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Chapter- II

Surface Preparation

1. Q.1.0.1. What is surface preparation and What is its purpose?

Surface Preparation is the methods used to prepare the metal

substrate surface prior to painting / coating.

The purpose ie. Correct & effective surface preparation forms the basis
for providing a painting system which will successfully achieve a good paint
coating & adhesiveness, the quality of finish & length of life of coating needed to
meet the particular demands of specification.

2. Q 1.0.2. What factors affect s in surface preparation, the life of

paint system?

Factors. (Contamination) Affects.

1. Residues of oils, grease & soil. Prevent adhesion.

2. Residues of various chemical & salts Induction corrosion.
3. Rust on surface / Rust scales. Interferes on coating bonding
By poor adhesion.
4. Loose broken Mill scale Early failure of paint system
5. Tight Mill scale Later failure of paint system
6. Anchor pattern – Rough peaks Leading to coating failure
(too high profile) since profile are inadequately
Protected with paints
Cause rust spots.
7. Sharp ridges, burrs, edges, cuts & Leading to coating failure, since
Irreqularities. Inadequate coat thickness over
Irregularities.

3. Q.1.0.3. When and What inspection of surface cleanliness to be

checked?
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Surface preparation to be checked for any contaminations as stated above

which leads to affect the length of life, the quality of finish and good paint coating
and adhesiveness of a painting system.

Surface preparation to be checked for any contaminations at three stages,

before & after surface preparation and also between each application of paint coats.

4. Q.1.0.4. What is the No. of Swedish Standard contain in B.S.7079 and

List the rust and blasting grades to gether with their brief relevant title?

Swedish Pictorial Standard SIS-05-59-00 Contained in BS 7079. The List of

rust and blasting Page 2 of 19 grades are detailed below.
Swedish standard gives visual information on the following. Grades are
defined by written descriptions together with representative photographic examples.
Rust Grades BS 7079 Blast Cleaning Grades (SIS-05-59-00)
(Similar to SSPC-Vis.1 -No Photographs Or Grade of Cleanliness. Depict
the condition of the steel surface before preparation(Un prepared Steel)
after preparation before painting

Rust Grades:
Grade Description
A. Covered in Mill scale with little or no rust.
B. Covered with a mixture of both Mill Scale & Rust.
C. Mill Scale gone, Rusted with slight surface pitting.
D. Heavily rusted and pitted.

Blasting Grades:
Grade Description
SA1 Light blast cleaning
SA 2 Thorough blast cleaning
SA 2.5 Very through blast cleaning
SA 3 Blast cleaning to visually clean steel

5. Q.1.0.5. What are the rust Grade & No. of ISO Specification. List the
grades with brief relevantTitle. How it differs from BS 7079.and others
such as SSPC - Vis-1?
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ISO 8501 is the Specification No. for rust grades. This specification is
similar in their descriptions for rust Grades A, B, C, D, listed as in BS 7079 and
similar to SSPC-Vis-1.Obviously there are little difference in the wording of these
standards.

Both BS 7079 and ISO 8501-1 both gives visual information on the
rust. Grades are defined by written descriptions together with representative
photographic examples, whereas SSPC-Vis.-1 standard defined the rust grades only
by written description.

The reference standard should be decided in the pre-job conference or

pre-inspection meetings.

6. Q.1.0.6 .Regarding Hand & Power Tool Cleaning (Wire Brush Cleaning )
state What always concludes this process and to What Standard?

The refers to the method of cleaning by hand such as grinding,

abrasive discing, scraping etc.but usually concluded by wire brushing in order that a
Visual Standard to compare with the Swedish International Standard SIS-05-59-
00 –“Pictorial Surface Preparation Standards for Painting Steel Surfaces”.
Contained in BS 7079- a British Standard documents relates to metal preparation.
I.e. “Preparation of Steel substrates before application of Paints and
Related Products”.

This methods are similar as described in BS 7079 & ISO 8501-1

Grade ST 2 & 3 & SSPC-SP 2 & 3.

