CW6: PART 1

TECHNICAL SPECIFICATION FOR

THE EXTERNAL PROTECTION OF STEEL LINE PIPE
AND FITTINGS USING FUSION BONDED POWDER
AND ASSOCIATED COATING SYSTEMS
PART1 - REQUIREMENTS FOR COATING
MATERIALS AND METHODS OF TEST
Date
J229b ( Rev 08/98)
.
CW6: Part 1
J229b ( Rev 08/98) - i -
CONTENTS
Page
FOREWORD v
BRIEF HISTORY vi
SECTION ONE - GENERAL REOUIREMENTS
1. SCOPE 1
2. REFERENCES 1
3. DEFINITIONS 2
4. COATING MATERIALS 2
4.1 Acceptable materials 2
4.2 Identification of materials 3
4.3 Production data sheets 3
4.4 Toxicity and handling 3
5. VARIANTS 3
SECTION TWO - BASIC PROPERTIES AND TESTS FOR POWDER AND CURED COATING
6. BASIC PROPERTIES OF THE POWDER 4
6.1 General 4
6.2 Infra-red scan 4
6.3 Gel time 4
6.4 Particle size analysis 4
6.5 Density 4
6.6 Moisture content 4
6.7 Thermal analysis 4
6.8 Stability 4
7. BASIC PROPERTIES OF THE DETACHED COATING FILM 4
7.1 General requirements 4
7.2 Micro-sectioning 4
7.3 Tensile strength 5
7.4 Elongation 5
7.5 Dielectric strength 5
CW6: Part 1
- ii - J229b ( Rev 08/98)
Page
7.6 Water permeability 5
7.7 Water absorption 5
8. BASIC PROPERTIES OF THE CURED APPLIED COATING 5
8.1 Physical performance test requirements 5
8.2 Environmental test requirements 6
8.3 Thermal stability test 7
9. QUALITY CONTROL REQUIREMENTS 7
10. COMPLIANCE 7
SECTION THREE - BASIC PROPERTIES AND TESTS OF MULTI-COMPONENT LIQUID
COATING MATERIALS AND CURED COATING
11. BASIC PROPERTIES OF UNMIXED COATING MATERIALS 8
11.1 General 8
11.2 Total non-volatile content 8
11.3 Viscosity 8
11.4 Relative density 8
11.5 Mixing ratio 8
11.6 Potlife 8
11.7 Flash point 8
11.8 Stability 8
12. BASIC PROPERTIES OF DETACHED COATING FILM 8
12.1 General requirements 8
12.2 Micro sectioning 9
12.3 Tensile strength 9
12.4 Elongation 9
12.5 Dielectric strength 9
12.6 Water permeability 9
12.7 Water absorption 9
13. BASIC PROPERTIES OF CURED APPLIED COATING 9
13.1 Physical performance test requirements 9
13.2 Environmental test requirements 10
13.3 Thermal stability test 11
14. QUALITY CONTROL REQUIREMENTS 11
CW6: Part 1
J229b ( Rev 08/98) - iii -
Page
15. COMPLIANCE 11
APPENDICES
A METHODS FOR THE EVALUATION OF THE THERMAL CHARACTERISTICS OF
POWDER AND CURED COATING 13
B FLEXIBILITY TEST 23
C HOLIDAY DETECTION OF COATINGS 26
D EVALUATION OF RESISTANCE TO IMPACT 27
E EVALUATION OF RESISTANCE TO WATER IMMERSION 30
F EVALUATION OF RESISTANCE TO CATHODIC DISBONDING 32
G STRAIN/POLARIZATION TEST 36
CW6: Part 1
- iv - J229b ( Rev 08/98)
CW6: Part 1
J229b ( Rev 08/98) - v -
FOREWORD
This specification has been adopted by Transco and is an editorial revision of the former British Gas TransCo
specification GBE/CW6 Part 1. It reflects the identity and organizational structure of Transco - a part of BG
plc.
This Transco specification has been approved for use throughout Transco.
Comments and queries regarding the technical content of this Transco specification should be directed to:
Lead Engineer
Transco
Norgas House
PO Box 1GB
Killingworth
Newcastle upon Tyne
NE99 1GB
Further copies of this Transco specification can be obtained from Dataform Print Management using the print
requisition form G004 quoting the Form Number of this Transco engineering document (not the designation)
and your cost code.
Transco engineering documents are revised, when necessary, by the issue of new editions. Users should
ensure that they are in possession of the latest edition by referring to the Transco Register of Engineering
Documents available on the Transco Information Library.
