"A RECIPE FOR RUST "

Take 2 parts iron (FE).

Combine with 3 parts Oxygen (O).
Add water and salt to taste.
Increase temperature to speed up process.
TEMPERATURE: Generally corrosion rates increase with
increases in temperature. This is due to several interrelated factors:
1.Higher temperatures tend to promote the corrosion reaction
kinetics. Therefore except in cases where oxygen is free to
escape, higher temperatures boost the corrosion rate.
(Essentially makes the corrosion reaction go to completion
more quickly)
2.Corrosive by-products will have a higher diffusion rate at higher
temperatures and thus will be delivered to the corroding surface
more efficiently.
(Note: In open systems certain corrosive gases actually have
lower solubility at higher temperatures. Thus an increase in
temperature may result in a decrease in the corrosive gas
solubility and accordingly a decrease in the corrosion rate as well.)
pH: Almost without exception the rate of corrosion increases with
decreasing pH (increased acidity). This is due to corresponding
increase in the H+ (hydrogen ion) concentration as well as the
associated increase in the solubility of most other potentially
corrosion enhancing substances.
OXYGEN AND OXIDIZER LEVELS: As one would suspect
oxygen acts as an oxidizing agent in the corrosion process as do
other common oxidizers such as Cl2 (chlorine gas) and Br2
(bromine gas). As the concentration of these agents rises,
corrosion rates increase.

PAINTING INSPECTION
ADHESION TESTING, MECHANICAL

TO USE
Ensure the test area is clean and oil/grease free, lightly abrade the area and apply mixed two pack
heavy duty adhesive. Firmly place the aluminium alloy dolly in position onto the adhesive ensuring that
the skirted flange is to the adhesive. Leave for manufacturers recommended cure time. Place the core
drill supplied around the dolly and cut through the coating to the substrate (this ensures that only the area
of the dolly flange receives the pull off forces). Apply the pull off gauge and apply pull off force, (some
models use a ratcheted lever, others a knurled wheel) until failure occurs. This will usually involve a loud
bang and the instrument will jump from the substrate. Examine the face of the dolly and apportion
adhesive failure according to areas exposed, at the pull off force indicated on the scale.

PAINTING INSPECTION
MAGNETIC COATING THICKNESS GAUGE
BANANA GAUGE

THIS IS ONE OF THE MOST IMPORTANT ITEMS OF

EQUIPMENT FOR BGAS AND EXTENSIVE PRACTICAL
TRAINING IS REQUIRED.

SURFACE PREPARATION.
BLASTING POTS - MACHINES
EXHAUST

RECCOVA
VALVE PART
OF DEAD MAN
SYSTEM

Blasting Pots and Machines come in many varieties and sizes.

3 points to remember:
A) Blast cleaning is dangerous, so dont get too close it !
B) Grit exits the nozzles (Venturi) at 450 mph or 720 kph !
C) When the blaster releases the dead man handle the pot will
exhaust the air inside very quickly, it is noisy and always
contains particles of grit !!!!!

SAFETY SAFETY SAFETY - SAFETY

SURFACE PROFILE
SURFACE ROUGHNESS - AMPLITUDE

THE ABOVE SUBSTRATE HAS BEEN GRIT

BLASTED AND IS AN ACTUAL PICTURE OF
THE BLASTED PROFILE.
THE PROFILE IS 28.5 MICRONS HIGH, AND
THE SAMPLE SIZE IS APPROXIMATELY
0.5mm x 0.5 mm VIEWED UNDER
MAGNIFICATION.

BLASTING ABRASIVES.

COPPER SLAG
NON METALLIC MINERAL
EXPENDABLE ABRASIVE
NOT TO BE REUSED!!!

SUPPLIED AS A GRIT
SHATTERS ON IMPACT AS IT IS VERY
BRITTLE

BLASTING ABRASIVES.

GARNET
NON METALLIC MINERAL ABRASIVE
EXPENDABLE ABRASIVE
BUT MAY BE REUSED UP TO 3 TIMES IF RECYCLING
AND CLEANING SYSTEMS ARE IN PLACE!!!