7. Q.1.0.7.What is hand or Power tool cleaning. List the grades of wire

brushing (Cleaning) with brief relevant title and what are the rust grades
on which the wire brushing can be carried out?
The Hand and Power tool cleaning is the method of Surface preparation by hand
either by manual or mechanical. In other words it called Wire Brushing (Manual or
Mechanical).
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Grades of Wire Brushing.(Cleaning) Description.

BS 7079 & ISO 8501-1
ST 2 Thorough Hand and Power tool Cleaning
(Manual)

ST 3 Very Thorough Hand and Power tool

Cleaning (Mechanical)

The rust grades B,C & D only can be carried out by Wire Brushing
( Manual or Mechanical).

8. Q.1.0.8. Why the rust grade A is not possible to clean by wire

brushing?

The rust grade A is not possible to clean by wire brushing (Manual or

Mechanical),because this grade A covered with adhering Mill Scale, which are very
hard to remove by this method of surface preparation.

9. Q.1.0.9. What is Burnishing.

The undesirable polishing of steel surface leading to possible poor
adhesion problem of the subsequent paint system by the Wire Brushing process.
i.e. the Hand and Power tool Cleaning ( Manual or Mechanical).
9. Q.1.0.9. Compare the blasting grades stated in SIS-05-59-00, BS
7079,ISO 8501-1 , BS 4232 , NACE & SSPC?

SIS-05-59-00 BS 7079&ISO 8501-1 BS 4232 NACE

SSPC
N.A. N.A. N.A. 5. Water
Blast. SP 12
SA1 Light Blast Cleaning. Identical SA 1 N.A. 4.
Brush Off. SP 7
SA2 Thorough Blast Cleaning. Identical SA 2 3 rd.Quality
3.Commercial. SP 6
SA2.5Very through Blast Cleaning. Identical SA 2.5 2 nd.Quality 2.Near
White Metal. SP 10
SA3 Blast cleaning to Visually Identical SA 3 1 st.Quality. 1. White
Metal. SP 5
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Clean Steel.
N.A. ST2 Hand Tool N.A.
N.A. SP 2
N.A. ST3 Power Tool N.A. N.A.
SP 3
10. Q.1.0.10. State the different methods of surface preparation of metals.
There are many methods used to prepare metals prior to Painting.
1. Dry abrasive blast cleaning.( Open site )
2. Cabinet and vacuum reclaim dry blast cleaning.
3. Hand and Power tool cleaning.
4. Wet Blast Cleaning.
5. Pressure Washing.(Cleaning only).
6. Flame cleaning
7. Needle Gunning
8. Abrasive Discs
9. Weathering
Prior to any type of surface preparation it is essential that all Oil, grease and
other surface contaminations are removed completely due to the fact that they may
still be present after preparation has taken place.
In addition the preparation process needs to be carried out with a high degree
safety, since use of pneumatic equipment and the incidence of dust which an
occasion can be Toxic.

11. Q.1.0.11. What are the difference between Wet Blast Cleaning and
Pressure washing?

Wet Blast Cleaning. Pressure Washing

A method of blast cleaning of pressure up to 60,000 A low pressure method of
removing contamination
Psi which employs water or water & abrasives which from a surface with water and
without abrasive
Environmentally friendly and which is particularly Injection.
Useful for the removal of toxic coating.
i. Equipment used can be with or without an Equipment used can be without
an abrasive Injection
abrasive injection.
ii. Used to remove scales, rust, paints & toxic coating. Mainly used for cleaning
painted surface with or
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without
detergent.Removes surface contamination
Such as Salts and
Chlorides.
iii. Operates at very high pressure (From 100 psi up to Operates at low pressure,
typically at 100 psi.
60,000 psi).
iv. Can cut a surface profile on steel. Cannot create a surface
profile. Mainly used for
Cleaning painted
surface particularly in
maintenance painting.

