CUSTOMER: ____________________ EQUIPMENT NO.: ________________________
LOCATION: ____________________ INSPECTED BY: ________________________
SUBSTRATE: (steel/alloy( (concrete) (other) ______________________________________
DRAWING NO.: _________________
The following equipment ______________________________________________________

Has been accepted for (lining) (coating) application by CEILCOTE at the location specified
above. This equipment is accepted (with) (without) exception(s) and with the understanding
that the substrate may be subject to repair if workmanship and/or material deficiencies become
apparent during the surface preparation operation (i.e. steel-welds, pinholes, etc. concrete
honeycombs, voids, etc.)
EXCEPTION(S) NOTED: ______________________________________________________
___________________________________________________________________________
DATE CORRECTED: ___________
BOUNDARIES OF RELEASE: _________________________________________________
___________________________________________________________________________
________________________________________
FIELD SUPERINTENDENT, FOREMAN, QC
________________________________________
AUTHORIZED CUSTOMER REPRESENTATIVE
CHAPTER 4
4. PRE-WORK INSPECTION
4.1 PRE-WORK INSPECTION
4.1.1 Pre-Work Inspections of substrates in work areas shall be completed prior to the
start of the lining/coating application in the areas. These inspections will be
documented on the Equipment Acceptance Report with all results and findings
stated on the report. This form is Supplement “A” in Chapter 3. Areas that are
inaccessible to inspection, (ie lack of scaffold, no lighting, beneath water, no
entry permit etc.) shall be noted on the Inspection Report with an explanation of
the inaccessibility. Inspection of these areas shall occur when access is
available and all results and finding shall be stated on an inspection report.
4.2 CONTROL DOCUMENTS FOR SUBSTRATE INSPECTIONS
4.2.1 Steel and Alloy substrate inspections shall conform to ASTM, STP837- Manual of
Protective Linings for Flue Gas Desulfurization Systems, Chapter 4 - Design and
Fabrication of System Components. This Manual, Supplement “A” in this Chapter
4, contains the guidelines for acceptable steel substrate conditions, welds,
appurtenances, gouges, stampings, structural members and nozzles and
Ceilcote’s CPT-2 “Steel Substrate Specification to Receive Monolithic lining”.
4.2.2 Concrete substrates shall conform to Ceilcote Standards CS-10 Quality of

Concrete Surfaces and CP-11 Repair and Preparation of Concrete for Lining.
CS-10 is Supplement “B” and CP-11 is Supplement “C” in this Chapter 4.
4.2.3 Additional requirements and/or modifications to the information contained in the

documents listed must be approved by Ceilcote’s Management or Research and
Development Department.
4.3 INSPECTION ATTENDANCE
4.3.1 Pre-Work Inspections shall be attended and witnessed by representatives of all

concerned parties.
4.3.2 Established inspection guidelines shall be reviewed prior with all concerned
parties prior to all inspections.
4.4 EXCEPTIONS
4.4.1 Exceptions to any work, workmanship, materials or conditions noted on any

inspection reports shall be documented on the Non-Conformance Report.
CHAPTER 4 (Cont.)
4.5 EQUIPMENT ACCEPTANCE REPORTS
4.5.1 Equipment Acceptance Reports
4.6 ADDITIONAL INSPECTION REQUIREMENTS
4.6.1 All additional Inspection Requirements beyond the control documents above shall
be stated as an addendum to the appropriate section before implementation.
CHAPTER 4
SUPPLIMENT “A”
STEEL DESIGN, FABRICATION AND WELD SPECIFICATIONS
SUBSTRATE SPECIFICATION CPT 2

Steel Substrate Specification To Receive Monolithic Linings
CPT-2
STEEL SUBSTRATE
SPECIFICATION TO RECEIVE
MONOLITHIC LININGS
March 2006
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NOTES TO THE SPECIFIER
1. This document has been prepared to assist specifiers in the preparation of steel
substrates for Ceilcote Corrosion Control Products.
2. This specification defines the necessary practices for surface preparation of steel
tanks and other steel equipment.
3. Application under this specification must be done in accordance with the

following procedures.
4. Questions regarding these practices and guidelines should be directed to

CEILCOTE.
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CPT-2
STEEL SUBSTRATE
MONOLITHIC LININGS
The specification information below is intended for use by architects, engineers or other
specifiers in defining the criteria needed for acceptable substrates.
1.0 MATERIAL
1.1 Material shall be new full weight carbon steel that is free from laminations or
other physical imperfections.
All plates shall be flat with no appreciable buckle or warpage.
2.0 CONSTRUCTION
2.1 Standard Fabrication Practice
.1 Tanks and other steel structures shall be of welded construction and shall
be fabricated, in accordance with standard commercial practices to obtain
an economical product of uniform quality.
2.2 Design
.1 All tanks shall be constructed with a minimum number of pieces. Steel

plate thickness for shells, heads, tops and bottoms shall be of sufficient
thickness or to be stiffened properly to withstand all loads and pressures
to be encountered during operation. However, plate thickness for design
and engineering considerations, which are not contained in this
specification, shall be the responsibility of the owner or supplier of the
steel structure.
2.3 Location of Stiffening Members
.1 When steel plates, are stiffened with "I" beams, angles, channels or buck
stay, the stiffening members should be welded to the exterior steel
surfaces if possible.
Angles or channels used for stiffening or reinforcing at the top edge of

tanks should be welded flush with the top. If necessary to offset these
steel members, the offset should be continuously welded, so that there are
no crevices or voids.
CPT-2
STEEL SUBSTRATE
MONOLITHIC LININGS
2.4 Closed Tanks-Manways
.1 All closed tanks or vessels shall be fitted with at least one (1) manhole or
manway at least 12 inches by 20 inches or 18 inches in diameter.
2.5 Tank Nozzles
.1 Tank nozzles shall be flanged design where possible and should be over 2
inches in diameter. Threaded nozzles should be avoided. Flanged
nozzles 2 inches and greater in diameter shall have maximum length in
accordance with the following schedule:
Maximum Length Shell

Nozzle Diameters To Face of Flange
2" 3" *
3" 4"
4" 8"
8-24" 16"
24-36" 24"
Over 36" Any Length
* This is not always possible to line
2.6 Bottom Support
.1 Tanks with cone bottoms up to 20 feet in diameter do not require any

special bottom support as long as they are properly designed, to withstand
loads and pressures encountered during operation. Flat bottom of
cylindrical tanks or rectangular tanks, should be given full bearing support
in order to limit deflection of "oil canning" to a minimum. Pressure
grouting to fill voids between the foundation and steel tank bottom, should
be used if inspection reveals that abnormal deflection or "oil canning" may
occur when the tank is filled.
CPT-2
STEEL SUBSTRATE
MONOLITHIC LININGS
3.0 WELDING
3.1 Continuous Welding
.1 All welding shall be continuous. No intermittent welds shall be allowed.
3.2 Finish of Welds
.1 All welds shall be ground to remove all sharp edges, laps, undercuts and
other surface irregularities and projections. All weld splatter shall be
removed. Chipping, may be utilized if followed by grinding for finish.
A Welds must be ground smooth, free of all defects as per NACE

Weld Preparation Designation “C” (NACE Standard RPO 178-2003
Standard Recommended Practice Fabrication Details, Surface
Finish Requirements, and Proper Design Considerations for Tanks
and Vessels to be Lined for Immersion Service).
3.3 Ripple Finished Welds
.1 Relatively smooth, ripple finished welds are acceptable. It shall not be

necessary to grind welds dead smooth or flush to the parent metal. No
pinholes, pits, blind holes or similar depressions shall exist in the finish
surface of the weld.
3.4 Finish of Sharp Edges and Fillets
.1 All sharp edges and fillets, and similar abrupt contours shall be rounded
off, be grinding or machining to a 1/8" minimum radius. A 1/4" radius at
fillets or changes in contour is preferred.
4.0 INTERNAL COMPONENTS
4.1 Removal
.1 Internal components such as heating coils, which are not lined, shall be
removed (if possible) from the tank prior to the lining operation.
CPT-2
STEEL SUBSTRATE
MONOLITHIC LININGS
4.2 Support of Hanging of Internal Components
.1 If possible, internal components shall not be supported, or hung from

brackets, or braces attached to the shell or bottom of the tank. If such
methods are necessary, please consult your Ceilcote representative.
5.0 TESTING
5.1 The tank or steel structure shall be hydrostatically tested at pressure

recommended by the designer. Any leaks or other defects discovered, as the
result of these tests shall be repaired prior to commencement of the lining
operation.
6.0 CLEANING
Any dirt, grease, oil, chemical, corrosion products or other foreign materials, which
cannot be removed by sandblasting, shall be thoroughly; cleaned from the surfaces to
be lined by the tank fabricator.
CHAPTER 4
SUPPLIMENT “B”
CEILCOTE CONSRUCTION SPECIFICATION CS-10
QUALITY OF CONCRETE SURFACE
AND
CEILCOTE CONSTRUCTION PRACTICE CP-11
REPAIR AND PREPARATION OF CONCRETE FOR LINING

CS-10
October 2004
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1. This document has been prepared to assist specifiers in the preparation of

concrete to receive Ceilcote Corrosion Control Products.
2. This specification defines the necessary practices to achieve the desired

concrete surface for proper bonding of monolithic flooring and linings.