CLASSIFIED AS DIAMOND TYPE HARDNESS

WEARS WITH USE RATHER THAN SHATTERS
& SUPPLIED IN GRIT FORM

BLASTING ABRASIVES.

METALLIC GRIT
METALLIC ABRASIVE
REUSED WITH RECYCLING AND CLEANING SYSTEMS

HIGH WEAR OF EQUIPMENT, NOT NORMALLY

USED IN ENCLOSED BLASTING SYSTEMS BY ITS
SELF. VERY HARD AND SLOWLY WEARS WITH
USE. SUPPLIED IN GRIT FORM

BLASTING ABRASIVES.

METALLIC SHOT/GRIT
MIXED
METALLIC ABRASIVE
REUSED WITH RECYCLING AND CLEANING SYSTEMS

LOW WEAR OF EQUIPMENT, NORMALLY USED IN

ENCLOSED BLASTING SYSTEMS. THE MIX
ENABLES ACCURATE AND CONTROLLED
SURFACE PROFILES.

BLASTING ABRASIVES.

METALLIC SHOT
METALLIC ABRASIVE
REUSED WITH RECYCLING AND CLEANING SYSTEMS

LOW WEAR OF EQUIPMENT, NORMALLY USED IN

ENCLOSED BLASTING SYSTEMS BY ITS SELF OR
MIXED WITH GRIT. VERY HARD AND SLOWLY
WEARS WITH USE. SUPPLIED IN ROUND FORM

BS 7079 Part A, ISO 8501, SS 05 59 00

BLASTING STANDARDS

SA 1
LIGHT BLAST CLEANING
WHEN VIEWED WITHOUT MAGNIFICATION, THE
SURFACE SHALL BE FREE FROM VISIBLE OIL, GREASE
AND DIRT AND FROM POORLY ADHERING MILLSCALE,
RUST, PAINT COATINGS AND FOREIGN MATTER.

BLASTING STANDARDS

SA 1 BLAST TO RUST GRADE B SUBSTRATE

BS 7079 Part A,

ISO 8501, SS 05 59 00

BLASTING STANDARDS

SA 2
VERY THOROUGH BLAST CLEANING
WHEN VIEWED WITHOUT MAGNIFICATION, THE SURFACE
SHALL BE FREE FROM VISIBLE OIL, GREASE AND DIRT AND
FROM MILLSCALE, RUST, PAINT COATINGS AND FOREIGN
MATTER. ANY REMAINING TRACES OF CONTAMINATION
SHALL SHOW ONLY AS LIGHT STAINS IN THE FORM OF
SPOTS OR STRIPES.

BLASTING STANDARDS

SA 2 BLAST TO RUST GRADE A SUBSTRATE

BS 7079 Part A,

ISO 8501, SS 05 59 00

BLASTING STANDARDS
SA 2
THOROUGH BLAST CLEANING
WHEN VIEWED WITHOUT MAGNIFICATION, THE SURFACE
SHALL BE FREE FROM VISIBLE OIL, GREASE AND DIRT AND
MOST OF THE MILLSCALE, RUST, PAINT COATINGS AND
FOREIGN MATTER. ANY RESIDUAL CONTAMINATION SHALL
BE FIRMLY ADHERING.

BLASTING STANDARDS

SA 2 BLAST TO RUST GRADE B SUBSTRATE

BS 7079 Part A,

ISO 8501, SS 05 59 00

BLASTING STANDARDS

SA 3
BLAST CLEANING TO VISUALLY CLEAN STEEL
WHEN VIEWED WITHOUT MAGNIFICATION, THE SURFACE
SHALL BE FREE FROM VISIBLE OIL, GREASE AND DIRT AND
FROM MILLSCALE, RUST, PAINT COATINGS AND FOREIGN
MATTER.
IT SHALL HAVE A UNIFORM METALLIC COLOUR.