12.Q.1.0.12. What are the safety aspects in Wet blast Cleaning?

i. Operates at very high pressure up to 20,000 psi.Personal safety

associated with high operating pressure is important factor to be
considered.
ii. Water resistant protective clothings, leg wears and helmets to be
worn.

13. Q.1.0.13. Name three test for locating soluble Iron salts and Mill Scales
on a blast cleaned Surface? Also name a test to locate traces of hydro
carbon oils,grease & finger prints.

(A) Hygroscopic salts.(Water loving salts causes excessive blistering in the paint
film).
a. Soluble Iron salts (Colourless) -Potassium Ferricyanide Test. Spray a fine
mist of distilled water on to small area of blast cleaned surface and wait for any
water droplets to evaporate. Apply a potassium ferricyanide test paper (pale
green colour paper) by pressing down for 2 – 5 seconds. Remove and check
visually for any salt have been drawn by capillary action. If salts present it will
be indicated on the PFC paper as Prussian blue spots.

b.Soluble Chloride Salts (Colourless) – Silver Nitrate Test. Similar to PFC test.
Instead of PFC paper Silver Nitrate test paper is used. The removed test paper
is placed on a digital machine which detects the amount of chloride salts in %.
Or in mg.
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c.Mill Scales- Copper Sulphate Test. A fine mist of slight acidic copper
sulphate solution is sprayed on to a localized area of approximately
100mm diameter. Area to be then checked for any presence of mill
scale. Any mill scale particles shows black spots where as cleaned / clear
steel turns a bright copper color.

(B) Ultra violet Light (lamp) test can be used to illuminate a surface to revere traces
of certain hydro carbon oils, grease & finger prints etc. on blast cleaned surface. Only
approved UV lamp should be used since direct look in to unshielded UV lamp can
quickly cause severe eye damage.

14. Q.1.0.14. What must all pneumatically and electrically operated power
tool equipment be.

For safety reasons, all pneumatically and electrically operated power

tool equipment must be Often specified that the brushes used are of Non – Sparking
type.

In these cases the brushes would be made from Phosphor Bronze

or Beryllium Bronze.

15. Q.1.0.15. What is Needle Gunning? What is the advantages &

disadvantages of it.

Needle Gunning or Needle Scalar some time called as Jason Hammer is

an air or electrically operated surface cleaning device with a Head or piston fitted with a
bundle of springs mounted needles of small cross section positioned forward of the
striking piston. The piston in turn strikes the needle simultaneously propelled them
against the surface to be cleaned (Bounce in and out).Needle gunning like chipping and
scaling hammer certain types fitted with Vacuum devices.
Needle Gunning is an effective cleaning device around bolt and rivet
heads, weld corners and other irregular surface.
Usually permission is required for their use, since they can create the
profile amplitude above 100microns can leave rogue peaks and impressed impurities
into the surface.
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16. Q.1.0.16.What is flame cleaning.What is the advantages & disadvantages

of it.

Flame cleaning is a surface cleaning method over corroded surface and

designated by the letter F l. By this process a high temperature flame of around 3000
deg. C is passed over a corroded surface. This causes the metal and rust to expand at
different rates and loosen them from each other. The intense heat also causes the rust
to dehydrate & become a powder and frees the surface from moisture. oil & grease.
Prior to Flame cleaning the any heavy layers of rust shall be removed by
chipping. After Flame cleaning the surface shall be cleaned by power tool wire brushing
to remove the product of Flame cleaning process.

Disadvantages. Advantages

i. Safety for dealing high temperature naked flame around Metal is perfectly
dry for painting.
3000 deg. C.
ii. Heat damage & warping to materials at this high temperature.
iii. Heat causes loss of strength to steel materials particularly to
Steel fastenings.