CEILCOTE.
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CS-10
GUIDELINE SPECIFICATION
The specification information below is intended for use by architects, engineers, or other
specifiers in defining the criteria needed for acceptable substrates.
1.0 SCOPE
1.1 This specification defines the quality of the concrete surface required for the
application of Ceilcote tank linings and coatings.
1.2 This specification covers a new concrete only.
1.3 Performance of a Ceilcote lining or coating will be dependent on compliance with

this specification.
2.0 DISCUSSION
2.1 Quality of the concrete influences two major performance factors:
.1 Surface strength affects ability of the lining to withstand

temperature fluctuations.
.2 Air voids affect the ability to obtain a holiday or pinhole-free lining.
2.2 Two basic types of concrete surfaces are present in all tanks:
.1 The floor, which is cast as a slab, may have laitance on the surface
(a skin of under cured concrete) or a curing membrane.
.2 The walls, which have had their initial cure under a form, are less
likely to have laitance or under cured cement. Almost invariably the
walls will contain air pockets or voids. Formed surfaces may have
form release agents or retarded cement, which may produce a
bond breaker to any applied lining or coating.
2.3 Methods used for waterproofing, such as under-slab film or exterior

membrane, should be brought to the attention of Ceilcote; they may
influence final drying of the concrete.
CS-10
3.0 CONCRETE QUALITY
3.1 Appearance: The following defects must be repaired before the lining can
proceed:
Air Pockets
Pinholes Indicating Hidden Air Pockets
Tie Holes
Form Burrs
Honeycombs
Cracks, Cold Joints, Control Joints
3.1.1 These defects may be corrected by the contractor; refer to Ceilcote
Recommended Practice Number CP-11
3.2 Surface Tensile Strength: Floors and walls must be free of the following
contaminants that affect the surface strength of the concrete:
Form Oils
Curing Sealer
Soft Concrete
Laitance
3.2.1 These contaminants may be removed by the contractor; refer to

Ceilcote Recommended Practice Number CP-11
3.2.2 Required strength depends on the maximum and minimum

temperatures, as follows
Location Max Deg F Min Deg F Surface Tensile PSI

Indoors 140 40 300
Outdoors 160 30 300
Indoors 160 30 300
Outdoors 160 40 300
CP-11
REPAIR AND PREPARATION
OF CONCRETE FOR LINING
March 2005
********************************************************************************************
1. This document has been prepared to assist specifiers in the repair and
preparation of concrete for Ceilcote Corrosion Control Products.
2. This specification defines the necessary practices for preparing of the concrete
surface.


CEILCOTE.
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CP-11
specifiers in defining the criteria needed for the repair and installation of the concrete before
application of the lining system.
1.0 SCOPE
1.1 This is recommended practice for preparing concrete surfaces to comply with
Ceilcote Construction Specification Number CS-10.
1.2 This practice is for new or old concrete surfaces to receive Ceilcote Linings or
Coatings.
1.3 This recommended practice is published to provide the user of Ceilcote products
with information concerning repair methods that have been employed with
success in past installations. Its publication does not constitute a warranty of any
sort by CEILCOTE.
2.0 REPAIR METHODS
2.1 Air Pockets Before and After Blasting
.1 Discussion: Practically all formed concrete has air pockets in or just

below the surface. The best preparation is to lightly grit blast the surface
to roughen it for mechanical bond of the lining and to open up holes just
below the surface. Blasting is not always necessary and does add
considerable cost. An important consideration for deciding whether or not
to blast is the amount of temperature variation expected.
In climates where 40°-50°F (4.5-10°C) is minimum, it is probable that

blasting may not be necessary. If lower temperatures are expected or if a
failure in the vessel will shut down a plant, blasting should not be done.
Whether or not the concrete is blasted, the holes should be filled before
lining, particularly if sun will shine on surface during lining or coating.
2.2 Portland Cement Based Material
.1 Such materials are satisfactory for repairing defects in cured concrete if

they include an acrylic or styrene butadyene latex material.
.2 Cement does not bond well to cured concrete; the lining may pull it loose
from base concrete due to shrinkage of the repair concrete.
CP-11
.3 Cement does not cure well in thin layers, resulting from filling small air
pockets; thin sections tend to dry out before they hydrate producing poor
surfaces for bonding.
Again, our lining may pull this poorly cured cement from the concrete
surface.
.4 After filling with cement, a carbonate layer usually remains on the

surrounding concrete. This surface, if not removed by stoning, can cause
failure in our lining system.
.5 Fast hardening cement base compounds: Many or these compounds are
designed for use on horizontal surfaces; they are so fluid that they do not
apply well on vertical surfaces. Some of these emit ammonia when they
cure and this appears to affect the curing mechanism of polyester linings
to inhibit bond; thus, they must be used with caution.
2.3 Resin Based Compounds
.1 These are the preferred repair materials and are available from Ceilcote.
Type S-11 Powder is the base for filling compounds. Prior to lining with a
polyester type lining, the S-11 Powder is mixed with Ceilcote 380 Primer
and troweled on. If the lining is to be epoxy, the S-11 Powder is mixed
with 680 Primer.
2.4 Epoxy Linings/Coatings
Ceilcote 680 Primer/Saturant Liquid - 3 quarts Hardener No. 9 - 1 quart Type S-

11 Powder - 1 3/4 gal (approximately 8 pounds). CEILCOTE 610 Ceilpatch can
also be used.
.1 Mix hardener and liquid together for at least 1 minute with a powered
beater.
.2 Add the powder and mix until a smooth thixotropic paste is formed. The
proper consistency should not fall from a trowel at a thickness of 1 1/2"
and should trowel like whipped butter. More or less powder may be used.
.3 Use the trowel like a squeegee, stroking in four directions so all holes
become filled even with the surface of the concrete. Only a very thin film
should remain on the concrete, and this can be the primer for linings that
do not require spark testing.
.4 Allow to dry (8-12 hours depending on temperature) and then inspect for
partially filled holes. They must be filled with an additional paste.
CP-11
.5 If hardening is too rapid, use a mixing ratio of 4 quarts liquid to 1-quart

hardener.
2.5 Polyester Linings/Coatings
Ceilcote 380 Primer/Liquid - 1 gal Hardener No. 2 - 3 fl. oz. Type S-11 Powder -
2 gal (approximately 9-14 pounds). Ceilcote 310 Ceilpatch can also be used.
.1 Mix hardener into liquid at least 1 minute with a powered beater.
.2 Add the powder and mix until a smooth thixotropic paste is formed. The
proper consistency should not fall from the trowel at a thickness of 1 1/2"
and should trowel like whipped butter. More or less powder may be used.
.3 Allow to cure (8-16 hours depending on temperature) and then inspect for
missed voids. Apply more fill if necessary.
.4 Allow to dry (4-8 hours depending on temperature) and then inspect for
partially filled holes or shrinkage cracks. Shrinkage cracks may form in
larger voids; they must be filled with an additional application of paste.
2.6 Deep Holes
.1 Concrete Fill: Concrete may be used to fill large holes. It is important to

undercut the edges of the area to obtain a mechanical bond or use
CEILCOTE 400 Corocrete over properly prepared surface. After 24 hours
for polyester/vinyl ester systems and 8 hours for epoxy systems, prepare
surface as normal surface preparation.
.2 Resinous Concrete or Grout: Resin grouts compatible with the lining to be

used for casting back or a form. Forms must be waxed for easy removal.
Formed resin grouts cure with a glazed surface, which must be roughened
by sandblasting or grinding before lining will adhere properly.
2.7 Cracks
.1 These usually result from concrete shrinkage or settling of the structure.

