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. NonConformance 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: ____________________________

Non-Conformance noted:

Date: ______________ Comments:

cc:

_____________________

_____________________________________________________

Date: _________________________________ Corrective Action Required:

Contractor:

By:

__________________________

________________________________________________

Corrected by: ______________

Verified by: ______________

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 ********************************************************************************************

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 SPECIFICATION TO RECEIVE 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

2.2

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.

Design .1

2.3

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. 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 SPECIFICATION TO RECEIVE MONOLITHIC LININGS 2.4

Closed Tanks-Manways .1

2.5

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.

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.


WELDING 3.1

Continuous Welding .1

3.2

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

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

3.3

Ripple Finished Welds .1

3.4

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.

Finish of Sharp Edges and Fillets .1

4.0

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).

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.

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.


Support of Hanging of Internal Components .1

5.0

TESTING 5.1

6.0

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.

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.

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 QUALITY OF CONCRETE SURFACE October 2004 ********************************************************************************************


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.

3.


4.


********************************************************************************************

CS-10 QUALITY OF CONCRETE SURFACE 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

2.0

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.

DISCUSSION 2.1

2.2

2.3

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.

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.

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 QUALITY OF CONCRETE SURFACE 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 Indoors Outdoors Indoors Outdoors

Max Deg F 140 160 160 160

Min Deg F 40 30 30 40

Surface Tensile PSI 300 300 300 300

CP-11 REPAIR AND PREPARATION OF CONCRETE FOR LINING March 2005 ********************************************************************************************


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.

3.


4.


********************************************************************************************

CP-11 REPAIR AND PREPARATION OF CONCRETE FOR LINING The specification information below is intended for use by architects, engineers or other specifiers in defining the criteria needed for the repair and installation of the concrete before application of the lining system. 1.0

2.0

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.

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 REPAIR AND PREPARATION OF CONCRETE FOR LINING .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.

2.3

.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.

Resin Based Compounds .1

2.4

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.

Epoxy Linings/Coatings Ceilcote 680 Primer/Saturant Liquid - 3 quarts Hardener No. 9 - 1 quart Type S11 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 REPAIR AND PREPARATION OF CONCRETE FOR LINING .5 2.5

If hardening is too rapid, use a mixing ratio of 4 quarts liquid to 1-quart hardener.

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.

2.6

2.7

.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.

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.

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 REPAIR AND PREPARATION OF CONCRETE FOR LINING .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 records for abrasive blast cleaning.

maintain

the

following

documentation

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 ********************************************************************************************


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.

3.


4.

Questions regarding these practices and guidelines should be directed to CEILCOTE. ********************************************************************************************

CP-14 SURFACE PREPARATION OF CONCRETE FLOORS The specification information below is intended for use by architects, engineers or other 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

5.0

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.

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

LINING Q.C. RECORD PSYCHROMETRIC READINGS

PROJECT NO

:C

ITEM NO LOCATION

:D :B

CLIENT : A

SIGNATURE

INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR’S INSPECTOR CEILCOTE’S INSPECTOR

: : : :

CLIENT / G / E

TIME

DRY BULB WET BULB REL. HUM. °F °F %

G

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J

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Legend: ACC=Acceptable NA= Not Acceptable

DIFF. °F

CEILCOTE / G /

DATE

SURF. TEMP. °F

DEW POINT °F

APPLICATOR /G / S WEATH. COND.

LOST TIME

NO. MEN.

Weather Conditions R=rain, C=cloudy, F=fog, S=sunny

TOTAL HOURS

ACCEPT. / NOT ACCEPT.

LINING Q.C. RECORD PSYCHROMETRIC READINGS

PROJECT NO

:

ITEM NO LOCATION

: :

CLIENT :

SIGNATURE

INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR’S INSPECTOR CEILCOTE’S INSPECTOR DATE

TIME

: : : :


Legend: ACC=Acceptable NA= Not Acceptable

CLIENT / /

SURF. TEMP. °F

DEW POINT °F

APPLICATOR / /

DIFF. °F

WEATH. COND.

CEILCOTE / /

LOST TIME

NO. MEN.

Weather Conditions R=rain, C=cloudy, F=fog, S=sunny

TOTAL HOURS

ACCEPT. / NOT ACCEPT.