17. Q.1.0.17. What is the Chemical Cleaning process? Describ this process.
What are the disadvantage Of this process.
The Chemical Cleaning process is cleaning of metals by dipping in to a
Acid solution - Acid Pickling. This is the method of preparing steel surface by a
Chemical Reaction or Electrolysis or both.
This is a factory process for cleaning small steel components, which can
go to be painted or which are often galvanized as a part of factory operation.
Sequence of Operation.
i. Degreasing.(Cleaning & Preparation for metals.) – By using suitable
solvent.
Heavy deposits of rust and paints which prevent the pickling acid from contacting the
surface.
All scales must be cleaned off from the metal surface.
Using a suitable solvent or high temperature baking, in a baking oven degreasing to be
done. ie. all oils to be removed prior to pickling.
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ii. Pickling. - Immersing the component in to a tank suitable for Pickle Bath
Or Spray or flow the pickle bath over the work Or Pull the work Through
the bath.
Suitable Pickle bath in commercial pickling is an acid usually dilute Sulphuric acid at a
given temperature. Other acids such as Hydro choleric
(Muriatic), Phosphoric or Mixture of these three may be used.
Acids used to be to attack and remove mill scales and other contaminations without
attacking the steel.
iii. Neutralising. – Treating the pickled Metals to remove acids and remaining
contaminations.
Prevent the pickled metal ie.steel from rusting and corrosion.
Water wash or Rinsing in water to remove acid and remaining contamination from the
pickled surface.
Application of an Alkali solution to check all traces of acids are completely removed from
the steel surface.
Checking the pH of the pickled steel surface by litmus paper test (Orange & Blue).
The pH balance of the surface should be between 3 & 5 to prepare the metal for
painting.
iv. Phosphating. – A final treatment if specified. Only applicable to Footner or
Duplex process.
A solution 1 to 2 % Phosphoric acid held at 80 deg. C. to be treated on the pickled
surfaces for 1 to 2 minutes.
This will provide a thin rust inhibitive phosphate coating on the pickled steel surface.
v. Final water wash. – to remove any process contamination product.

Disadvantages or Limitation.
i. Associated danger with handling acids.
ii. The size of the metal to be cleaned is governed by the size of the acid tank.
iii. Disposal of resulting acid effluent.
iv. Process leaves some traces of mill scale on the surface that later causing premature
paint failure.
v. Inhibitors should be added to minimise the attack of Hot or Cold solution of acids
followed by Hot water
rinse.
18. Q.1.0.18.What is Dry Abrasive blast Cleaning.Briefly describe this
equipments for cleaning process.
The Dry abrasive blast cleaning usually carried out in open site and
hence the other word called
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Open Site Abrasive Cleaning. ( Site Blast Cleaning).

The required equipments including safety features are as follows.
i. Air Compressor. (Max.100psi.)-Capable of deliver sufficient air to maintain
required pressure at Nozzle.
ii. Air Filter – Compressed air must be free of contaminants including oil, water &
moister.
iii. Pressurized Pot or Abrasive Blast Unit – Of types Jet & Gravity feed units &
Vacuum machines Contains
the abrasives.
iv. Carbon Impregnated Hoses. – Reduces possibility of Static Shock, free from
damage or sharp bends and
heavy objects rest on it. Hoses should be properly grounded.
v. Blast Cleaning Nozzles – Types Straight bore(Lesser Velocity 220mph) & Venturi
(Higher velocity 450mph )
in common use. Lined with tungsten Carbide for longer life by reducing wear & tear.
Other linings are Silicon.
Carbide and Norbide (Boron Carbide) which are 1.5 & 2.5-3.5 times longer life than
tungsten Carbide respectively.
vi. Dead Man’s Handle. – A device which cuts off flow of abrasive if operator lets go off
handle.
(A Statutory Safety Feature)
vii. External Coupling. – Helps to prevent blow out
ix. Personal Equipments. – Air feed Helmet, Ear defenders, boots, gloves,
leather Apron etc.
x. Safety Features – such as warning signs, tapes or barriers and safety sheeting or an
encapsulated are to
Other site workers and or surrounding buildings or
equipments.
xi. Abrasives. – The cleaning consumable materials used in blast cleaning.
Abrasive used in open
site should be Expandable.