Compliance with this engineering document does not confer immunity from prosecution for breach of statutory
or other legal obligations.
Contractors and other users external to Transco should direct their requests for further copies of Transco
engineering documents to the department or group responsible for the initial issue of their contract
documentation.
DISCLAIMER
This engineering document is provided for use by Transco and such of its contractors as are obliged by the terms
of their contracts to comply with this engineering document. Where this engineering document is used by any
other party, it is the responsibility of that party to ensure that the engineering document is correctly applied.
CW6: Part 1
- vi - J229b ( Rev 08/98)
BRIEF HISTORY
First published as BGC/PS/CW6:Part 1
Re-issued as GBE/CW6:Part 1
January 1985
January 1993
BG plc 1992
This Transco specification is copyright and must not be reproduced in whole or in part by any means without
the approval in writing of BG plc.
CW6: Part 1
J229b ( Rev 08/98) - 1 -
TECHNICAL SPECIFICATION FOR
THE EXTERNAL PROTECTION OF STEEL LINE PIPE AND
FITTINGS USING FUSION BONDED POWDER AND
ASSOCIATED COATING SYSTEMS
PART 1 - REQUIREMENTS FOR COATING MATERIALS AND
METHODS OF TEST
SECTION ONE - GENERAL REQUIREMENTS
1. SCOPE
This Transco Technical Specification* CW6 specifies materials for use as anti-corrosion coatings on steel line
pipe and fittings. It deals specifically with the properties and performance tests to establish suitability for use
with Part 2 of this specification, which deals with factory applied coatings, and for use with CW5 for certain
field applied coatings.
Section One of this specification covers general requirements. Section Two covers fusion bonded powder and
Section Three covers multi-component liquid coating materials.
* Hereinafter referred to as 'this specification'.
2. REFERENCES
This specification makes reference to the documents listed below. Unless otherwise specified the latest
editions of these documents, including all addenda and revisions, shall apply.
Statutes and Regulations
- Classification, Packaging and Labelling of Dangerous Substances
Regulations 1984
- Control Of Substances Hazardous to Health (COSHH) Regulations
- The Health and Safety at Work etc. Act 1974
British Standards
BS 1387 - Specification for screwed and socketed steel tubes and tubulars and for
plain end steel tubes suitable for welding or for screwing to BS 21
pipe threads
BS 2015 - Glossary of paint terms
BS 3900 - Methods of test for paints:
Part B2: Determination of volatile matter and non-volatile matter
Part F2: Determination of resistance to humidity (cyclic condensation)
Part F3: Resistance to artificial weathering (enclosed carbon arc)
Part F4: Resistance to continuous salt spray
BS 7079 - Preparation of steel substrates before application of paints and related
products
CW6: Part 1
- 2 - J229b ( Rev 08/98)
American Society for Testing and Materials
ASTM G14-77 - Test for impact resistance of pipeline coatings - (Falling weight test)
Transco specifications
CM2 - Specification for internal coating materials for steel line pipe and
fittings
CW5 - Code of practice for the selection and application of field applied
external pipework coatings
CW6 - Technical specification for the external protection of steel line pipe
and fittings using fusion bonded powder and associated coating
systems:
Part 2 - Factory applied coatings.
3. DEFINITIONS
For the purposes of this Specification the following definitions shall apply:
Transco : Transco - a part of BG plc.
Transco representative: the person appointed from time to time by Transco and notified in writing to the
Contractor to act as Transco representative for the purposes of the Contract.
Contractor: the person, firm or company with whom Transco enters into a contract to which this
specification applies, including the Contractor's personal representatives, successors and permitted assigns.
Manufacturer: the producer of the coating material being offered for test or his appointed agents or assigns.
4. COATING MATERIALS
4.1 Acceptable materials
4.1.1 Coating systems
Only coating systems conforming to this specification shall be considered for application in accordance with
CW6: Part 2. Coating systems may include the use of primer or chemical pretreatment of the steel surface to
enhance adhesion. In such cases, the pretreatment and coating material shall be clearly specified as a
combined system.
Where recycled material is used, the ratio of recycled to virgin material shall be stated. Any coating system
made up with a recycled material mix shall meet the requirements of this specification.
Fusion bonded powder shall also meet the requirements of Part 1 of this specification without the use of
chemical pretreatment.
