Coating

Inspection
 Introduction

•Coating inspection ensures protective coatings are applied correctly.

•It helps prevent corrosion, extend asset life, and reduce maintenance costs.
•Inspection covers: surface preparation, environmental checks, application, and final testing.
•Objective: Ensure coatings meet project specs, manufacturer guidelines, and international standards.
Main Inspection Objectives
Surface Preparation Verification
Ensure proper cleaning before coating application

Thickness Control
Verify correct coating thickness in microns/mils

Quality Assessment
Confirm uniformity, adhesion, and proper cure

Defect Detection
Identify holidays, blisters, sags, runs, or cracking

Standards Compliance
Meet project specs and manufacturer recommendations
Visual Inspection: First Line of Defense
Trained inspectors examine coatings for visible damage and
irregularities
Environmental Conditions for Coating
Application
• Ambient Temperature
• Must be at least 5°C (9°F) above the dew point temperature.
• This minimizes the risk of moisture condensation on the substrate, which can severely compromise
coating adhesion.
• Relative Humidity
• Must be below 85%.
• Higher humidity increases the likelihood of condensation and may interfere with coating curing,
especially with moisture-sensitive systems (e.g., epoxy, polyurethane).
• Wind Velocity
• Must be appropriate for the coating application method being used.
• Excessive wind can:
• Cause overspray or dry spray during spray applications
• Accelerate solvent evaporation, affecting film formation
• Introduce dust or debris, contaminating the surface
• Substrate Temperature
• Must be monitored continuously and remain above the dew point to prevent condensation.
• Coatings should not be applied if the substrate is at or near the dew point temperature .

Best Practices
•Use a dew point meter or climatic condition monitor (e.g., Elcometer 319,
Defelsko DewCheck) to record:
• Ambient temperature
• Relative humidity
• Dew point
• Substrate temperature
•Document environmental readings before and during coating application.
•Pause application if any parameter falls outside the specified limits.
 Pre Application Inspection Checklist

1. Surface Preparation
•Cleanliness
•Surface must be free from dust, oil, grease, salts, rust, mill scale, old coatings,
and other contaminants.
•Verification by:
•Visual inspection (per ISO 8501-1 or SSPC-SP standards)
•Soluble salt testing (e.g., Bresle test)
•Dust tape test (per ISO 8502-3)
•Surface Profile (Roughness)
•Confirm surface roughness is within specification for the coating system (e.g., 50–
100 µm for many epoxies).
•Measured using:
•Replica tape (Testex)
•Needle gauge / surface profile gauge
•Standard comparators (e.g., ISO 8503-1)
 2. Ambient Conditions

•Must meet the following criteria:

• Dew point: Substrate Ambient temperature: Within manufacturer’s recommended range
• temperature at least 5°C above dew point
• Relative humidity: Below 85%
• Wind speed: Suitable for the chosen application method to prevent overspray and
contamination
•Monitored using:
• Digital or analog dew point meters
• Infrared thermometer for substrate temperature
• Thermo-hygrometer
3.Equipment Readiness for ambient conditions
•Spray equipment or brushes/rollers:
• Calibrated and clean
• Correct nozzle size, pressure settings, and tip
configuration
•Mixing tools:
• Clean and functioning (e.g., air-powered mixers)
•Measuring instruments:
• Wet film gauge
• DFT gauge (for later use)
•Lighting:
• Sufficient for proper surface visibility and inspection
Proven Removal Techniques
Chemical Cleaning
Specialized solvents dissolve oils and salts without damaging the underlying substrate material.

High-Pressure Water Jetting

Ultra-high-pressure systems exceeding 30,000 PSI effectively remove coatings and embedded contaminants.

Abrasive Blasting
Controlled abrasive media removes contaminants while creating optimal surface profile for coating adhesion.

Mechanical Methods
Targeted mechanical cleaning and solvent wiping address localized contamination areas efficiently.
Surface Preparation: Foundation of Coating
Success
01 02 03

Contaminant Removal Profile Measurement Contamination Testing

Advanced cleaning methods like Surface profile measurement ensures Chloride testing using Bresle Patch
SSPC-SP 5 (White Metal Blast) proper texture and roughness for method detects harmful salts that
effectively remove contaminants, old optimal coating adherence and long- can cause premature coating failure
coatings, and surface impurities. term performance. and corrosion.
Contaminant Removal in
Coating Inspection

Ensuring Durable
Protection
Common Substrate Contaminants

Soluble Salts

Environmental chlorides and sulfates from previous coatings or atmospheric

exposure.