19. Q.1.0.20. What are Abrasives and it types. Give example for each type.

Abrasives are the cleaning consumable used in blast cleaning, made

up of metallic or mineral materials hurled at steel to bring about it cleaning. There
are two main types and six general types of abrasives.
Two main types are
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i. Expandable Abrasives. – This type of abrasive’s are used only once. When they hit
the steel at high speed they shatter on impact and fall harmlessly to the floor.
Example. Copper Slag, Crushed Glass, Ice, Walnuts Shells and others.
ii. Recyclable (reclamation) Abrasives. – This types of abrasives are reused.
Purpose of is recycling is this abrasives are expensive. Less expensive abrasive’s like
sand can also be recyclable. Example. Metallic abrasives such as steel
grit, steel shots, cast steel & Iron and malleable Iron. The non –metallic
abrasive’s - Oxides such as Granite, Silicon Carbide, Aluminium Oxide etc. and slags
or Conglomerates such as refractory slag, mineral slag etc. and Silicaceous abrasive.
Six General types are.
I. Metallic – Steel Grit & Shots, Cast steel & Iron, Malleable Iron. Heat Treated to
different Hardness to increase their life (Reclaiming) and rate of cleaning. Hard (60-
65HRC)often used for etching & soft (35-50HRC)used for easier cleaning jobs.
ii. Non-Metallic (Hard Oxides) – Granite (Oxide),Silicon Carbide(Oxide),Aluminum Oxide
etc.
iii. Free Silica-the silicaceous. – Sands have greater break down into dust, hence should
no be used where dust hazardous present due the risk of Silicosis. Others are Flint /
Chert, Quartz (SiO2) etc.
iv. Agricultural.- Walnut shell(black),Coconut shell, Pecan shells, Peach Pit Shells, Filbert
Shells, Cherry pits, Almond Shells, Apricot Pit/Shells,RiceHulls,Ground Corn / Cobs, Sugar
etc.
v. Slag or Conglomerates – Refractory Slag & Mineral Slag.
vi. Specialties.- Dry Ice( CO2),Ice Water, Plastic beads, Sodium
Bicarbonate(Soda),Sponge etc.

20. Q.1.0.20. What is Cabinet and Vacuum Reclaim dry blast Cleaning
System. Briefly describe this Cleaning system.( Enclosed Blast Cleaning).

Cabinet and Vacuum Reclaim dry blast Cleaning System (Enclosed

Blast Cleaning) usually in a fixed position found in the factory situation and also in
the portable form for blasting flat areas.
The abrasive used is Iron & Steel Shots and Grit which can be
reclaimed, Cleaned, monitored for size and reused up to 20 times. The shots and grits
are mixed together to obtain required cleanliness and to keep the amplitude within the
specification requirement. For example if the required amplitude is 30 – 75 microns,
then mix of Shot & Grit might be around 75 by 25 % respectively.
It is essential that steel or iron shot / grit are to be used in a closed
cleaning system as they do not shatter on first impact. They would bounce back from
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the steel surface creating a danger to near by people and equipment. Also they are very
expensive and must be reclaimed to warrant the cost of using them.

21. Q.1.0.21. What is the British Standard No. Which deals with the Cabinet
and Vacuum Reclaim dry Blast cleaning abrasives of Iron & Steel Shots and
Grits.

The British Standard No. Which deals with the Cabinet and Vacuum
Reclaim Dry Blast cleaning is B.S. 2451

22. Q.1.0.22. What factors influence how clean and how rough the surface
become after (Open Site) Any Blast Cleaning?

Abrasive Factor Human Factor

i. Size Speed.
ii. Hardness. Angle.
iii. Density. Distance.
iv. Shape. Time.
v. Type.
vi. Cleanliness.
23. Q. 1.0.23. What are the effect of surface profile by the abrasive blast
Cleaning using Grit & Steel Shots.Give brief comparision.