4.1.2 Compliance with this specification
The Contractor shall be responsible for ensuring that all coating materials and equipment comply with all of
the provisions specified in this specification and Transco may make any investigation necessary, by way of
testing, batch sampling and manufacturing inspection, to satisfy itself of compliance by the Contractor.
4.1.3 Application of this Specification
It is intended that this specification be used to encourage and stimulate the development of progressively
better external pipeline coatings. Thus, where certain minimum performance values are stated and should
future coating material test submissions yield better performance than the specified requirements then, after
economic evaluation, these new values may be adopted as the minimum requirements and the specification
would be up-graded accordingly.
CW6: Part 1
J229b ( Rev 08/98) - 3 -
4.1.4 Supply of data
The Contractor shall furnish, on request and in confidence, such details as may be required by Transco, which
may include formulations, typical physical constants, manufacturing tolerances and application data
associated with the coating materials being used. Transco also reserve the right of direct communication with
the Manufacturer should the need arise.
Any change of formulation, or manufacturing supply route, of a material may be proposed for consideration as
a variant by Transco and supply of the modified material shall not be implemented until such time as the
revised procedure qualification trials have been completed.
4.2 Identification of materials
All materials supplied for coating operations shall be suitably marked giving the following information:
a) Manufacturer's name, initials or identification mark.
b) Name of material.
c) Batch number.
d) Date of manufacture and 'use by' date.
e) Storage temperature limits.
f) Safety data sheet (included with delivery).
Containers and any associated packaging shall, where appropriate, be marked in accordance with the
Classification. Packaging and Labelling of Dangerous Substances Regulations 1984.
The Contractor shall require the Manufacturer to supply certificates confirming that tests specified in this
specification have been carried out on the batches supplied and that the materials meet the specified
requirements. These certificates shall be made available for examination by Transco on request.
4.3 Production data sheets
The Contractor shall be responsible for obtaining data sheets from the Manufacturer which shall include
values for all the basic properties of the material as specified in the 'Basic properties' clause in the appropriate
Section of this specification.
4.4 Toxicity and handling
Any hazard including toxic, corrosive risks and fire risks, associated with coating materials offered for use to
meet the requirements of this specification shall be specified by the Manufacturer, together with his
recommendations for safe handling in accordance with the requirements of the Health and Safety at Work etc.
Act 1974 and the COSHH Regulations.
Containers and associated packages shall be marked with their weights and, where appropriate, be provided
with handling points, e.g. handles or hand holes.
5. VARIANTS
A contractor shall only propose variants to this specification where the text indicates that variants would be
considered by Transco.
CW6: Part 1
- 4 - J229b ( Rev 08/98)
SECTION TWO - BASIC PROPERTIES AND TESTS FOR POWDER AND CURED COATING
6. BASIC PROPERTIES OF THE POWDER
6.1 General
The Contractor shall obtain from the Manufacturer specified and qualified ranges of values for all properties
listed in 6.2 to 6.8 inclusive that will ensure an acceptable coating. The frequency of testing shall be in
accordance with 9.2.
6.2 Infra-red scan
An infra-red spectrogram, preferably made by using a standard potassium bromide (KBr) disc, shall be
obtained from a typical batch of the powder. This shall subsequently be used for comparison with type
spectrograms.
6.3 Gel time
A hot plate technique shall be used to obtain values of the gel time, and the values obtained of each batch
shall be used for comparison with values originally quoted.
6.4 Particle size analysis
The particle size distribution of the powder shall be the optimum to suit the particular method of application.
Particle size range shall be quoted in the production data sheet. Each batch shall be checked for conformity
with the values originally quoted.
6.5 Density
The density of the powder shall be measured for all batches produced, and the values shall conform with the
value originally specified.
6.6 Moisture content
The moisture content of the powder shall be less than 0.5% by weight and shall be checked for every batch.
6.7 Thermal analysis
Thermal analysis data for each batch shall be made available showing, by use of a Differential Scanning
Calorimeter (DSC), the glass transition of the raw powder and also the enthalpy of the curing powder. The
glass transition temperature of the fully cured powder shall also be quoted. The reference curve shall be
provided as part of the production data sheet (see 4.3). The limiting values of H , Tg
1
and Tg
2
(see Appendix A) shall be identified by the Manufacturer.
6.8 Stability
After ageing for 120 days at 25 1
0
C in a sealed container, the powder shall not exhibit any significant
change from the properties identified in 6.2 to 6.7 inclusive.