They must be expected to open and close with temperature changes.
This movement will almost certainly crack Ceilcote Linings and Ceilgard
Coatings if nothing is done to compensate for it.
CP-11
.2 Injection of Epoxy: A crack resulting from shrinkage may be filled by

injecting epoxy compound under pressure. In a successful pressure
injection repair, the epoxy will bond the edges of the crack and return the
wall or slab to a monolithic condition.
.3 The Crack as an Expansion Joint: The crack may be chipped or sawed to

create a groove about 1" wide x 1/2" deep. The lining should be applied
into the groove; later it will be filled with a suitable elastomeric sealant.
Refer to Ceilcote's Recommended Construction Practice Number CP-16.
.4 Disbonding Method: A strip of elastomer such as butyl rubber, natural

rubber or other that is resistant to the chemical environment and is not
adversely affected by lining resin is bonded over the crack. The strip
should be at least 1/16" thick x 6" wide. The lining is applied only to the
edges of the elastomer strip.
After the lining has cured, the strip is covered with at least two layers of 1
1/2-oz. glass mat impregnated with a resin compatible with the lining and
resistant to the environment. The overlay must bond 3" onto the lining on
each side of the strip.
2.8 Water Leaks
.1 Water may seep through porous concrete, especially if there are sections
of honeycomb. A tank properly waterproofed on the exterior will not leak.
If this has not been done and leakage occurs, there are two methods that
may stop it:
.2 Hydraulic Cement Method: Chip out a substantial "V" groove in the area of
leakage and pack it full of fast setting cement.
.3 Pressure Relief Method: For stubborn leaks, it may be necessary to drill a

well or excavate so ground water can be pumped from the wall until the
leak is stopped.
This method is not a sure remedy. After pumping has stopped more leaks
may show up. If the water table is very high, it may not be possible to
guarantee results with the lining even though lining was applied while
concrete was dry. Dryness of the concrete should be tested with a rubber
mat or plastic film covering the surface for 8 hours starting early morning,
without a sign of condensation on the underside, before proceeding with
lining.
CHAPTER 5
5. SURFACE PREPARATION VERIFICATIONS
5.1 STEEL AND STEEL/ALLOY SUBSTRATES - ABRASIVE BLASTING
5.1.1 AIR QUALITY
5.1.1.1 The compressed air supply should be checked for the presence of
contaminants in the air stream to determine air purity. Testing of the air
supply at initial start-up should be accomplished to evaluate and
establish acceptable air purity for the compressed air prior to actual
work start-up. If moisture is present in the air stream water traps and
moisture filters should be installed just before the blasting pot to remove
the water. Oil removing coalescer filters may also be installed to
remove oil mists if they are present in the air stream. Pressure tests of
the air stream should be taken periodically to assure that the air
pressure into the blast pot and at the nozzle is adequate.
5.1.2 CLEANLINESS OF SUBSTRATE AFTER ABRASIVE BLASTING
5.1.2.1 The substrate after it is abrasive blasted, shall be in accordance to the

SSPC blast designated in the appropriate Ceilcote Company
Installation Procedure/Specification. In most instances this would be
SSPC-SP5 "White Metal Blast Cleaning" 11/1/82. Areas of cleanliness
below the SSPC blast definition shall be documented and reblasted to
the SSPC definition. The SSPC definitions shall not be interpreted to
exclude the embedment of the blast media which occurs during
normal abrasive blast cleaning operations. Cleanliness of steel
determination is a visual test accomplished without magnification aids.
SSPC Blasting Specifications are contained in Supplement "A" of this
chapter.
5.1.3 DETERMINATION OF SURFACE PROFILE
5.1.3.1 This is accomplished by using a Keane-Tator Comparator

Model 745 or equal, in conjunction with the appropriate
reference disc either "S" or "GS". Approximately 5
readings are taken per 100 square feet of completed area.
Readings shall not be taken on abrupt contour changes such
as edges, inside and outside corners, and small diameter
piping. Areas where the surface profile is below the
stated minimum of the appropriate Ceilcote Company
Procedure/Specification shall be documented and reblasted.
A description of the Keane-Tator comparator and disc is
contained in Supplement "B" of this chapter.
CHAPTER 5 (Cont.)
5.1.4 ENVIRONMENTAL WORKING CONDITIONS
5.1.4.1 Humidity and dew point measurements shall be taken at the start of
each work shift and at established intervals thereafter to verify
acceptable standards and minimum. Environmental conditions, dew
point, humidity and temperature requirements are contained in the
appropriate Ceilcote Installation/Specification. Environmental
conditions measurements are obtained per ANSI/ASTM E-337 found in
this chapter as Supplement "C". Deviations to these restrictions may
occur with some abrasive blasting operations on steel steel/alloy
substrates particularly when previous linings/coatings are being
repaired and/or replaced.
5.1.5 PRIMING
Abrasive cleaned steel, steel/alloy substrates should be primed within a

maximum of 16 hours after being blasted unless Environmental Control
Equipment (i.e. de-humidification equipment) or very low relative humidity and
high dew point difference is present. Chapter 6 (Section 6.1 Priming) contains a
detailed description of this area.
5.2 CONCRETE SUBSTRATES
5.2.1 Ceilcote Construction Practice "Surface Preparation of Concrete" CP-l4 -

(Supplement "D" this chapter) states acceptable practices of surface preparation
for concrete substrates. After completion of the concrete surface preparation
priming may be delayed for a unspecified period of time provided the surface is
clean, dry, and free of contaminants immediately prior to priming application.
5.3 QUALITY CONTROL DOCUMENTATION REQUIREMENTS
5.3.1 Q.C. personnel will record and maintain the following documentation
records for abrasive blast cleaning.
1.) Environment conditions of the work areas for steel steel/alloy substrates only.
2.) Abrasive blasting dates of the areas cleaned.
3.) Surface profile measurements of the blast cleaned areas for steel steel/alloy
substrates only.
4.) Priming dates of all blast cleaned areas.
5.) Batch number placement of the primer.
5.4 DEVIATIONS - ADDITIONAL REQUIREMENTS

CHAPTER 5 (Cont.)
5.4.1 All deviations - additional requirements to this chapter shall be stated as a

addendum to the appropriate section after approval by Ceilcote before
implementation of any change.
CP-14
SURFACE PREPARATION
OF CONCRETE FLOORS
March 2005
********************************************************************************************
1. This document has been prepared to assist specifiers in the proper procedures
needed to prepare concrete for Ceilcote Corrosion Control Products.
2. This specification defines the necessary practices in surface preparation that

need to be addressed before linings or coatings are installed.


CEILCOTE.
********************************************************************************************
CP-14
SURFACE PREPARATION
OF CONCRETE FLOORS
specifiers in defining the criteria needed for proper surface preparation.
NEW CONCRETE
1.0 FINISHING AND CURING
1.1 Discussion: During the finishing operation water-rich cement rises to the
surface. When this cement dries, it leaves a weak and powdery film called
laitance. This film must be removed so the floor topping can bond to the stronger
composition of cement paste and sand below.
Method for removing the laitance will be covered in later sections.
1.2 Finishing Methods: The preferred finish is "once over" with steel trowel. This
method provides the strongest, most uniform concrete surface. Screed, broom or
wood float finishing is not as desirable since they may leave an irregular surface;
often too weak for suitable surfacing.
1.3 Surfacing Curing and Hardening Treatments: Do not use these unless they are
compatible with the surfacing; they may reduce adhesion of the surfacing and
may require subsequent mechanical removal.
1.4 Concrete Cure Time: It is best to cure new concrete 28 days prior to applying a
monolithic topping. This is not always practical and exceptions can be made.
.1 Summer Curing: With concrete temperature above 60°F (15°C), 14 days

should be sufficient. If the concrete is an adhesive bonded overlay or if a
vapor barrier is used under the slab, 28 days, or longer, should be allowed
for the concrete to stabilize internal moisture content and not necessarily
for strength development.
.2 High Early-Strength Concrete: In summer temperature it is possible to

cover this after 3 days cure. In winter, with concrete temperature 50-35°F
(10-2°C), 14 days should be allowed. If this concrete is an adhesive
bonded overlay or if a vapor barrier has been used, it should cure 14 days
in summer and 21 days in winter.
(Mat Test in accordance with ASTM D 4263)
.3 The major problem with curing is the water content. This can be checked
by taping a 1' square of polyethylene or other clear film to the floor. If
condensation appears on the underside of the film within 8 hours, the
concrete is not dry enough.
CP-14
SURFACE PREPARATION
OF CONCRETE FLOORS
2.0 SURFACE PREPARATION
2.1 Abrasive Blasting: This is an excellent method. If dust is a problem, wet

blasting may be used. Enclosed portable sandblast units are now available on a
local basis to be leased, rented, or purchased to accomplish such a task without
a great deal of dust.
2.2 Scabbling or Scarifying: They are mechanical preparations desirable when