Grit Steel Shots

i. Angular profile Spherical profile.
ii. Sharp cutting Edges. Smooth Cutting Edges.
Iii Shatters Mill scale. Shatters Mill scale.
iv. Leaves under cuts & surface Contaminants. Visually like grit blasted finish but
smoother.& may press impurities
in to the surface.
v. May Create rogue profiles. Reduce rogue profile.
vi. Less chances of hardens the steel surface. Greater extent of hardens the
surface.

24. Q.1.0.24.What is a surface profile or Anchor pattern or Texture.State and

briefly describe the the nomenclature of profile Produced by Abrasive blast
Cleaning.Also state the effect of this on the life of painted surfaces.
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Surface Profile or Anchor Pattern. Or Texture. Is the shape of cross section of the
blast finish & is the result of Sharp abrasive particles striking the steel at high speed and
leaving minute impact craters on the surface of steel.
Peak. Is the higher point of the profile.
Trough. Is the lower point of the profile.
Amplitude. Is the peak to trough height. The amplitude is governed by size of abrasives
used, angle of attack of blasting nozzle and hardness of abrasives and steel surface. The
unit of surface profile depth is generally measured either in Mils (1/ 1000 of inch.) or
Microns / Micrometers (1 / 1000000 of a meter.)
Rogue Peaks. Is the highest point of profile above the desired or permitted profile level.
These are eliminated or reworked by using abrasive paper rubbing followed by sweep
blast cleaning.
Effects of profiles on the life of painted surface. Too Shallow profile can result in
premature coating failure.
Too high a profile (Rogue Peaks) that projects through the coating resulting the rust
spots and lead to corrosion
There by later coating failure.

25. Q.1.0.25. State the methods of measurement of Amplitude or depth of

surface profile and briefly Describe each method.

Dial Gauge Depth Micrometer or surface profile Needle Gauge. This device is
similar to dial gauge with a base of a spring loaded needle rests on top and bottom of
profiles i.e. Peaks and valleys measures the depth and height of Anchor pattern. Between
10 to 20 readings in the profile differ in depth and the readings are averaged.
This is very sensitive test. The gauge must be set to zero on a flat piece of glass before
use. Though it can be used in the field, its best application is in the laboratory.
Surface Profile coupons. Available in 0.5mils (12to75mic.m.) in the increments from
0.5 to 3 mils (12 to75mic.m).These coupons allows to determine the surface profiles
through comparison. Clemtex Coupons
Surface Profile Comparators. Consists of a reference disc and 5X illuminated
magnifier. The disc has a set of leaves (5 Nos.) and each one is assigned a number
represent the depth of profile of the leaves. These reference discs are compared to the
surface profiles prepared through 5X power magnifier. The leaves most closely
approximates the roughness of the surface is considered to be the depth of profile of that
pattern of the surface.
Reference discs are available for Sand, Grit, Steel or Shot abrasives. Clemtex
comparators.
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Replica Tapes. Is a piece of tape with a small square or round compressible foam
plastic attached to a non – Compressible plastic film. There are two types of tapes,
Coarse (for 0.8 to 2.0 pattern) and Extra coarse (for 1.5 to 4.5 pattern) commonly used.
Testex Tapes.
These Test Tex tapes are applied to the surface (Dull Side down) and a hard rounded
object –burnishing tool such as a swizzle stick is used to crush(Rub off) the foam. This
will cause an exact reverse impression of the actual surface profile on the compressible
foam film.
Then the difference of thickness of compressible foam measured before and after the
rubbing by a dial anvil type micrometer will give the depth of surface profile.

26. Q.1.0.26. What factors influence the effect of environment on abrasive

blasting operation.

All of the below indicated factors have a serious effect on the abrasive
blasting operation as well as on the blast cleaned surface before painting.