7. BASIC PROPERTIES OF THE DETACHED COATING FILM
7.1 General requirements
The Contractor shall ensure that the tests specified in 7.2 to 7.7 inclusive are carried out by the Manufacturer
in accordance with 9.4. The tests shall be carried out on detached coating samples, m 400 to m 450 thick,
which have been prepared by application on to polished steel plates, 6 mm thick, previously coated with
polytetrafluoroethylene (PTFE).
7.2 Micro sectioning
A cross-section of the cured film shall be examined at a magnification of X100 and shall be seen to be
homogeneous and essentially free of voids, foaming or other defects.
CW6: Part 1
J229b ( Rev 08/98) - 5 -
7.3 Tensile strength
Test specimens of detached coatings shall be tested at an extension rate of 1 mm/min. Values for tensile
strength shall be quoted in MN/m
2
as maximum strength and strength at break.
7.4 Elongation
When tested in accordance with 7.3, the elongations at 'yield' and 'break' shall be quoted by the Manufacturer.
7.5 Dielectric strength
The dielectric strength of the cured material shall be quoted by the Manufacturer as kV/mm together with the
method of test.
7.6 Water permeability
The water permeability of the cured material, expressed as g/24 h m
2
/mm thickness shall be specified by the
Manufacturer together with the method of test.
7.7 Water absorption
The quantity of water absorbed after three months immersion at 20
0
C shall be quoted by the Manufacturer.
8. BASIC PROPERTIES OF THE CURED APPLIED COATING
8.1 Physical performance test requirements
8.1.1 General requirements
The Contractor shall ensure that the tests specified in 8.1.2 to 8.1.9 inclusive are carried out in duplicate by
the Manufacturer in accordance with 9.3 and results of the tests, demonstrating compliance, made available.
The tests shall be carried out on sections of 6 mm thick laboratory coated standard steel plate, as appropriate
to the test requirement. Prior to coating, the steel surface shall be blast cleaned using G34 grit to BS 7079
Sa 3 quality and surface profile of between m 50 and m 100 peak to trough height. The coating thickness
shall be in the range m 400 to m 450 . A destructive film thickness test shall be carried out to verify the
accuracy of the coating thickness measurement technique employed.
Testing of applied coatings shall be carried out seven days after application of the coating in respect of 8.1.6,
8.2.3 and 8.2.5.
8.1.2 Cissing and pinholing test
The coating shall not show signs of cissing or pinholing when applied to a prepared steel panel. In cases of
doubt, a further test may be carried out by applying the coating to a grit roughened glass panel and examining
it by viewing over a bright light source.
8.1.3 Blistering and appearance test
The coating shall not show signs of blistering and shall exhibit uniform appearance when examined by either
of the tests specified in 8.1.2.
8.1.4 Sagging test
The coating shall not exhibit sagging when applied to a steel panel in the vertical plane prepared in
accordance with 8.1.1.
8.1.5 Thermal analysis - coating cure test
Thermal analysis shall be carried out, in accordance with Appendix A, on samples taken from laboratory
prepared panels which are to be used for subsequent performance testing.
CW6: Part 1
- 6 - J229b ( Rev 08/98)
The values of Tg
1

and Tg
2

specified by the Manufacturer shall be in a range to ensure the coating is
adequately cured to meet subsequent performance tests.
The Contractor shall obtain complete results of all thermal analyses from the Manufacturer for record
purposes. Transco shall have the right to examine the results on request.
8.1.6 Flexibility test
Steel plates, 50 mm x 300 mm x 6 mm thick, shall be coated to a film thickness of m 400 to m 450 and be
properly cured. After bending in accordance with clause B.1 (at a deflection rate of 25 mm/min) over
appropriate sized mandrels, the coating shall not crack, disbond or pinhole and shall pass a holiday test in
accordance with Appendix C.
8.1.7 Impact resistance test
Impact resistance shall be determined in accordance with Appendix D using plate specimens. The method of
statistical analysis described in ASTM G14-77 shall also apply.
The coating shall withstand a minimum mean impact value of 1.5 J without resulting in a breakdown or loss
of adhesion of the coating.
8.1.8 Adhesion test
The adhesion test procedure shall be as specified in clauses E.5 and E.6 and the results assessed in accordance
with clause E.7.
8.1.9 Hardness test
The Manufacturer shall specify the method used to test coating hardness and shall quote the values obtained.
8.2 Environmental test requirements
8.2.1 General requirements
The Contractor shall ensure that the tests specified in 8.2.2 to 8.2.8 inclusive are carried out in duplicate by
the Manufacturer and the results of the tests, demonstrating compliance, made available.