BLASTING STANDARDS

SA 3 BLAST TO RUST GRADE A SUBSTRATE

Calculations:
PAINT DENSITY
D = WEIGHT
VOLUME

Calculations:
PAINT DRY FILM THICKNESS

DFT = WFT x VS%

Calculations:
PAINT VOLUME
Volume = AREA x WFT

1000

Calculations:
PAINT VOLUME SOLIDS
VS% = DFT
WFT

x 100

Calculations:
PAINT WET FILM THICKNESS

WFT = DFT
V

WFT =
OR

VS%
AREA

SURFACE TESTING
The Copper Sulphate Test

Copper sulphate test

The test is designed to detect mill-scale on the surface and
relies on the potential difference between mill-scale and
steel. When immersed in copper sulphate solution a redox
reaction takes place and copper metal is deposited on the
steel and not on the mill-scale.
Copper Sulfate Test. In test for Mill Scale, copper color
indicates absence of mill scale when steel is swabbed with 5
to 10 percent solution.

PAINTING INSPECTION
CROSS HATCH CUTTER

TO USE
The coating thickness determines the Cutter size used. The 1mm Cutter is suitable for
coatings under 60 microns, the 2mm cutter is suitable for coatings over 60 microns.
Simple operation, each Cross Hatch Cutter has 6 cutting blades spaced either 1mm or
2mm apart, one cutting pass makes 6 cuts in the coating, a second pass at 90 makes a
square lattice pattern. Apply Adhesive Tape over cut section and within 5 minutes remove
tape. Classify the cut area according to BS 3900 PT E6.

PAINT TESTING
DENSITY (SG) CUP

TO USE
WEIGHT THE CUP CLEAN, EMPTY AND DRY.
FILL THE CUP WITH PAINT TO 2mm OF THE BRIM. FIT
THE LID AND ALLOW AIR AND EXCESS PAINT TO
ESCAPE. REMOVE EXCESS PAINT BY WIPING AND
WEIGH THE CUP AGAIN ON SCALES THAT ARE
ACCURATE TO +/_0.1gm.
DEDUCT THE WEIGHT OF THE EMPTY CUP FROM THE
FINAL WEIGHT AND DIVIDE THE WEIGHT BY 100. THE
RESULTING ANSWER IS THE DENSITY IN GRMS/CC

PAINTING INSPECTION
THE DEW POINT CALCULATOR

THIS IS ONE OF THE MOST IMPORTANT ITEMS OF

EQUIPMENT FOR BGAS AND EXTENSIVE PRACTICAL
TRAINING IS REQUIRED.

PAINTING INSPECTION
WET FILM MEASUREMENT
ECCENTRIC WHEEL

TO USE
Hold between thumb & index finger and roll through wet paint starting at
the roll at zero.
SPRAYERS SHOULD BE COMPLETING THIS AS THEY SPRAY TO ENSURE THEY HAVE
APPLIED SUFFICIENT PAINT, IF THEY HAVE NOT THEY CAN APPLY MORE AT THAT TIME.

PAINT TESTING
VISCOSITY, FORD FLOW CUP, NO 4.

TO USE
LEVEL THE STAND & CUP. PLACE ANOTHER CUP UNDER THE FLOW CUP TO
CATCH THE PAINT. FILL THE CUP WITH PAINT ENSURING IT IS FULL WHILST
COVERING THE 4mm HOLE IN THE BOTTOM. RUN A STRAIGHT EDGE OVER THE
LIP OF THE CUP TO ENSURE IT IS FULL. SIMULTANEOUSLY REMOVE FINGER
FROM BOTTOM AND START STOP WATCH. TIME UNTIL 1ST BREAK IN FLOW. THE
TIME RECORDED IS THE VISCOSITY IN SECONDS AT THE TEMPERATURE.

CORROSION
GALVANIC SERIES.
Electro-motive force series or the Electro-Chemical series

Cathodic end of the table, will not corrode or slow to corrode.

NOBLE
MATERIAL
Graphite
Titanium
Silver
Nickel 200
Lead
Admiralty Brass
Copper
Tin
Mill Scale
Low Alloy Steel
Mild Steel
Aluminium Alloys
Zinc
Magnesium

KNOWN POTENTIAL AV. VALUES

+ 0.25 v
0.0 v
- 0.1 v
- 0.15 v
- 0.2 v
- 0.3 v
- 0.35 v
- 0.35 v
- 0.4 v
- 0.7 v
- 0.7 v
- 0.9 v
- 1.0 v
- 1.6 v

IGNOBLE
Anodic end of the table, will corrode or corrode at a faster rate.
Note and remember the relative positions of:
Mill Scale Steel Aluminium - Steel
The above materials are an extract from The Galvanic Series and not the complete list of
materials.