existing polymer toppings must be removed.
2.3 Shot blasting: This mechanical preparation propels steel shot at a high velocity
onto a surface. It is a self-contained system with a vacuum, which minimizes
dust.
2.4 Water Blasting: Utilizing high pressure, low water volume may also be employed
when dust or grit is a problem.
2.5 Determing Dryness: Concrete on a grade may be on wet soil or on a vapor

barrier where etching water cannot escape except by surface evaporation. It is
beneficial to tape a square of polyethylene film to the concrete and observe for
droplets of water on the underside (8-hour period). If droplets are present, repeat
test. If moisture persists, contact Ceilcote.
OLD CONCRETE
1.0 DISCUSSION
It is important to know the history of existing concrete. This should include not only the
chemicals to which it has been exposed but also construction details: Is concrete
poured directly on soil or clay or is there a sand or gravel bed? Is there a vapor barrier?
How far under the floor is the water table? Answers to these questions may influence
the type of surface preparation used.
2.0 CLEANING
2.1 To determine if contamination is present on concrete, perform a spot test with a
1: 1 solution of hydrochloric acid and water. If the acid foams, proceed to section
2.2. If it does not foam the concrete is either contaminated or covered with a
sealer. If contaminated, scrub with solvent (1, 1, 1 Trichloroethane,
perchlorethylene or naptha can be used in conjunction with an industrial
detergent) and then spot test again. It may be necessary to remove
contaminated concrete exposing sound substrate.
2.2 Abrasive blasting is the recommended method for substrate preparation. If dust
is a problem, wet abrasive blasting may be used. Note that concrete must be dry
before application of polymer system. Enclosed portable blast units such as
"blastrac" are now available on a local basis which can be leased, rented, or
purchased to accomplish such a task without a great deal of dust.
CP-14
SURFACE PREPARATION
OF CONCRETE FLOORS
3.0 REBUILDING OLD FLOORS
Concrete that is badly saturated with oils, caustics, or sugars must be removed and
replaced with new concrete. The new concrete must be bonded with an adhesive such
as Ceilcote's 17 Adhesive and, after curing, prepared as new concrete.
4.0 EXPOSED AGGREGATE
4.1 There are four possibilities for leveling the floor to original grade. The choice may
be governed by economics or time.
.1 Filled epoxies--such as Ceilcote F/T Corocrete.
.2 Fast Hardening Cements--perform well if given a broom finish after

troweling; no acid etch or other preparation is needed. These do not work
well with polyesters.
.3 Portland Cement Toppings--bonded with an adhesive such as Ceilcote 17

Adhesive.
.4 Bonded topping--such as CEILCOTE 400 Corocrete can be used with 1/2"

minimum thickness. Base concrete should be prepared as outlined in
Section 2.0.
5.0 CRACKS
Treatment of cracks depends on several factors: size (both length and width) and
expected temperature variations. Narrow, short cracks in areas with little temperature
variation can usually be covered with a layer of fiberglass before topping. Larger cracks
that are expected to move can sometimes be bridged with glass that is disbonded one
or two inches on each side of the crack, then topped. Very large cracks may be treated
as expansion joints according to Ceilcote's Construction Practice CP-16 and Ceilcote
Construction Specification CS-15.
CHAPTER 5
SUPPLIMENT “B”
SURFACE PROFILE EQUIPMENT

Thickness Gauge and Tape
(Testex Kit)
The Paint Test Equipment Testex Kit has all the necessary equipment contained in one kit to
cater for blast cleaned surface profile measurement
Testex Kit R2001Contents
R1002 - Two rolls of X-Coarse grade Testex Tape

R1004 - Testex Snap Gauge
R1003 - Burnishing ToolOther grades of Testex Tape can be supplied in this kit on
request.Accessories
NR001 - R1004 Calibration Certificate
Surface Profile Comparator and Magnifier
Elcometer 127 Keane-Tator Comparators allow the estimation of surface roughness, by both
touch and sight.
• Three versions: sand, shot and grit
• Five different grades of roughness in each comparator
• Designed to be used with the Elcometer 127 Illuminated Magnifier
• Available in Imperial units only
ISO Surface Roughness Comparator
A precision Nickel Comparator Plate which conforms to International Standard ISO 8503 for
grit and shotblast surface roughness comparison measurement
When steel has been blast cleaned, the surface consists of random irregularities with peaks
and valleys that are not easily characterised. Experts have recommended that the profile
should be identified as dimpled (shotblast) or angular (gritblast) and that they should be graded
as Fine, Medium or Coarse with each grade being defined by limits specified in ISO 8503,
these characteristics are considered to give sufficient distinguishing features for most painting
requirements.
Easy to use, place the Comparator against an area of the test surface, compare in turn the four
sectors of the Comparator against the test surface using the X7 magnifier, placed so that the
test surface is viewed simultaneously with a segment of the Comparator, the nearest profile to
the Comparator determines the grade.
The different grades are defined as follows. Fine grade profiles equal to segment 1 and up to
but excluding segment 2, Medium grade profiles equal to segment 2 and up to but excluding
segment 3 and Coarse grade profiles equal to segment 3 and up to but excluding segment 4.
Supplied in a Protective Wallet.
Part Numbers
R2006 - ISO Surface Roughness Comparator (Grit)
R2007 - ISO Surface Roughness Comparator (Shot)
RA001 - X7 Illuminated Magnifier
CHAPTER 5
SUPPLIMENT “C”
ENVIRONMENTAL CONDITIONS
Attached is ANSI / ASTM E-337, which outlines the techniques andrequirements to determine
relative humidity and dew point temperatures in determining environmental conditions.
Surface Thermometer
Elcometer 113 Magnetic Thermometer
The Elcometer 113 Magnetic Thermometer indicates the surface temperature of steel and
other magnetic materials continuously.
The thermometer is based on a bimetallic strip and therefore does not require batteries. It is
available in four scale ranges.
Elcometer 214L Infrared Digital Thermometer (Laser)

The Elcometer 214L Infrared Thermometer is compact, lightweight and easy to use. Simply
aim, pull the trigger and display the surface temperature of the object being measured.
Release the trigger to hold the reading.
The Elcometer 214L incorporates a clear, easy to read display with laser, backlight and low
battery indicator. Battery life is preserved by the auto switch off facility and the User's ability to
switch the backlight on or off as required.
The laser assisted alignment feature is useful for pinpointing the exact area of measurement.
Psychrometric Reading Entries
A- Customer’s name
B- Jobsite location (city & state)
C- Job number
D- Equipment number or identification
E- Witness’ signature representing the customer
F- Witness’ company
G- Date of readings
H- Time of readings (four readings per day)
I- Dry bulb temperature reading
J- Wet bulb temperature reading
K- Relative humidity percent taken from table VI
L- Surface temperature of equipment being lined
M- Dew point temperature taken from table I
N- Subtract dewpoint temperature from surface temperature
O- Weather conditions: R=rain, C=cloudy, F=fog, S=sunny
P- Number of hours of lost time due to weather conditions and readings
Q- Number of men unable to work due to weather conditions and readings
R- Total hours of lost time (no. hours times no. of men)
S- Readings recorder signature
T- Acceptable / Not Acceptable
PROJECT NO :C
LINING Q.C. RECORD ITEM NO :D
PSYCHROMETRIC READINGS LOCATION :B
CLIENT : A SIGNATURE
INSPECTION NOTICE NO : CLIENT APPLICATOR CEILCOTE
CLIENT’S INSPECTOR : / G / /G / / G /
APPLICATOR’S INSPECTOR : E S
CEILCOTE’S INSPECTOR :
DRY BULB WET BULB REL. HUM. SURF. DEW DIFF. WEATH. LOST NO. TOTAL ACCEPT. /
DATE TIME °F °F % TEMP. POINT °F COND. TIME MEN. HOURS NOT ACCEPT.
°F °F
G H I J K L M N O P Q R T
H I J K L M N O P Q R T
Legend: ACC=Acceptable NA= Not Acceptable Weather Conditions R=rain, C=cloudy, F=fog, S=sunny
PROJECT NO :
LINING Q.C. RECORD ITEM NO :
PSYCHROMETRIC READINGS LOCATION :
CLIENT : SIGNATURE
CLIENT’S INSPECTOR : / / / / / /
APPLICATOR’S INSPECTOR :
DRY BULB WET BULB REL. HUM. SURF. DEW DIFF. WEATH. LOST NO. TOTAL ACCEPT. /
DATE TIME °F °F % TEMP. POINT °F COND. TIME MEN. HOURS NOT ACCEPT.
°F °F
Legend: ACC=Acceptable NA= Not Acceptable Weather Conditions R=rain, C=cloudy, F=fog, S=sunny
PROJECT NO :
ACCEPTANCE INSPECTION OF LOCATION :
STEEL EQUIPMENT SIGNATURE
SPECIFICATIONS OKAY
SUBSTRATE / SURFACE CONDITION REMARKS
REQUIREMENT (9)
Cleanliness
Debris None
Oil or Grease or Contaminants None
Wax Markings None
Standing Water None
Construction
Dimensional Check Complies with
Contract Dwg
Manholes 18” ∅ or 12” x 20”
Nozzle Design Flanged
Nozzle Sizes ≥ 2”
Nozzle Lengths see Spec CPT-2
Abnormal Deflection on Tank Bottom None
Sharp Corners/Edges Rad. 1/8” / 1/4”
Inaccessible Parts to Coat/Grind None
Bolt Holes/Perforations Rad. 1/8” / 3/8”
Plate Defects: Scabs, Rollovers, Laminations None
Layout Marks Round Bottom
Internal Components
Attachments Removed
Testing
Hydrostatic Tests & Repair Completed
Welding
Welding, No Intermittent Welds Continuous
Sharp Edges None
Laps / Rollovers None
Undercuts None
Porosity None
Spatter None
Accessibility to Grinding Yes
Smoothness Yes
Additional Comments:
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
PROJECT NO :
WET FILM THICKNESS SUMMARY LOCATION :
(CONCRETE SUBSTRATE) SIGNATURE
AVERAGE WET FILM THICKNESS
LOCATION MATERIAL: __________________ MEASUREMENT SUMMARY REMARKS
BASECOAT TOPCOAT TOTAL THICKNESS
Note: Where necessary attach location diagram.