The Contractor shall be responsible for ensuring that the range of values for any material under consideration
will be capable of providing a finished product in compliance with the relevant Sections of CW6: Part 2
All tests shall be carried out on coatings properly cured and in the thickness range m 400 to m 450 .
8.2.2 Cathodic disbondment test
Sample panels shall be tested by the procedure specified in Appendix F. The coating, when subjected to an
impressed current at a negative voltage of 1500 mV at 20
0
C, shall not disbond for greater than 5 mm radius
from the edge of the damaged coating after 28 days.
8.2.3 Strain/polarization cracking test
The sample panels shall be subjected to a bend strain at 20
0
C and then polarized and tested as specified in
Appendix G with the test area selected on the minimum radius of the bend, i.e. area of maximum strain.
8.2.4 Water immersion test
The sample panels shall be subjected to a water immersion test as specified in Appendix E. The test shall not
show loss of adhesion greater than 3 mm after 28 days.
CW6: Part 1
J229b ( Rev 08/98) - 7 -
8.2.5 Humidity resistance test
Coated steel test plates shall be exposed for 2000 h in accordance with BS 3900: Part F2. The coating shall
not lose adhesion and no underfilm corrosion or blistering of the film shall occur.
8.2.6 Salt spray resistance test
Coated steel test plates shall be cross-cut and exposed for 2000 h to continuous salt spray conditions in
accordance with BS 3900: Part F4. The coating shall not lose adhesion, and no underfilm corrosion or
blistering of the film shall occur.
8.2.7 Artificial weathering test
Coated steel test plates shall be exposed for 2000 h to artificial weathering, in accordance with
BS 3900: Part F3, and shall show no signs of deterioration, apart from superficial chalking.
8.3 Thermal stability test
8.3.1 General requirements
The Contractor shall ensure that the test specified in 8.3.2 is carried out in duplicate by the Manufacturer and
the results of the test, demonstrating compliance, made available.
8.3.2 Test conditions
Coated steel test plates shall be exposed to dry heat at 50
0
C for three months to determine thermal stability
and shall still meet the full requirements of this specification.
9. QUALITY CONTROL REQUIREMENTS
9.1 Before dispatch from the factory, the Manufacturer shall carry out sampling and testing of the
manufactured material covered by this specification in accordance with 9.2, 9.3 and 9.4.
9.2 During the production of each separate batch of powder or twice every 8 h of continuous production
(whichever is the more frequent), the tests specified in 6.2 to 6.7 inclusive shall be carried out.
9.3 At least once every 8 h of continuous production, the tests specified in 8.1.2 to 8.1.9 inclusive shall
be carried out.
9.4 The tests specified in 7.2 to 7.7 inclusive and in 8.2.2, 8.2.3 and 8.2.4 and the requirements of 6.8
shall be carried out once per year.
9.5 Any time a production, source, process or formulation change is made to the coating system, the
tests specified in 7.2 to 7.7 inclusive, 8.2.2 to 8.2.8 inclusive and the requirements of 6.8 shall be carried out.
10. COMPLIANCE
The coating material shall not be dispatched until it has been demonstrated that the Manufacturers inspection
and testing complies with the requirements of this specification.
CW6: Part 1
- 8 - J229b ( Rev 08/98)
SECTION THREE - BASIC PROPERTIES AND TESTS OF MULTI-COMPONENT LIQUID
COATING MATERIALS AND CURED COATING
11. BASIC PROPERTIES OF UNMIXED COATING MATERIALS
11.1 General
This Section Three covers multi-component liquid systems suitable for both spraying and brush application.
The Contractor shall obtain, from the Manufacturer, specified and qualified ranges of values for all properties,
listed in 11.2 to 11.8 inclusive, that will ensure an acceptable coating. The frequency of testing shall be in
accordance with 14.2.
11.2 Total non-volatile content
The total non-volatile content shall be specified by the Manufacturer for each individual material component
as supplied. The method of test shall be in accordance with the method given in BS 3900: Part B2.
11.3 Viscosity
The viscosity of each material component as supplied, and that of the mixture when prepared for use in the
correct ratio, shall be specified by the Manufacturer, together with the method of test.
11.4 Relative density
The relative density of each material component as supplied, and that of the mixture when prepared for use in
the correct ratio, shall be specified by the Manufacturer, together with the method of test.
11.5 Mixing ratio
The mixing ratio of material components shall be specified by the Manufacturer, both by weight and by
volume.