BS 7079 Part A,

ISO 8501, SS 05 59 00

HAND & POWER TOOL CLEANING

ST 2
THOROUGH HAND & POWER TOOL CLEANING
WHEN VIEWED WITHOUT MAGNIFICATION THE SURFACE
SHALL BE FREE FROM VISIBLE OIL, GREASE AND DIRT AND
FROM POORLY ADHERING MILLSCALE, RUST, PAINT
COATING AND FOREIGN MATTER.

HAND & POWER TOOL CLEANING STANDARDS

ST 2 TO RUST GRADE B SUBSTRATE

BS 7079 Part A,

ISO 8501, SS 05 59 00

HAND & POWER TOOL CLEANING

ST 3
VERY THOROUGH HAND & POWER TOOL CLEANING
AS FOR ST2 BUT THE SURFACE SHALL BE TREATED MUCH
MORE THOROUGHLY TO GIVE A METALLIC SHEEN ARISING
FROM THE METAL SUBSTRATE.

HAND & POWER TOOL CLEANING

ST 3 TO RUST GRADE B SUBSTRATE

PAINT TESTING
FINENESS OF GRIND, HEGMAN GAUGE

TO USE
FILL THE DEEPEST END WITH PAINT. DRAW THE PAINT ALONG HE GAUGE WITH THE
PROFILED SCRAPER TO FILL THE ENTIRE LENGTH. WITH IN 3 SECONDS LOOK PARALLEL
ALONG THE LENGTH OF THE GAUGE TO SEE WHERE, WITHIN A 3cm LENGTH, WHERE 5 TO
10 AGGREGATES BREAK THROUGH THE SURFACE. THIS WILL SHOW WHERE THE PAINT
CHANGES FROM GLOSS TO MATT WITH GLOSS BEING THE DEEPER END AND MAT BEING
THE SHALLOW END.

PAINTING INSPECTION
HIGH VOLTAGE HOLIDAY DETECTOR

TYPICAL HIGH VOLTAGE SETS FOR PINHOLE AND HOLIDAY

DETECTION OPERATE UP TO 5KV, THIS IS FAR TOO HIGH
FOR A NORMAL PAINT SYSTEM. USED FOR PAINTING
SYSTEMS THAT ARE ABOVE 500 MICRONS.

PAINTING INSPECTION
WET SPONGE HOLIDAY DETECT

The sponge electrode is wetted in water with a tiny amount of detergent/washing up liquid
added, and squeezed out to remove excess water. Attach earthing wire to items under
inspection. After switching on and selection of operating voltage, the sponge is traversed
methodically over the area. On a vertical surface it is better to work upwards. On contact with
a pinhole, the wetting agent (detergent) allows immediate penetration of the water, so
providing a very low resistance circuit back to the control box. A high pitched bleep indicates
the presence of a pinhole, the exact position of which is located by using a corner of the
sponge. The position is then marked ready for repair. Used for coating thicknesses of LESS
than 500 microns. Typical voltage range 9 to 90 volts, some can be set at 67.5 volts.

PAINTING INSPECTION
ADHESION TESTING
HYDRAULIC ADHESION TEST EQUIPMENT (HATE)

TO USE
This is a much quicker test with a higher degree of accuracy than the mechanical. The HATE
use Cyano-acrylic impact adhesives and can usually be done approximately two hours
after dolly/adhesive application, the dollys are mild steel and reusable because they are
heated up to destroy the adhesive after use. Big downside for this test is initial cost and
usually high maintenance.

PAINTING INSPECTION
THE WHIRLING HYGROMETER
ASPIRATED HYGROMETER OR PSYCHROMETER

THIS IS ONE OF THE MOST IMPORTANT ITEMS OF

EQUIPMENT FOR BGAS AND EXTENSIVE PRACTICAL
TRAINING IS REQUIRED.