Temperature of both Air and Metal Substrate. If the temperature of steel surface is
much colder than surrounding Atmosphere (air), the moisture may condense on the
blasted surface, causing the blasted surface to be rusted. The temperature to be
measured using suitable thermometers.
Humidity (Relative Humidity). In high humidity (moisture) results the rapid rusting.
Final dry abrasive blast cleaning should not be done in the rain or high humid condition.
Dew point. Is the temperature at which will condense and turn to liquid. If abrasive
blasting is done when the environmental condition close to dew point, flash rusting may
occur. The R.H. & dew points to be checked using Sling Psychrometer and psychrometer
Charts.
Environmental Conditions. In environmental exposure (Atmosphere) such as in
marine and industrial environments where air contains particles of chemical salts due
these the salt may deposit on the blasted work surface. After blast cleaning prior to
painting if required the chemical deposit such as ferrous sulfate, ferrous hydroxides may
be determined by means of pH or litmus paper tests. Presence of neutral salts such as
sodium Chloride will not reveal by special indicators.

27. Q.1.0.27. What is a Hyperdermics needle gauge? Briefly describe the

function of this.
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The hypodermic needle gauge is used to measure the pressure at which

the abrasive is delivered
to the blast nozzle. This needle gauge is used to measure the air pressure at the nozzle.
The hypodermic needle is inserted in to the blast hose just behind the
nozzle, while the blast unit is in operation. If the pressure is low, the reason and cause
for the same to be analysed and corrected.

28. Q1.0.28. What is the nozzle gauge and briefly explain the nozzle throat
test.
The nozzle gauge is used to measure the throat size of venture type of
nozzle. As the nozzle is used, abrasives wear down the lining there by increasing the
diameter of the throat of the nozzle and decreasing its efficiency.
First a mark is made on the gauge using a grease pencil at the
approximate size of the nozzle. Then the gauge is inserted at the back of the nozzle and
twisted one full turn (360 deg.)The gauge is with drawn and the black mark examined.
The ID of the nozzle is indicated where the grease pencil is rubbed off.
At the Orifice size measured, the indicates the volume of air in cubic Feet
per minute(CFM) Or Cubic meter per minute(CMM).necessary to deliver 100 psi (689Kpa.)
at the nozzle.

29. Q.1.0.29. What are the abrasive cleanliness tests. Briefly describe the each
test.
Abrasive can be tested for cleanliness through the use of a simple test.
These tests are briefly discussed below.
Vial Test
Abrasives shall be clean and free of contaminants such as Oil, Dirt, Soluble chemical salts.
Equipment required for the tests are Clear Jar or Vial with tight lids or stoppers, distilled
water, Chemical test paper.

A small sample of abrasives (1 part by volume- in question) is scooped in to the Jar and
some distilled water or water of a known pH (2 parts by volume) is poured in.
i. Test for any Oil & Dirt.
The mixture is shaken well. If any oil film appears on the water or if water appears to be
clouded with dirt which indicates that abrasive is contaminated.
ii. Test for presence of any Chemical Salts.
Specific test papers may indicate the presence of soluble chemicals. Litmus and pH paper
will indicate the presence of any chemicals salt which when dissolved in water form an
acidic and basic solution.
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Note The litmus and pH paper will not detect the presence of chlorides.
Basic. If the red litmus paper changes to blue color- it indicates the solution is basic.
Acidic. If the blue litmus paper is changed in to red color – it indicates the solution is
acidic.
Neutral. If the red / blue litmus paper does not changes it’s color it indicates the solution
is neutral.
However, even if the solution is neutral, it does not indicate the absence of
soluble chemical salts, because some chemical salts such as sodium chloride (common
table salt) form a neutral solution.