LINING Q.C. RECORD ACCEPTANCE INSPECTION OF STEEL EQUIPMENT INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR’S INSPECTOR CEILCOTE’S INSPECTOR

PROJECT NO

:

ITEM NO LOCATION

: :

: : : :

SUBSTRATE / SURFACE CONDITION

CLIENT / /

SPECIFICATIONS REQUIREMENT

OKAY (9)

SIGNATURE APPLICATOR / /

CEILCOTE / /

REMARKS

Cleanliness Debris Oil or Grease or Contaminants Wax Markings Standing Water

None None None None

Construction Dimensional Check Manholes Nozzle Design Nozzle Sizes Nozzle Lengths Abnormal Deflection on Tank Bottom Sharp Corners/Edges Inaccessible Parts to Coat/Grind Bolt Holes/Perforations Plate Defects: Scabs, Rollovers, Laminations Layout Marks

Complies with Contract Dwg 18” ∅ or 12” x 20” Flanged ≥ 2” see Spec CPT-2 None Rad. 1/8” / 1/4” None Rad. 1/8” / 3/8” None Round Bottom

Internal Components Attachments

Removed

Testing Hydrostatic Tests & Repair

Completed

Welding Welding, No Intermittent Welds Sharp Edges Laps / Rollovers Undercuts Porosity Spatter Accessibility to Grinding Smoothness

Continuous None None None None None Yes Yes

Additional Comments: ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________

LINING Q.C. RECORD WET FILM THICKNESS SUMMARY (CONCRETE SUBSTRATE) INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR’S INSPECTOR CEILCOTE’S INSPECTOR LOCATION

: : : :

PROJECT NO

:

ITEM NO LOCATION

: :

CLIENT / /


AVERAGE WET FILM THICKNESS MATERIAL: __________________ MEASUREMENT SUMMARY BASECOAT TOPCOAT TOTAL THICKNESS

Note: Where necessary attach location diagram.

REMARKS

CEILCOTE / /

LINING Q.C. RECORD ACCEPTANCE INSPECTION OF CONCRETE SUBSTRATE INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR’S INSPECTOR CEILCOTE’S INSPECTOR

PROJECT NO

:

ITEM NO LOCATION

: : SIGNATURE

: : : :

SUBSTRATE / SURFACE CONDITION Debris Standing Water Dimensional Check Sharp Edges (1/8” / 1/4” ) Chamfers and/or Large Radius Concrete Cure / Dryness

CLIENT / /

SPECIFICATION REQUIREMENT

REMARKS

None Complies with Contract Dwg Radiused Yes Confirmed 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 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

CEILCOTE / /

None

Honey Combs

Concrete Penetration Design (Wall/Soffit)

OKAY (9)

APPLICATOR / /

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. dehumidification 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, rerusting, "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.


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.


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 nonconductive, 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 2500, 6400, 6640, 6650, 695 Ceilcrete 505 CorolineSeries (except 505.2) 25, 61, 64, 74. 652 Lining 505.2 Coroline, 68 Lining 100 Flakeline Series 200 FlakelineSeries 300 Flakeline Series 661 Flaketar

VOLTAGE 15 000 - 20.000 15 000 - 20,000 15 000 - 20.000 7 000 - 10.000 7 000 - 10.000 3 000 - 5.000 2 000 - 3,000 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 GUIDELINE SPECIFICATION FOR HOLIDAY TESTING MARCH 2006

******************************************************************************************** The specification information below is intended for use by architects, engineers or other 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 GUIDELINE SPECIFICATION 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 Flakeline 200 Series

5,000


2,500


2,500

IP-1 GUIDELINE SPECIFICATION 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 .2 .3

6.

Electo-Technics high frequence generator - Model BD-60C. 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.

CALIBRATION 6.1 Verification and measurement of the voltage being generated for testing may be done using one of the following instruments: .1 .2

7.

Peak Voltage Calibrator Voltage Meter (with step down probe) for non-pulsating DC instruments. Test voltage should be measured prior to and after all testing cycles.

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 GUIDELINE SPECIFICATION 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 underthickness 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 B C D E F

-

EQUIPMENT ACCEPTANCE REPORT NON-CONFORMANCE REPORT ABRASIVE BLASTING RECORD LINING BASECOAT & TOPCOAT RECORD SPARK TEST RECORD DRY FILM TEST RECORD

LINING Q.C. RECORD (SURFACE PREP. & PRIMING)

SHEET NO :

DATE :

EQUIPMENT NO : JOBSITE : :

OF

PROJECT NO :

INSPECTOR : REPORT NO. :

PSYCHROMETRIC READINGS TIME


LOCATION

SURF. TEMP. DEW POINT °F °F

+ DIFF.