PROJECT NO :
ACCEPTANCE INSPECTION OF LOCATION :
CONCRETE SUBSTRATE SIGNATURE
SPECIFICATION OKAY
SUBSTRATE / SURFACE CONDITION REMARKS
REQUIREMENT (9)
Debris None
Standing Water None
Dimensional Check Complies with
Contract Dwg
Sharp Edges (1/8” / 1/4” ) Radiused
Chamfers and/or Large Radius Yes
Concrete Cure / Dryness Confirmed
Honey Combs None
Structural Cracks None
Surface Contamination None
Laitance (Excessive to Thin Film) None
Curing Agent / Form Oil None
Bug Holes (Excessive to Formed Conc) None
Water Leaks None
Protruding Reinforcement / Tie Bars None
Unbonded Render / Surface Repairs None
Formwork Joints Contoured Yes
Formwork Tie Bar Cone Patching Firm
Concrete Penetration Design (Wall/Soffit) Acceptance
Surface Mounted Equipment Removed
Lining Termination Points Confirmed
Expansion Joints / Isolation Joints Acceptable
Other Joints Acceptable
Surface Strength Acceptable
Hydrostatic Testing Completed
Other Contractor Activity in Area None
Additional Comments:
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
CHAPTER 6
6. LINING/COATING APPLICATION VERIFICATION
6.1 PRIMING
6.1.1 STEEL STEEL/ALLOY SUBSTRATE PRIMING
6.1.1.1 These substrates must be primed within a maximum of 16 hours after

abrasive blast cleaning unless environmental control equipment (i.e. de-
humidification equipment) or very low relative humidity and high dew
point difference is present. This area shall not be primed if the
environmental conditions (per AMSI/ASTM E-337) are
unacceptable as defined in the appropriate Ceilcote Installation
Procedure/Specification, or if the surface exhibits visible rusting, re-
rusting, "bloom", or moisture. Random wet-film thickness tests shall be
taken during application to achieve a nominal 1-4 mils of primer on the
substrate. Wet-film testing is accomplished per Supplement "A" of this
chapter. Wet-film thickness may vary from primer to primer, consult the
appropriate Ceilcote Company Installation Procedure/Specification for
nominal wet-film thickness*
6.1.2 CONCRETE SUBSTRATE PRIMING
6.1.2.1 These substrates shall not exhibit moisture or contamination

prior to primer application. Exceptions to this are found in the
appropriate Ceitcote Company Installation Procedure/Specifications for
the particular primer being applied. Concrete substrates may be tested
for moisture per Supplement "B" Concrete Mat Test of this chapter.
6.1.3 PRIMER LIMITATIONS
6.1.3.1 Some Ceilcote Primers (i.e. Ceilcote 380 Primer) should be tested for
styrene sensitivity prior to basecoat application per Supplement "C"
Styrene Sensitivity Testing of this chapter. Other primers may have time
limitations regarding exposure time prior to basecoat application,
consult the appropriate Ceilcote Company Installation Procedure /
Specifications for this specific primer regarding this.
6.1.4 VISUAL INSPECTION
6.1.4.1 During application and after initial cure of the primer a visual inspection
shall be conducted to identify areas of unacceptable workmanship,
drips, runs. un-cured areas or other deficiencies.
CHAPTER 6 (Cont.)
6.2 BASECOAT APPLICATION
6.2.1 BASECOAT APPLICATION ENVIRONMENTAL CONDITIONS
6.2.1.1 Environmental conditions (ANSI/ASTM E-337) of the work area shall

conform to the requirements of the appropriate Ceilcote Company
Installation Procedure/Specifications of the material being applied.
6.2.2 WET-FILM THICKNESS TESTING
6.2.2.1 Wet-film thickness measurements shall be taken randomly, as required,

per Supplement "A" this chapter. Material thickness (max./min.)
guidelines are found in the appropriate Ceilcote Installation
Procedure/Specifications.
6.2.3.1 During application and after initial cure of the basecoat a visual
inspection shall be conducted to identify areas of unacceptable
workmanship, visual defects, sags, runs, un-cured areas or other
deficiencies.
6.3 TOPCOAT APPLICATION
6.3.1 TOPCOAT APPLICATION ENVIRONMENTAL CONDITIONS
6.3.1.1 Environmental conditions (ANSI/ASTM E-337) of the work area shall

conform to the requirements of the appropriate Ceilcote Company
Installation Procedure/Specifications of the material being applied.
6.3.2 WET-FILM THICKNESS TESTING
6.3.2.1 Wet-film thickness measurements shall be taken randomly, as required,

per Supplement "A" this chapter. Material thickness (max./min.)
guidelines are found in the appropriate Ceilcote Company
Installation Procedure/Specifications.
6.3.3.1 During application and after initial cure of the topcoat, a visual
inspection shall be conducted to identify areas of unacceptable
workmanship, visual defects, sags, runs, un-cured areas or other
deficiencies.
CHAPTER 6 (Cont.)
6.4 SUBSEQUENT COATS - ADDITIONAL COAT APPLICATION
6.4.1 Any addition coats will be subject to the conditions as stated in 6.3.1. 6.3.2. and
6.3.3.
6.5 QUALITY CONTROL DOCUMENTATION REQUIREMENTS
6.5.1 Quality Control personnel will record, document and maintain the following:
1.) Environmental conditions (ANSI/ASTM E-337) in the work area.

2.) Batch number placement of all material (primer. basecoat, topcoat, etc.)
3.) Basecoat application areas and dates.
4.) Topcoat application areas and dates.
5.) Repaired areas and dates.
6.) Spark testing results (Chapter 7)
7.) Dry film test results (Chapter 7)
6.6 REPAIRS
6.6.1 Repairs are to be made per the appropriate Ceilcote Company Installation
Procedure / Specifications for the material applied.
6.7 DEVIATIONS - ADDITIONAL REQUIREMENTS
6.7.1 All deviations - additional requirements to this chapter shall be stated as a

addendum to the appropriate section after approval of the Ceilcote Research and
Development Dept.
CHAPTER 6
SUPPLEMENT "A"
WET-FILM GAGE TEST PROCEDURES
Hold the face of the wet-film gage perpendicular to the surface where the freshly applied
material is in place. Press the gage firmly and evenly into the material until it rests on the
substrate. After a few seconds withdraw the gage evenly without sliding it across the surface.
The wet-film thickness of the material being tested will .be between the highest probe with
material present and the next higher probe without material present on the gage. If material
appears on a11 probes, rotate the gage to the next highest scale; if no material is present
rotate the gage to the next lowest scale and repeat the measurement technique. Readings
must always be taken immediately after material application. Gages must be cleaned with
solvent soaked rages immediately after each measurement.
CHAPTER 6
SUPPLEMENT "B"
CONCRETE MAT TEST FOR MOISTURE
To check for the presence of moisture in concrete tape a sheet of polyethylene (sq. ft. x 1 sq.
ft. minimum) at 4 mils thick, onto the concrete, completely sealing this area. After
approximately 24 hours lift off the polyethylene sheet and observe for the presence of water or
moisture droplets. If either water or moisture droplets are present then the concrete is
considered to contain moisture.
CHAPTER 6
SUPPLEMENT "C"
STYRENE SENSITIVITY TEST
The styrene sensitivity test for Vinyl Ester Primers such as 380 Primer is accomplished by
wetting a small area of the primer with styrene or acetone, using a rag or brush. If this primed
surface area becomes tacky or is softened the surface is deemed styrene sensitive and
acceptable for material application. If it does not become tacky or softened it is deemed
styrene insensitive and not acceptable for material application.
CHAPTER 7
7. LINING/COATINGS TESTING VERIFICATION