BLAST HOSE PRESSURE

TESTING
HYPERDERMIC NEEDLE GAUGE

INSERT NEEDLE IN TO BLAST HOSE AT AN

ANGLE OF 45 DEG WITH AIR FLOWING.
NO GRIT FLOWING!!
NEEDLE MUST POINT TOWARDS THE
NOZZLE.
READ THE PRESSURE ON THE GAUGE.
SAFETY SAFETY - SAFETY

IMPORTANT PIGMENT.
MICACEOUS IRON OXIDE
Micaceous hematite, Natural lamellar hematite, Specular iron oxide, Micaceous iron oxide,
Natural specular hematite ore is MAGNETIC and has an effect on DFT readings taken with
Magnetic Dry Film thickness gauges.

Moisture ingress path to substrate

indicated by arrows

Micaceous Iron Oxide comes from a variety of places, is processed to remove

impurities and then by drying, grinding and sieving is refined to produce a grey
material with a metallic sheen and a lamellar structure. It is this lamellar
structure combined with exactly the right particle size distribution which enables
it to be used as a pigment in paints.
MIO is a naturally occurring lamellar (plate like) form of ferrous oxide, Fe203

MECHANICAL CLEANING TOOLS.

Top : Chisel Gun Bottom: Needle Gun

Caution: Both lead to very high surface profile.

POLYMERS & POLYMERISATION

Within each molecule, the atoms are bound together by covalent
bonds. For most polymers, these molecules are in the form of long
and flexible chains in which a string of carbon atoms constitutes the
backbone. Furthermore, these long molecules are composed of
structural entities called mer units, which are repeated along the
chain. A single mer is called a monomer, and the term polymer
means many mer units. As an illustration, a mer unit and the zigzag
backbone structure of polyethylene are shown below.

MER UNIT

Picture is of polyethylene. (a) The "mer" and chain structure of carbon

and hydrogen atoms. (b) A perspective view of the molecule, showing
the zigzag backbone structure.

IN PAINTING, POLYMERISATION IS THE

PROCESS PAINT GOES THROUGH TO FORM
THE DRY PAINT FILM

POLYMERS & POLYMERISATION

By using different starting materials and processing techniques, we
can produce polymers having different molecular structures. As
illustrated in below, these structures can be classified into 3 different
categories:

(i) LINEAR
(ii) BRANCHED
(iii) CROSSLINKED
In linear polymers, the mers are joined together end to end in single
chains. The long chains are flexible and may be considered as a mass
of spaghetti. Extensive van der Waals bonding between the chains
exist in these polymers. Some of the common linear polymers are
polyethylene, polyvinyl chloride, polystyrene, nylon and the
fluorocarbons.

LINEAR POLYMER
POLYMERS & POLYMERISATION

Polymers may also have a molecular structure in which side-branch

chains are connected to the main ones. These polymers are called
branched polymers. The branches result from side reactions that
occur during the synthesis of the polymer. The formation of side
branches reduces the chain packing efficiency, resulting in a lowering
of the polymer density.

BRANCHED POLYMER

POLYMERS & POLYMERISATION

In crosslinked polymers , adjacent linear chains are joined to one

and another at various positions along their lengths as shown.
Generally, crosslinking is accomplished by additive atoms or
molecules that are covalently bonded to the chains.
Crosslinked polymers are the strongest.

CROSSLINKED POLYMER

POLYMERS & POLYMERISATION

PLOYMERS ARE IN 3 DIMENSIONAL FORM

LINEAR

BRANCHED

CROSSLINKED

Surface Testing
Potassium Ferricyanide

The Blue colouring shows the presence of Fe (Iron) Salt

contamination. Potassium Ferricyanide Test Kit
Simply spray a solution from the aerosol supplied onto the
blasted steel and then place a Potassium Ferricyanide Test
Paper onto this location for 5 seconds.
If the test paper has blue specks then there is Fe salt
contamination.

MECHANICAL CLEANING TOOLS.

POWER BRUSHES

Power brushes come in many varieties and sizes.

2 points to remember:
A) If over used they BURNISH the substrate, which means they
polish it.
B) Needles always come out of the brushes at high speed due
to use and centrifugal force and they are very dangerous.

