Problem Solving Forum (66)


What is the effect of the wind-chill factor on the curing of epoxy and PU when temperatures are similar?


What is the maximum temperature that an epoxy powder coating can resist when applied on steel substrate?


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


In what circumstances is third-party inspection recommended for commercial coating work?


How should a contractor respond when he/she reads a specification requirement that "the nominal dry film thickness of the coating shall be 3 mils"?


On a recent project, complex pre-fabricated, hot-dipped galvanized panels exhibited thicknesses in the range required for the entire subsequent coating system. It was not practical or possible to accurately map the thickness of the galvanizing across all the various parts, and DFT gauges available only measure the entire non-ferrous coating, including the galvanizing. How should thickness-per-coat minimums and maximums be controlled and verified for subsequent coatings?


If an atmospheric coating system of a zinc-rich epoxy, epoxy mid coat and polyurethane color topcoat has properly cured with no visual defects, should I be worried if the thickness of any coat exceeds any specified maximum?


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


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


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


What are the criteria for selecting coatings for application during extreme (atmospheric) heat?


How many times can a building be repainted before the paint becomes too thick to perform properly?


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


When is it necessary to install sealant between the base of building walls and concrete sidewalks or pavement to prevent moisture from wicking up the wall? How does the climate affect this decision?


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


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


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


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


How does one determine if concrete is sound enough to receive a thick-film coating?


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


A specification for a bridge to be built of high-performance weathering steel requires an SSPC-SP 10, a profile of 3 to 5 mils, and metallizing with a final DFT of 10-12 mils. What challenges, time, and costs are associated with obtaining the profile?


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


The literature indicates that UHP waterjetting produces a profile on steel, although of a micro nature. Is this sufficient roughness for good adhesion of thin-film primers?


How do you measure wet film thickness on shop-applied organic zinc-rich primers to accurately predict dry film thickness? Our shop applies a great deal of OZ primer, and we have found that WFT readings with a standard gauge are not accurate predictors.


What generic types of coatings work best as liquid-applied air barriers, considering both cost and effectiveness, and what should be the dry film thickness of this system?


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


As a facility owner, how can I justify the cost of quality control measures, such as third-party inspection, to upper management in my company?


How should a contractor respond to a specification requirement that “the nominal dry film thickness of the coating shall be 3 mils?”


I have several 20-year-old carbon steel tanks for storing demineralized water. The original coating (type unknown) has started to blister. What material, at what DFT, should be used to refurbish the coating?


What is the best way to remove thick-film elastomers from floors and ship decks?


What is the best method of testing for moisture content in concrete masonry unit (CMU) walls before application of coatings?


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


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


Can fluoropolymer coatings that are still very glossy be overcoated (if, for example, the topcoat is losing color or the color needs to be changed)? If so, what type of coating can be used, and what surface preparation is required?


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


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


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


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


What is the effect of the wind-chill factor on the curing of epoxy and PU when temperatures are similar?


What is the maximum temperature that an epoxy powder coating can resist when applied on steel substrate?


How can it be determined if moisture within a CMU wall is causing repeated coating failure? If so, can the source of moisture entry be accurately identified for correction?


RH probes are commonly used in concrete floors to determine moisture content. Can they be used in CMU walls or pre-cast walls?


How many times can a building be repainted before the paint becomes too thick to perform properly?


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


How long can a blasted surface be left before priming under different temperatures/relative humidity environments?


If a paint data sheet notes a required primer thickness of 125 microns, but the project specification calls for 50 microns, how is this resolved?


When the relative humidity in a paint shop exceeds 80%, how can you apply waterborne inorganic zinc so that it cures sufficiently for topcoating in a reasonable time?


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


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


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


Specifications often state that glossy surfaces must be dulled before overcoating. What are some methods for doing this, especially when sanding isn’t feasible or desirable?


What is the remedial action if a blaster produces too high a surface profile for the required primer thickness?


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


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


How is it possible to determine if concrete is sound enough to receive a thick-film coating?


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


When moisture permeates concrete slabs or walls below grade, how can this problem be solved and does it require excavation?


How do you measure wet film thickness on shop-applied organic zinc-rich primers to accurately predict dry film thickness?

Our shop applies a great deal of OZ primer, and we have found that WFT readings with a standard gauge are not accurate predictors of DFT.


What generic types of coatings work best as liquid-applied air barriers, considering both cost and effectiveness, and what should be the dry film thickness of this system?


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


As a facility owner, how can I justify the cost of quality control measures, such as third-party inspection, to upper management in my company?


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


What quality control checks can I use to assure the cleanliness of steel abrasive in a fabricator's or shipyard's shop?


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


What is the best method of testing for moisture content in concrete masonry unit (CMU) walls prior to application of coatings?


If I apply a zinc-rich epoxy primer at 3 mils’ dry film thickness in the shop with air temperature of 90 F, what checks can I make to determine when it is safe to handle and stack the primed steel components?


 
 
   

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