7.1 SPARK TESTING - (Steel - Steel/Alloy Substrates Only)
7.1.1 The Ceilcote Company's Spark Testing Practice STP-1 (Supplement "A" in this
chapter) outlines the qualifications, equipment and procedures to properly
evaluate and test linings/coatings using a high voltage detector or spark tester as
it is commonly called. All linings/coating installed over a conductive substrate
(steel steel/alloy) should be spark tested prior to being placed in service, unless
otherwise noted.
7.1.2 Calibration records of the spark test equipment shall conform to the requirements
of Chapter 9 - Instrumentation Calibration/Standards.
7.1.3 Q.C. documentation of the spark test, should list the date of the original (first)
spark test and the date or dates of the retesting of any repair areas.
NOTE: The spark test is an installation and application aid to identify a holiday
or imperfection. It should not be used to evaluate the quality, performance or
workmanship of a lining or coating. The test itself is destructive in nature and
extreme care should be taken in the set-up and execution of this test to provide
adequate and reliable testing results.
7.2 DRY FILM THICKNESS TESTING - (Carbon Steel Only)
7.2.1 The Steel Structures Painting Council Procedure SSPC-PA2, Paint Application
Specification #2, Measurement of Dry Paint Thickness with Magnetic Gages
(Supplement "B") in this chapter outlines the procedure to accurately measure
dry film thickness of a lining or coating (non-magnetic) over a magnetic substrate,
typically carbon steel.
7.2.2 Calibration records of the dry film thickness test equipment shall conform to the
requirements of Chapter 9 – Instrumentation Calibration/Standards.
7.2.3 Q.C. documentation of the dry film thickness test should list the date of the
original test with the thickness results of each reading average based on a 6 ft.
grid system. All areas repaired should list the date of retesting and the thickness
results.
NOTE: Strong magnetic fields from welding equipment or power lines may
interfere with the operation of the gages. Periodic calibration checks of the
testing instrument on the substrate to be tested is recommended to increase
reading reliability whenever possible.
CHAPTER 7
7.3 SPARK TESTING AND DRY FILM TESTING - (Concrete Substrates)

Concrete substrates which are lined or coated are not tested due to the non-
conductive, non-magnetic properties of the substrate.
7.4 Additional requirements to any areas within the chapter should be stated as a
addendum to the appropriate Ceilcote Installation Procedure/Specifications.
7.5 Concrete substrates which are lined or coated may be spark tested by using an
appropriate conductive primer. Consult Ceilcote for details.
CHAPTER 7
SUPPLEMENT "A"
HIGH VOLTAGE HOLIDAY DETECTION
(SPARK TESTING) PRACTICE
(STP-1)
SCOPE: The objective of spark testing a lining or coating is to identify a holiday or imperfection
that may lead to passage of corrosive material to the substrate. This is done by imposing an
electrical stress across the non-conductive surface (Ceilcote lining or coating) at such a
voltage that a spark will easily arc if a pin hole or air gap exists to the conductive
substrate.
POLICY: Spark testing should be used as an aid in the application of a lining or coating, and
not to determine or evaluate the quality, performance or physical characteristics of a lining or
coating. Spark testing will detect cracks, internal voids, holidays, and thin spots within a
Ceilcote lining or coating. Due to the destructive nature of the test spark testing will only be
done once prior to the actual use of the lining or coating under projected service conditions
and at the recommended testing voltage only. Testing at higher than recommended voltages
may be destructive and burn holes through a good lining. Spark testing is not recommended
for linings or coatings that have already been in service.
QUALIFICATIONS: Personnel performing the spark testing must be knowledgeable and

trained in the correct methods and voltage requirements of each lining and coating to be
tested.
EQUIPMENT: Wet sponge type spark testers are unsatisfactory for testing Ceilcote linings and
coatings. Spark testing units capable of producing either straight D.C. or a pulsating D.C.
spark at a range of 0 volts to 25,000 volts are preferred. Equipment of this type includes the
following:
1. Electro-Technics High Frequency Generator - Model 30-60C
2. Tinker-Razor Holiday Detector - Model A-P and Model A-P/A-C
Units may be 115 VAC or battery operated. Other spark testing equipment may be
suitable. Questions concerning the selection or use of various spark testing
instruments should be directed to Ceilcote, Research and Development Dept.
CALIBRATION: Verification and measurement of the voltage being generated for testing may
be done using one of the following instruments:
1. Peak Voltage Calibrator

2. Voltage Meter (with step down probe) for non-pulsating DC instruments. Test
voltage should be measured prior to and after all testing cycles.
CHAPTER 7 (Cont.)
PROCEDURE: All Ceilcote linings and coatings that are to be spark tested will be tested at the
voltages specified. Spark testing will be done to the entire lining or coating surface unless
otherwise indicated. All repaired areas of holidays, pinholes and areas where grinding or
similar repair has been done will be spark tested.
The following voltages are recommended for spark testing Ceilcote linings and coatings:
PRODUCT VOLTAGE
2500, 6400, 6640, 6650, 695 Ceilcrete 15 000 - 20.000
505 CorolineSeries (except 505.2) 15 000 - 20,000
25, 61, 64, 74. 652 Lining 15 000 - 20.000
505.2 Coroline, 68 Lining 7 000 - 10.000
100 Flakeline Series 7 000 - 10.000
200 FlakelineSeries 3 000 - 5.000
300 Flakeline Series 2 000 - 3,000
661 Flaketar 2 000 - 3.000
* Linings and coatings not listed above will be tested at 100 volts per mil based on
the stated target thickness of that product.
** All deviations to this procedure must be authorized by Ceilcote Research &

Development Dept. prior to implementation of the deviation.
COMMENTS:
1. Grounding - All test equipment should be grounded either to the electrical source
with 115 VAC powered units or the substrate with battery powered units or both.
Steel substrates should be electrically grounded to a common ground prior to
testing.
2. Cure Time - All linings and coatings must be cured prior to spark testing and shall
not exhibit soft spots or residual solvent on the surface. Qualified personnel shall
determine degree of cure prior to spark testing.
3. Corona - Is defined as the bombardment of high energy particles within a field.

This is caused when air breaks down electrically and is evidenced by a purplish
glow. a hissing noise and the smell of ozone or nitric oxide. Corona does not
indicate pinholes as this is indicated by a spark to the substrate. The presence of
a Corona may not indicate irregularities of the lining or coating.
4. Safety - As with all electrical test equipment care should be taken in the set-up
and use of spark testing equipment to avoid electrical shock to the operator and
personnel in the work area.
IP-1
FOR HOLIDAY TESTING
MARCH 2006
********************************************************************************************
specifiers in defining the criteria needed for proper inspection.
1.0 CAUTION
UNCURED LININGS MAY BE FLAMMABLE. VESSEL SHOULD BE WELL