SAFETY SAFETY SAFETY - SAFETY

BS 7079 Part A
ISO 8501, SS 05 59 00

RUST GRADES
RUST GRADE A
STEEL SURFACE LARGELY COVERED WITH
ADHERENT MILLSCALE WITH LITTLE IF ANY
RUST.

BS 7079 Part A
ISO 8501, SS 05 59 00

RUST GRADES
RUST GRADE B
STEEL SURFACE, WHICH HAS BEGUN TO
RUST AND FROM WHICH MILLSCALE HAS
BEGUN TO FLAKE.

BS 7079 Part A
ISO 8501, SS 05 59 00

RUST GRADES
RUST GRADE C
STEEL SURFACE, ON WHICH THE MILLSCALE
HAS RUSTED AWAY OR FROM WHICH IT
CAN BE SCRAPPED, BUT WITH SLIGHT
PITTING VISIBLE UNDER NORMAL VISION.

BS 7079 Part A
ISO 8501, SS 05 59 00

RUST GRADES
RUST GRADE D
STEEL SURFACE, ON WHICH THE MILLSCALE
HAS RUSTED AWAY AND ON WHICH
GENERAL PITTING IS VISIBLE UNDER
NORMAL VISION.

SURFACE TESTING
THE SILVER NITRATE TEST
TESTING FOR SOLUBLE CHLORIDE SALTS

Contents
Bottle of reagent, test tubes, wooden spatulas, plastic
dropper, distilled water and spray bottle.
Method
Test purity of the distilled water. Spray approximately 20ml
distilled water onto surface of steel. Collect run off into test
tube. Fill test tube to approximately full. Add 4 drops of
reagent. The presence of soluble chlorides will show up as a
white precipitate.
Limitations
Provides a stop/go indication only. Does not provide
quantifiable results.

PAINTING INSPECTION
MAGNETIC TEMPERATURE GAUGE, LIMPET GAUGE

The air temperature (ambient) is the temperature recorded from the dry bulb
thermometer. To measure the steel substrate temperature a magnetic gauge,
known commonly as a limpet gauge is used, or a digital thermometer,
thermocouple, sometimes called a touch pyrometer. Limpet Gauge must be in
contact with the substrate for at least 15 minutes and not in direct sunlight.

SURFACE PROFILE
MEASUREMENT.
DIAL MICROMETER

TO CALIBRATE: CLEAN ANVILS &

ENSURE DIAL IS SET TO ZERO, LOCK THE DIAL.
REPLICA TAPE TO BE USED AS INSTRUCTED.
PLACE TAPE BETWEEN ANVILS AND READ
MEASUREMENT, DEDUCT THICKNESS OF TAPE
TO OBTAIN SURFACE PROFILE READING.

SURFACE PROFILE
MEASUREMENT.

NEEDLE GAUGE

CALIBRATE ON FLAT GLASS.

ENSURE DIAL IS SET TO ZERO.
TAKE MINIMUM OF 10 READINGS AND
CALCULATE AVERAGE.

SURFACE PROFILE
MEASUREMENT.
SURFACE PROFILE COMPARATOR

PLACE ON SUBSTRATE AND ASSESS THE

SUBSTRATE IN COMPARISON TO SEGMENTS.
ENSURE YOU USE CORRECT TYPE.
THE 2 TYPES ARE FOR SHOT AND GRIT.
THE GRIT COMPARATOR MAY BE USED FOR
SHOT/GRIT MIXTURE.

PAINTING INSPECTION
WET FILM COMB GAUGES

TO USE
IMMEDIATELY AFTER APPLICATION OF PAINT DIP END OF GAUGE IN TO WET
FILM ENSURING BOTH END FEET ARE AT THE SURFACE OF THE SUBSTRATE OR
PRECEDING COAT. REMOVE AND LOOK AT THE TEETH TO SEE WHICH ARE
COVERED WITH WET PAINT. SOME WILL BE FULLY COVERED AND SOME
PARTIALLY, THE READING IS RECODED AS THE WET FILM IS BETWEEN.
SPRAYERS SHOULD BE COMPLETING THIS AS THEY SPRAY TO ENSURE THEY HAVE
APPLIED SUFFICIENT PAINT, IF THEY HAVE NOT THEY CAN APPLY MORE AT THAT TIME.