30. Q.1.0.30. What is the test for abrasive’ size. Briefly describe this test.

The test for abrasive for abrasive size is called Sieve or mesh Test.
when in doubt about whether a given abrasive is correct size these test may be
performed. Each type of Abrasives are generally available in more than one size.
Abrasives are graded according to how fine a mesh or Sieve Screen that they can pass
through without one particle of abrasive remaining on the mesh.
The equipment required is a Triple beam balance and a Set of NBS
screen. A convenient quantity of abrasive is weighed and then poured in to top of nested
screens. The screens are nested so that the screen with the largest openings is in top,
graded down through the screen with the smallest opening on the bottom.
Example. From top to bottom mesh size # 8, # 15, # 16, # 40, # 50 – As per ASTM D
1366.
The Screens are shaken over a retaining pan; The abrasive particles are
retained on the screen which sizes are just smaller than the abrasive particles. The finest
abrasive particle passes all the way through and are caught on the pan.
The next step is weigh the particles remains on each screens and
calculate the percentage retained. That is with 1 Kg. of abrasives used 238 g. of abrasives
is retained at a given level. Then the percentage by weight of abrasive retained at the
give level of mesh or sieve size is 23.8 %. Calculate similarly the % by weight of
abrasives retained at others level of mesh or sieve size.

31. Q.1.0.31. What is the test to check the cleanliness of compressed

air.Briefly describe the test.

The test to check the cleanliness of compressed air is Blotter Test as per
ASTM D 4285. Standard method for indicating Oil or Water in Compressed Air.
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The test method is used to check visually for any traces of oil or water
(moisture) in the compressed air to be used in the abrasive blasting or in spray
application of painting.
Involves the use of white absorbent paper held in the air stream discharging
from the compressor.
Allow the compressed air to operate for several minutes to reach the operating condition
to remove accumulated condensation in the system.
Fastened the collector material to a rigid backing in order to avoid personal
contact with the air stream. The collector / tester material may be an absorbent collector
such as blotter paper or a non absorbent collector such as a rigid transparent plastic.
The collector or tester should be positioned with 24 inch of air discharging
point (only air without abrasive) centered in the air stream for one minute minimum. The
collector is then examined for presence of any contamination such as oil, water
(moisture) or both.
Acc. to ASTM D 4285, any indication of oil discoloration on the collector shall be
cause of rejection of compressed air for use. Any indication of water contamination on the
collector shall also be a cause of rejection of compressed air to be used, since water is
detrimental in abrasive / air blast cleaning & coating applications.

32. Q.1.0.32. What is called Reclamation or Recycling.Briefly describe the four

major methods.

Reclamation or Recycling is the process of reusing the abrasive for

further blasting operation.
Purpose of recycling is the abrasives are expensive.There are four major method of
reclamation or recycling of abrasives in general use.
i. Screen reclamation method. Similar to sieve test. The abrasive runs over a series
of screens; the top large size screen eliminates over sized materials. The remaining
abrasives falls down to a smaller screen. The dust and fines passes through, leaving only
usable abrasive in the screen. This method can be done both by hand (manually) or
mechanically.
ii. Air screen wash method. In this method the over sized abrasives are removed by
mechanical screens by distributing the abrasives over a wide sloping plate which causes it
to fall over the edge. As it falls the abrasives passes through an air stream at a pre-
determined velocity. The usable heavy abrasives are carried a short distance and then fall
in to a chute. This method is considered less precise than the screen method.
iii. Water Method. In this method the abrasives are passed through a water wash,
which separates the dust and fines from coarse particles. The upward velocity of water is
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reduced which causes the heavier abrasives to be deposited in the bottom of reclaimer.
The remaining abrasives are dried in a kiln before being used.
The water method is inexpensive and is helpful in reducing dust but
require large amount of water that should be filtered and purified before being released
in to drains of rivers.
Because of use of water, this method is only used with the non-
corrodible materials and never with Iron and steel.
iv. Cyclone Method. In this separating method the abrasives are drawn through a hose
in to a cylinder similar to high power sweeper. Rapidly moving air in the cylinder sends
the dust and fines out the top of cylinder and the heavier, reusable materials falls through
a screen at the bottom.

34. Q.1.0.34 What is Steam Cleaning.

A low pressure method by Steam for removing contamination from a surface, particularly
oil and grease.

35. Q.1.0.35. What is the procedure for removing oil and greasefrom a surface
if found after the preparation has taken place.

36. Q.1.0.36. what is the procedure to remove algae and mould growth from
pipe work.

37. Q.1.0.36. Some metals are difficult to prepare.Name three and describe
how you might prepare them.
1

1
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