VENTILATED PRIOR TO TESTING SO FLAMMABLE OR EXPLOSIVE VAPORS ARE
NOT PRESENT. REFER TO THE SAFETY SECTION IN THE PRODUCT AND
INSTALLATION PROCEDURES LITERATURE. OBSERVE PROPER SAFETY
PRECAUTIONS WHEN USING HIGH VOLTAGE EQUIPMENT. OBSERVE
MANUFACTURERS' SAFETY REQUIREMENTS.
2.0 SCOPE
2.1 The purpose of spark testing is to detect holidays in a lining so that a corrosive
environment cannot find a free passage to the substrate. This is done by imposing
electrical stress across the lining to a conductive substrate (usually carbon steel or
a conductive primer) and using a voltage such that a spark will easily arc if a hole
exists through the lining.
3.0 POLICY
3.1 Our policy is to use approximately 100 volts per mil based on the normal thickness
of the lining. This insures that there will still be enough voltage to jump on air gap
at the maximum lining thickness.
3.2 Spark testing should be used as an aide in the application of a lining or coating, and
not to determine or evaluate the quality, performance or physical characteristics of
a lining or coating. Spark testing will detect cracks, internal voids, holidays, and thin
spots within a Ceilcote lining or coating. Due to the destructive nature of the test,
spark testing should only be done once prior to the actual use of the lining or
coating under projected service conditions, and at the recommended voltages. This
may be destructive and burn holes through a good lining. Spark testing is not
recommended for linings or coatings that have already been in service.
IP-1
FOR HOLIDAY TESTING
3.3 Where equipment is to be lined prior to final erection, it is advisable to spark test
only after erection so that any lining damage due to handling will be detected at that
time.
3.4 Even though this test is a semi-destructive test, it is a necessity to ensure a pinhole
free lining/coating. When spark-testing make passes quickly to minimize damage.
Leaks will be detected at recommended voltages immediately.
4.0 QUALIFICATION
4.1 Personnel performing the spark testing must be knowledgeable and trained in the
correct methods and voltage requirements of each lining and coating to be tested.
4.2 The following voltages are recommended for detecting holiday in Ceilcote linings
and coatings:
Product Voltage
Ceilcote 2500, 5500, 695 15,000 - 20,000
Coroline 505, 505M, 505AR, 538, 800 15,000 - 20,000
Lining 25, 61, 64, 74, 652 15,000 - 20,000
Flakeline 100 Series 10,000
Mat Reinforced Flakeline 200 Series 7,500

IP-1
FOR HOLIDAY TESTING
5. EQUIPMENT
5.1 Wet sponge type low voltage spark testers are used for coating systems under 20
mils in thickness. Spark testing units capable of producing either straight DC or a
pulsating DC voltage at a range of 0 volts to 25,000 volts are preferred. Equipment
of this type includes the following:
.1 Electo-Technics high frequence generator - Model BD-60C.

.2 Tinker-razor Holiday Detector - Model A-P and Model A-P/A-C.
.3 Units may be 115 VAC or battery operated. Other spark testing equipment
may be suitable. Questions concerning the selection or use of various
spark-testing instruments should be directed to Ceilcote.
6. CALIBRATION
6.1 Verification and measurement of the voltage being generated for testing may be
done using one of the following instruments:
.1 Peak Voltage Calibrator

.2 Voltage Meter (with step down probe) for non-pulsating DC instruments. Test
voltage should be measured prior to and after all testing cycles.
7. COMMENTS
7.1 Grounding:
All test equipment should be grounded either to the electrical source with 115 VAC
powered units or the substrate with battery-powered units or both. Steel substrates
should be electrically grounded to a common ground prior to testing.
7.2 Cure Time:
All linings and coatings must be cured prior to spark testing and shall not exhibit soft
spots or residual solvent on the surface. Qualified personnel shall determine
degree of cure prior to spark testing (normal temperatures, next day is generally
adequate).
IP-1
FOR HOLIDAY TESTING
7.3 Existing Linings:
There is evidence that high voltage testing of linings that have been in service may
burn holes or give false readings. Because there is a relatively high electrical stress
put on the lining during spark testing and since the lining has a finite dielectric
strength, areas in the lining where the lining is thin or where a void exists but does
not go all the way through will usually break down, causing a hole all the way
through to the steel, resulting in a visible strong spark.
When you spark test, in addition to finding existing holes, you are actually breaking
down the lining, making new holes where the dielectric strength is exceeded.
7.4 Testing on Concrete:
Linings on concrete can be spark tested. A conductive primer is usually required.
7.5 Corona:
Is defined as the bombardment of high-energy particles within a field. This is

caused when air breaks down electrically and is evidenced by a purplish glow, a
hissing noise and the smell of ozone or nitric oxide.
Corona does not indicate pinholes as this is indicated by a spark to the substrate.
The presence of a Corona does not indicate irregularities of the linings or coating.
7.6 Pinholes:
When a pinhole or leak is detected, it should be marked immediately for repair.

After repair, the patched area should be re-tested.
7.7 Wet Sponge Test:
The wet sponge test method is not recommended for coatings 20 mils or less in
thickness.
7.8 As with all electrical test equipment, care should be taken in the set-up and use of
spark testing equipment to avoid electrical shock to the operator and personnel in
the work area.
CHAPTER 8
8. QUALITY CONTROL RECORDS
8.1 QUALITY CONTROL DOCUMENTATION RECORDS
8.1.1 Equipment Acceptance Reports - are used to document all equipment

inspections. Supplement: "A" this chapter, reflects this documentation.
8.1.2 Non-Conformance Reports - are used to document items which adversely

affect lining/coating integrity and installation. Supplement "B" this chapter,
reflects this documentation.
8.1.3 Abrasive Blasting Records - Psychrometer readings and abrasive blast test are
recorded on forms describing the work area, abrasive blast profile and dates of
abrasive blasting and priming on a daily basis. Areas requiring re-work are
listed on these drawings to show where the affected areas are located.
Supplement "C" this chapter depicts this documentation.
8.1.4 Lining Records - lining application dates and batch number placement are
recorded on forms describing the work area. These contain the lining records for
all lining operations on a daily basis. Supplement "D" this chapter, depicts this
documentation.
8.1.5 Spark Test Records - the spark test dates and results of areas tested showing
areas of leak repairs and are recorded on forms describing the work area.
Repair and retesting dates of leak areas are listed. Supplement "E" this
chapter, depicts this documentation.
8.1.6 Dry Film Test Records - the dry film thickness measurement obtained on a
6ft grid layout on the lining surface. Areas of over-thickness and under-
thickness are noted on these records. All measurements are recorded on forms
describing the work area. Supplement "F" this chapter, reflects this
documentation.
8.1.7 Additional Records - any additional testing, observations, or documentation

are entered into each of the above areas as required These additional
requirements will be documented in a manner which most accurately describes
the results. They may include, but not limited to the use of equipment
drawings, inspection forms or pictures.
CHAPTER 8 (Cont.)
8.1.8 Record Retention - jobsite Q.C. records are to be complied and maintained at the
jobsite. These records will accurately reflect all the data complied and be
updated daily.
8.1.9 Record Disposition - Q.C. records are to be distributed when the lining/coating
installation is complete. Upon completion they are to be distributed in book form
to the authorized agencies. Originals are to be compiled and returned to
Ceilcote for evaluation and retention.
CHAPTER 8
SUPPLEMENT "A" THRU "F"
EXAMPLES OF REPORTS
SUPPLEMENT
A - EQUIPMENT ACCEPTANCE REPORT

B - NON-CONFORMANCE REPORT
C - ABRASIVE BLASTING RECORD
D - LINING BASECOAT & TOPCOAT RECORD
E - SPARK TEST RECORD
F - DRY FILM TEST RECORD
LINING Q.C. RECORD SHEET NO : OF
(SURFACE PREP. & PRIMING) PROJECT NO :

DATE : EQUIPMENT NO :
INSPECTOR : JOBSITE :
REPORT NO. : :
PSYCHROMETRIC READINGS
DRY BULB WET BULB REL. HUM. SURF. TEMP. DEW POINT + DIFF. COND. WORK
TIME LOCATION °F °F % °F °F PERMITTED
Surface Preparation Priming

Material
LOCATION / AREA AIR ABRASIVE SURFACE PROFILE PRIMER WET FILM METHOD
CHECK TYPE CLEANLINESS BATCH # THICKNESS
SIZE
Comments:
LINING Q.C. RECORD SHEET NO : OF
(BASECOAT & TOPCOAT) PROJECT NO :

REPORT NO. : :
PSYCHROMETRIC READINGS
DRY BULB WET BULB REL. HUM. SURF. TEMP. DEW POINT + DIFF. COND. WORK
TIME LOCATION °F °F % °F °F PERMITTED
Basecoat Topcoat
Material Material
LOCATION / AREA BATCH WET FILM SURFACE BATCH WET FILM SURFACE
# THICKNESS CHECK # THICKNESS CHECK
Comments:
SHEET NO : OF
LINING Q.C. RECORD

(BASECOAT & TOPCOAT) PROJECT NO :
REPORT NO. : :
DRY FILM THICKNESS MEASUREMENTS

MATERIAL: AVERAGE
DATE LOCATION / AREA RECORDED THICKNESS TAKEN ON 6’ GRID SYSTEM
LINING RECORD SHEET NO : OF
(SPARK TEST) PROJECT NO :
REPORT NO. : :
DRY FILM THICKNESS MEASUREMENTS

REPAIR METHOD DATE
DATE MATERIAL TESTED: VOLTAGE: CORRECTED
EQUIPMENT ACCEPTANCE REPORT
DATE : PROJECT NO. :
CUSTOMER : EQUIPMENT NO. :
LOCATION : INSPECTED BY:

SUBSTRATE: (STEEL/ALLOY) (CONCRETE) (OTHER)
DRAWING NO. :
The following equipment ______________________________________________________________

Has been accepted for (lining) (coating) application by Ceilcote at the location specified above. This
equipment is accepted (with) (without) exception(s) and with the understanding that the substrate may
be subject to repair if workmanship and / or material deficiencies become apparent during the surface
preparation operation (i.e. steel-welds, pinholes, etc. concrete honeycombs, void, etc.).
Exception(s) noted: __________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
DATE CORRECTED: ___________________________________________________________________
BOUNDARIES OF RELEASE: ______________________________________________________________
__________________________________________________________________________________
_________________________________________
AUTHORIZED CEILCOTE SIGNATURE
_________________________________________
AUTHORIZED CUSTOMER REPRESENTATIVE SIGNATURE
PROJECT NO :
NON-CONFORMANCE REPORT LOCATION :
SIGNATURE
Non-Conformance Noted: ..........................................................................................................................