Oils & Greases

Organic residues from handling, manufacturing processes, or equipment

lubrication.
Contamination Testing in
Coating Inspection

Ensuring Durable
Protective Coatings
Critical quality control processes that determine the longevity and
effectiveness of protective coating systems across industries
Contamination Testing Methods: The Bresle Patch Test
Extraction Process

The internationally recognized Bresle method utilizes a sealed adhesive

patch system filled with deionized water to extract soluble salts directly
from the substrate surface over a measured time period, typically 16 hours
for optimal results.

Precision Measurement

Extracted salt concentrations are measured using specialized conductivity

probes like the DeFelsko PosiTector SST, which converts electrical
conductivity readings into precise salt concentration values expressed in
micrograms per square centimeter.

Industry Standards

This method is formally recognized by ISO 8502-6 and ASTM D4940

standards, providing quantifiable contamination data that ensures
compliance with strict industry acceptance criteria.
 Comprehensive Testing Standards and Methods
Salt Contamination Testing Dust and Particulate Assessment
Bresle Method (ISO 8502-6 & 8502-9): Adhesive patch ISO 8502-3 Tape Test: Clear adhesive tape pressed onto
filled with deionized water, extracted solution measured surface, dust collection compared to standard rating charts.
with conductivity meter. General service acceptance: < 20 Typical acceptance criteria: ≤ Rating 2 (few, small
mg/m². Critical service (offshore): < 5 mg/m². particles).

Alternative Methods: Chloride-specific colorimetric test

kits and ion chromatography for precise laboratory
analysis.

Oil and Grease Detection Environmental Controls

Water Break Test (ASTM F22): Clean water spray test - pH Testing: Post-cleaning verification with litmus paper,
uniform film indicates cleanliness, beading indicates acceptable range pH 6-8. Moisture Control: Surface
contamination presence. temperature must be ≥ 3°C above dew point to prevent
condensation contamination.
Solvent Wipe Test (SSPC-SP1): Clean solvent-soaked
cloth application with visual staining assessment.
 During Application Inspection
• 1. Wet Film Thickness (WFT)
• Purpose: Ensures applied coating meets required
thickness before curing.
• Method:
• Measure using a wet film thickness gauge (e.g., comb
gauge or wheel type).
• Take measurements immediately after application,
before the film begins to set.
• Frequency: At regular intervals across representative
areas (e.g., every 10 m² or per spec).
• Acceptance Criteria:
• WFT must correspond to target Dry Film Thickness
(DFT) considering the coating’s solids content (WFT =
DFT / % solids by volume).
2.Application Technique
•Verify:
• Correct method is used (e.g., airless
spray, conventional spray, brush, roller).
• Uniform and continuous coating with no
runs, sags, holidays, or excessive
overspray.
• Proper overlap between passes (e.g.,
50% overlap for spray).
• Agitation or pot life monitoring
(especially for 2-component coatings).
•Observations:
• Applicators are trained and follow the
product data sheet (PDS).
• Correct mixing ratio and induction time
are followed.
3.Environmental Monitoring
•Parameters to Record:
• Ambient temperature
• Relative humidity
• Dew point
• Substrate temperature
• Wind speed (if outdoors)
•Instruments Used:
• Dew point meter / thermo-hygrometer
• IR thermometer or contact thermometer
• Wind meter (anemometer), if needed
•Requirements:
• Substrate temperature at least 5°C above the
dew point
• Relative humidity below 85%
• Conditions must remain within coating
manufacturer’s recommendations
•Monitoring Frequency:
• Before starting application
• At intervals during application (typically every 2
hours or per spec)
• Any time weather changes are suspected
 Post-Application Inspection
1.Dry Film Thickness (DFT)
•Purpose: Verifies that the applied coating meets specified
thickness after curing.
•Method: Non-destructive measurement using a DFT gauge
(magnetic, eddy current, or ultrasonic depending on
substrate).
•Frequency: As per project specifications or ISO 19840 / SSPC-
PA 2.
•Acceptance Criteria: Within the specified minimum and
maximum DFT range.
2.Adhesion Testing
•Purpose: Evaluates the bond strength between coating and
substrate.
•Methods:
• Pull-off test (per ASTM D4541 / ISO 4624)
• Cross-cut test (per ASTM D3359 / ISO 2409)
•Frequency: As per spec or coating system requirements.
•Acceptance Criteria: Manufacturers or project-specific
adhesion rating or MPa/kPa value.
3.Holiday Testing (for protective coatings on conductive
substrates like pipelines or tanks)
•Purpose: Detects discontinuities such as pinholes, voids, or
thin spots.
•Method:
• Low-voltage wet sponge tester (for coatings <500 µm)
• High-voltage spark tester (for coatings >500 µm)
• Follow NACE SP0188 / ISO 29601
•Acceptance Criteria: No holidays (or all identified holidays
repaired and retested).