COND.

Surface Preparation LOCATION / AREA

AIR CHECK

Comments:

ABRASIVE TYPE SIZE

SURFACE CLEANLINESS

WORK PERMITTED

Priming Material PROFILE

PRIMER BATCH #

WET FILM THICKNESS

METHOD

LINING Q.C. RECORD (BASECOAT & TOPCOAT)

SHEET NO :

DATE :

EQUIPMENT NO : JOBSITE : :

OF

PROJECT NO :

INSPECTOR : REPORT NO. :

PSYCHROMETRIC READINGS TIME

LOCATION


SURF. TEMP. DEW POINT °F °F

+ DIFF.

Basecoat

Comments:

BATCH #

WET FILM THICKNESS

SURFACE CHECK

WORK PERMITTED

Topcoat Material

Material LOCATION / AREA

COND.

BATCH #

WET FILM THICKNESS

SURFACE CHECK

SHEET NO :

LINING Q.C. RECORD (BASECOAT & TOPCOAT)

PROJECT NO :

DATE :

EQUIPMENT NO :

INSPECTOR :

JOBSITE :

REPORT NO. :

:

OF

DRY FILM THICKNESS MEASUREMENTS MATERIAL: DATE

LOCATION / AREA

RECORDED THICKNESS TAKEN ON 6’ GRID SYSTEM

AVERAGE

LINING RECORD (SPARK TEST)

SHEET NO :

OF

PROJECT NO :

DATE :

EQUIPMENT NO :

INSPECTOR :

JOBSITE :

REPORT NO. :

:

DRY FILM THICKNESS MEASUREMENTS REPAIR METHOD DATE

MATERIAL TESTED:

VOLTAGE:

DATE 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

LINING Q.C. RECORD NON-CONFORMANCE REPORT

PROJECT NO

:

ITEM NO LOCATION

: : SIGNATURE


: : : :

CLIENT / /

APPLICATOR / /

Non-Conformance Noted: .......................................................................................................................... ...................................................................................................................................................................... ...................................................................................................................................................................... ...................................................................................................................................................................... ...................................................................................................................................................................... ...................................................................................................................................................................... ......................................................................................................................................................................

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

Date: ................................................................... Non-Conformance Corrected On: .....................................................

Verified By: ......................................................

Comments: ................................................................................................................................................. ...................................................................................................................................................................... ...................................................................................................................................................................... ......................................................................................................................................................................


CEILCOTE / /

LINING Q.C. RECORD SURFACE PREPARATION INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR’S INSPECTOR CEILCOTE’S INSPECTOR Date

Time

: : : :

Location

: :

:

ITEM NO LOCATION

: :

CLIENT / /


CEILCOTE / /

Surface Preparation Comp. Air Check Abrasive Check Surface Surface Remarks Oil Water Type & Size Chlorides Cleanliness Profile

Legend: ACC NA

PROJECT NO

Acceptable Not Acceptable


LINING Q.C. RECORD PRIMING AND PATCHING (CONCRETE SUBSTRATE) INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR CEILCOTE’S INSPECTOR Date

Time

PROJECT NO

:

ITEM NO LOCATION

: : SIGNATURE

: : : : Location

CLIENT / /

APPLICATOR / /

1st Prime Coat Material:

Surface Patching

2nd Prime Coat Material:

Batch No. WFT

Resin Qty Batch No.

Batch No. WFT


CEILCOTE / /

Remarks

LINING Q.C. RECORD PRIMING (STEEL SUBSTRATE) INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR CEILCOTE’S INSPECTOR Date

Time

PROJECT NO

:

ITEM NO LOCATION

: :

: : : : Location

CLIENT / /


Prime Coat Application Method Material: __________________ ( 9) Batch No.


WFT

Roller

Spray

Remarks

CEILCOTE / /

LINING Q.C. RECORD BASECOAT

PROJECT NO

:

ITEM NO LOCATION

: : SIGNATURE


: : : :

CLIENT / /

Primer Surface Check Date

Location Cleanliness

Styrene / Solvent Sensitivity

Legend: ACC NA

: :



Visual Defects

APPLICATOR / /

CEILCOTE / /

Basecoat Material: ________________ Remarks Batch No.