......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
Corrective Action Required: .......................................................................................................................

......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
Date: ...................................................................
Non-Conformance
Corrected On: ..................................................... Verified By: ......................................................
Comments: .................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................

PROJECT NO :
SURFACE PREPARATION LOCATION :
SIGNATURE
Surface Preparation
Date Time Location Comp. Air Check Abrasive Check Surface Surface Remarks
Oil Water Type & Size Chlorides Cleanliness Profile
Legend:
ACC : Acceptable
NA : Not Acceptable

PROJECT NO :
PRIMING AND PATCHING LOCATION :
APPLICATOR :
1st Prime Coat Surface Patching 2nd Prime Coat
Date Time Location Material: Material: Remarks
Batch No. WFT Resin Qty Batch No. WFT
Batch No.

PROJECT NO :
PRIMING (STEEL SUBSTRATE) LOCATION :
SIGNATURE
APPLICATOR :
Prime Coat Application Method
Date Time Location Material: __________________ ( 9) Remarks
Batch No. WFT Roller Spray

PROJECT NO :
BASECOAT LOCATION :
SIGNATURE
Basecoat
Primer Surface Check
Material:
________________
Date Location Remarks
Styrene / Visual
Cleanliness Batch No. WFT
Solvent Defects
Sensitivity
Legend:
ACC : Acceptable
NA : Not Acceptable

PROJECT NO :
TOPCOAT LOCATION :
SIGNATURE
Topcoat
Basecoat Surface Check
Material:
_________________
Styrene / Visual
Solvent Defects
Sensitivity
Legend:
ACC : Acceptable
NA : Not Acceptable

PROJECT NO :
RESIN TOPCOAT LOCATION :
SIGNATURE
Resin Topcoat
Topcoat Surface Check
Material:
_________________
Styrene / Visual
Solvent Defects
Sensitivity
Legend:
ACC : Acceptable
NA : Not Acceptable

PROJECT NO :
WET FILM THICKNESS SUMMARY LOCATION :
AVERAGE WET FILM THICKNESS
LOCATION MATERIAL: __________________ MEASUREMENT SUMMARY REMARKS
BASECOAT TOPCOAT TOTAL THICKNESS

PROJECT NO :
DRY FILM THICKNESS LOCATION :
SIGNATURE
DATE LOCATION LINING SYSTEM DFT READINGS AVERAGE DFT REMARK

PROJECT NO :
SPARK TEST LOCATION :
SIGNATURE
Spark Test Data Date of Retest Certification
Date Location Mat’l: _____________ Voltage: Fault
___________
Number of Faults Repair Initial Date

PROJECT NO :
NON-CONFORMANCE REPORT LOCATION :
SIGNATURE
Non-Conformance Noted: ..........................................................................................................................

......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
Corrective Action Required: .......................................................................................................................

......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
Date: ...................................................................
Non-Conformance
Corrected On: ..................................................... Verified By: ......................................................
Comments: .................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................
......................................................................................................................................................................

PROJECT NO :
ADHESION TEST RECORD ITEM NO :
ASTM D 4541-85 LOCATION :
SIGNATURE :
DATE LOCATION REF PULL OFF TEST RESULT (PSI) REMARKS
AREA NO. VALUE OBSERVATIONS

PROJECT NO :
HARDNESS RECORD ITEM NO :
B.S. 2782 PART 10, METHOD 1001 : 1977 LOCATION :
SIGNATURE :
RECORDED HARDNESS
DATE LOCATION / AREA AVERAGE
MATERIAL :

PROJECT NO :
POT TESTING LOCATION :
SIGNATURE :
Manufacturing Retest
Date Material Batch No. Remarks Initial
Date Pot Life Pot Life T.F. Cures

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Quality Assurance /

Chapter 2 ............Field Quality Control/Quality Assurance Program

Chapter 3 ……..………………………………………..Inspection Forms

Chapter 4 …………………………………………...Pre-Work Inspection

Chapter 5 …….…………………….Surface Preparation Verifications

Chapter 6 …………....………..………..Lining Application Verification

Chapter 7 ………………..………..Lining/Coating Testing Verification

Chapter 8 ………………...…………………….Quality Control Records

Chapter 9 ………….…………Instrumentation Calibration Standards

Chapter 10 .Technical Bulletins, Installation Specifications, Details

The objective of this Quality Control Manual is to provide a reference of

2. FIELD QUALITY CONTROL/QUALITY ASSURANCE PROGRAM

2.4 QUALITY ASSURANCE/MATERIALS

Manufacturing Quality Control is the responsibility of the R&D Department. They

3.2 EQUIPMENT ACCEPTANCE REPORTS

3.3 INSPECTION FORMS – GENERAL

Reports should include inspector’s name, customer’s name, appropriate dates,

Equipment: ____________________________ Contractor: _____________________

Non-Conformance noted: _____________________________________________________

Date: _________________________________ By: __________________________

Corrective Action Required: ________________________________________________

Date: ______________ Corrected by: ______________ Verified by: ______________

CUSTOMER: ____________________ EQUIPMENT NO.: ________________________

LOCATION: ____________________ INSPECTED BY: ________________________

SUBSTRATE: (steel/alloy( (concrete) (other) ______________________________________

DRAWING NO.: _________________

The following equipment ______________________________________________________

EXCEPTION(S) NOTED: ______________________________________________________

DATE CORRECTED: ___________

BOUNDARIES OF RELEASE: _________________________________________________

4.1 PRE-WORK INSPECTION

4.2 CONTROL DOCUMENTS FOR SUBSTRATE INSPECTIONS

4.2.2 Concrete substrates shall conform to Ceilcote Standards CS-10 Quality of

4.2.3 Additional requirements and/or modifications to the information contained in the

4.3 INSPECTION ATTENDANCE

4.3.1 Pre-Work Inspections shall be attended and witnessed by representatives of all

4.4.1 Exceptions to any work, workmanship, materials or conditions noted on any

4.5.1 Equipment Acceptance Reports

4.6 ADDITIONAL INSPECTION REQUIREMENTS

STEEL DESIGN, FABRICATION AND WELD SPECIFICATIONS

SUBSTRATE SPECIFICATION CPT 2

NOTES TO THE SPECIFIER

3. Application under this specification must be done in accordance with the

4. Questions regarding these practices and guidelines should be directed to

All plates shall be flat with no appreciable buckle or warpage.

2.1 Standard Fabrication Practice

.1 All tanks shall be constructed with a minimum number of pieces. Steel

2.3 Location of Stiffening Members

Angles or channels used for stiffening or reinforcing at the top edge of

2.4 Closed Tanks-Manways

2.5 Tank Nozzles

Maximum Length Shell

* This is not always possible to line

2.6 Bottom Support

.1 Tanks with cone bottoms up to 20 feet in diameter do not require any

3.1 Continuous Welding

.1 All welding shall be continuous. No intermittent welds shall be allowed.

3.2 Finish of Welds

A Welds must be ground smooth, free of all defects as per NACE

3.3 Ripple Finished Welds

.1 Relatively smooth, ripple finished welds are acceptable. It shall not be

3.4 Finish of Sharp Edges and Fillets

4.0 INTERNAL COMPONENTS

Equipment: ________ Contractor: _

Date: _______ By:

Date: Corrected by: Verified by: __

CUSTOMER: EQUIPMENT NO.: ____

LOCATION: INSPECTED BY: ____