4.Cure Verification
•Purpose: Confirms the coating is properly cured before
service or overcoating.
•Methods:
• Solvent rub test (e.g., MEK rub – ASTM D4752)
• Hardness test (e.g., pencil hardness, Shore D)
• Visual tackiness check
•Timing: After full cure per manufacturer’s datasheet
(based on temperature/humidity).
5. Visual Inspection
•Purpose: Detects surface defects and appearance issues.
•Inspection Points:
• Runs, sags, drips
• Overspray or dry spray
• Dust, debris, inclusions
• Missed or uneven areas
• Color/finish consistency
•Standards: Refer to ISO 12944, SSPC-VIS guides, or client specifications.
Common Coating Inspection Tools
Modern coating inspection relies on a comprehensive toolkit of precision instruments; each designed for specific measurement and assessment requirements. These tools must
maintain calibration traceability and operate within environmental specifications to ensure reliable, repeatable results.

Surface Profile Gauge Holiday Detection Equipment

Measures substrate roughness using replica tape or digital profilometry to verify High-voltage holiday detectors identify microscopic pinholes and discontinuities in
optimal coating adhesion conditions. Critical for ensuring surface preparation meets coatings, particularly critical for pipeline and immersion service applications where
specifications and predicting coating performance. coating integrity is paramount.

Environmental Monitoring Adhesion Testing Systems

Dew point meters and psychrometers monitor temperature, humidity, and dew Pull-off adhesion testers (ASTM D4541) and cross-cut adhesion tools (ASTM D3359)
point conditions to ensure proper application environment and prevent moisture- quantify coating-substrate bonding strength and predict long-term coating
related coating defects. performance under service conditions.

Thickness Measurement Systems Advanced Visual Inspection

DFT (Dry Film Thickness) and WFT (Wet Film Thickness) gauges provide precise High-resolution borescopes, calibrated magnifiers, and specialized lighting systems
coating thickness measurement using magnetic, eddy current, or ultrasonic enable detailed surface examination and defect documentation in complex
principles with micron-level accuracy. geometries and confined spaces.

Calibration Critical: All measurement instruments require regular calibration verification using certified reference standards. Calibration certificates must be current and
traceable to national standards, with calibration intervals determined by manufacturer recommendations, usage intensity, and environmental conditions.
 Key Tools Used

•Wet Film Gauge – measures wet coating thickness during application

•Dry Film Thickness Gauge (DFT Gauge) – non-destructive measurement after
curing
•Holiday Detector – detects discontinuities in non-conductive coatings
•Adhesion Tester – evaluates how well the coating adheres to the substrate
•Surface Profile Gauge – measures anchor profile of blasted steel
•Climatic Condition Meters – monitor temperature, humidity, dew point
• Following Instruments shall be used with
third party calibration certificates

DFT Gauge WFT Gauge

Surface Profile Gauge
Holiday Detector Pull-off Adhesion Tester Dew point meter
• Relevant Standards

SSPC (Society for Protective Coatings)

NACE (National Association of Corrosion Engineers – now AMPP)
ISO 8501, ISO 8502, ISO 8503 – surface prep and inspection standards
ASTM – testing standards (e.g., D3359 for adhesion, D4414 for thickness)

• Inspector Certification Levels

•NACE/AMPP Coating Inspector Program (CIP) – Level 1, 2, and 3
•BGAS-CSWIP – British certification for coating inspectors
•SSPC PCI – Protective Coatings Inspector certification
Industry Standards & Guidelines
SSPC AMPP/NACE
Society for Protective Coatings standards Corrosion engineering protocols

ISO Standards ASTM Methods

8501 & 12944 for surface prep and protection D4417, D3359 testing procedures