WFT

LINING Q.C. RECORD TOPCOAT INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR’S INSPECTOR CEILCOTE’S INSPECTOR

PROJECT NO

:

ITEM NO LOCATION

: :

: : : :

Basecoat Surface Check Date


Styrene / Visual Solvent Defects Sensitivity

Legend: ACC NA

: :


CLIENT / /



CEILCOTE / /

Topcoat Material: _________________ Remarks Batch No.

WFT

LINING Q.C. RECORD RESIN TOPCOAT INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR’S INSPECTOR CEILCOTE’S INSPECTOR

PROJECT NO

:

ITEM NO LOCATION

: :

: : : :

Topcoat Surface Check Date


Styrene / Visual Solvent Defects Sensitivity

Legend: ACC NA

: :


CLIENT / /



CEILCOTE / /

Resin Topcoat Material: _________________ Remarks Batch No.

WFT

LINING Q.C. RECORD WET FILM THICKNESS SUMMARY (CONCRETE SUBSTRATE) INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR’S INSPECTOR CEILCOTE’S INSPECTOR

: : : :

PROJECT NO

:

ITEM NO LOCATION

: : SIGNATURE

CLIENT / /

APPLICATOR / /

CEILCOTE / /

AVERAGE WET FILM THICKNESS LOCATION

MATERIAL: __________________ MEASUREMENT SUMMARY BASECOAT TOPCOAT TOTAL THICKNESS


REMARKS

LINING Q.C. RECORD DRY FILM THICKNESS INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR’S INSPECTOR CEILCOTE’S INSPECTOR DATE

LOCATION

: : : :

PROJECT NO

:

ITEM NO LOCATION

: :

CLIENT / /

LINING SYSTEM DFT READINGS



AVERAGE DFT

REMARK

CEILCOTE / /

LINING Q.C. RECORD SPARK TEST

PROJECT NO

:

ITEM NO LOCATION

: : SIGNATURE


: : : :

CLIENT / /

Spark Test Data Date

Location

Mat’l: _____________ Voltage: ___________ Number of Faults


APPLICATOR / /

CEILCOTE / /

Date of Fault

Retest Certification

Repair

Initial

Date

LINING Q.C. RECORD NON-CONFORMANCE REPORT

PROJECT NO

:

ITEM NO LOCATION

: : SIGNATURE


: : : :

CLIENT / /

APPLICATOR / /

Non-Conformance Noted: .......................................................................................................................... ...................................................................................................................................................................... ...................................................................................................................................................................... ...................................................................................................................................................................... ...................................................................................................................................................................... ...................................................................................................................................................................... ......................................................................................................................................................................

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

Date: ................................................................... Non-Conformance Corrected On: .....................................................

Verified By: ......................................................

Comments: ................................................................................................................................................. ...................................................................................................................................................................... ...................................................................................................................................................................... ......................................................................................................................................................................


CEILCOTE / /

PROJECT NO

ADHESION TEST RECORD ASTM D 4541-85 INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR’S INSPECTOR CEILCOTE’S INSPECTOR

: : : :

DATE

REF NO.

LOCATION AREA

:

ITEM NO : : LOCATION SIGNATURE : CLIENT / /

PULL OFF TEST RESULT (PSI) OBSERVATIONS VALUE


APPLICATOR / /

CEILCOTE / /

REMARKS

PROJECT NO

HARDNESS RECORD B.S. 2782 PART 10, METHOD 1001 : 1977 INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR’S INSPECTOR CEILCOTE’S INSPECTOR

DATE

: : : :

LOCATION / AREA

:

ITEM NO : LOCATION : SIGNATURE : CLIENT / /

APPLICATOR / /

RECORDED HARDNESS MATERIAL :


CEILCOTE / /

AVERAGE

PROJECT NO

LINING Q.C. RECORD POT TESTING INSPECTION NOTICE NO CLIENT’S INSPECTOR APPLICATOR’S INSPECTOR CEILCOTE’S INSPECTOR Date

Material

: : : :

Batch No.

:

ITEM NO : LOCATION : SIGNATURE : CLIENT / /

Manufacturing Date Pot Life

Retest Pot Life


APPLICATOR / /

T.F. Cures

Remarks

CEILCOTE / /

Initial

QA QC Manual 2008

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