11.6 Pot life
The pot life measured in accordance with the definitions contained in BS 2015 shall be quoted by the
Manufacturer.
11.7 Flash point
The flash point of each material component as supplied, and that of the mixture when prepared for use, shall
be specified by the Manufacturer
11.8 Stability
The separate material components when stored at 20
0
C to 25
0
C for a period of 6 months shall:
a) Show no signs of hard settlement.
b) Show no deterioration in application properties.
c) Show no deterioration in curing properties.
The separate material components, when stored in closed containers approximately 75 mm diameter x 75 mm
high, two-thirds full at 20
0
C to 25
0
C for 24 h, shall not show signs of skinning or other deterioration.
12. BASIC PROPERTIES OF DETACHED COATING FILM
12.1 General requirements
The Contractor shall ensure that the tests specified in 12.2 to 12.7 inclusive are carried out by the
Manufacturer at the frequency specified in 14.4. The tests shall be carried out on detached coating samples
which have been prepared by application on to polished steel plates, 6 mm thick, previously coated
CW6: Part 1
J229b ( Rev 08/98) - 9 -
with PTFE. The coating shall be applied to give a minimum dry film thickness of 1.5 mm and allowed to cure
at 20
0
C to 25
0
C and 60% to 70% relative humidity for a period of seven days to achieve optimum
properties before test. Samples shall be of uniform thickness for all tests.
12.2 Micro-sectioning
A cross-section of the cured film shall be examined at a magnification of X100 and shall be seen to be
homogeneous and essentially free of voids or other defects.
12.3 Tensile strength
Test specimens of detached coatings shall be tested at an extension rate of 1 mm/min. Values for tensile
strength shall be quoted in MN/m
2
as maximum strength and strength at break.
12.4 Elongation
When tested in accordance with 12.3, the elongations at 'yield' and 'break' shall be quoted by the
Manufacturer.
12.5 Dielectric strength
The dielectric strength of the cured material shall be quoted by the Manufacturer as kV/mm together with the
method of test.
12.6 Water permeability
The water permeability of the cured material, expressed as g/24 h m
2
/mm thickness shall be specified by the
Manufacturer together with the method of test.
12.7 Water absorption
The quantity of water absorbed after three months immersion at 20
0
C shall be quoted by the Manufacturer.
13. BASIC PROPERTIES OF CURED APPLIED COATING
13.1 Physical performance test requirements
13.1.1 General requirements
Coating materials shall develop adequate handling properties within 24 h of application to suit factory or field
conditions.
The Contractor shall ensure that the tests specified in 13.1.2 to 13.1.7 inclusive are carried out in duplicate by
the Manufacturer in accordance with 14.3 and the results of the tests, demonstrating compliance, made
available.
The tests shall normally be carried out on standard steel surfaces which have been blast cleaned, using G34
grit, to BS 7079, Sa 3 quality to produce a profile of between m 50 and m 100 peak to trough height.
Coating application shall normally be by a suitable technique with pre-heating of components, where
necessary. The coating shall be applied to give a dry film thickness of not less than 1.5 mm and allowed to
cure at 20
0
Cto 25
0
C and 60% to 70% relative humidity for a period of 24 h to achieve optimum properties
before test.
Testing of applied coatings shall be carried out seven days after the coating application.
13.1.2 Cissing and pinholing test
The coating shall show no signs of cissing or pinholing when applied to a prepared steel panel. In cases of
doubt, a further test may be carried out by applying the coating to a grit roughened glass panel and examining
it by viewing over a bright light source.
CW6: Part 1
- 10 - J229b ( Rev 08/98)
13.1.3 Blistering and appearance test
The coating shall show no signs of blistering and shall exhibit uniform appearance when examined by either
of the tests specified in 13.1.2.
13.1.4 Sagging test
The coating shall not exhibit sagging when applied to a steel panel in the vertical plane prepared and coated in
accordance with 13.1.1 and which, immediately subsequent to coating, has been placed in a vertical position
and has remained in that position until the coating is dry.
13.1.5 Flexibility test
Steel plates, 50 mm x 300 mm x 6 mm thick, shall be coated in accordance with 13.1.1 and be properly cured.
After bending in accordance with clause B.1 (at a deflection rate of 25 mm/min) over appropriate sized
mandrels, the coating shall not crack, disbond or pinhole and shall pass a holiday test in accordance with
Appendix C.
13.1.6 Impact resistance test
Coated steel plates shall be tested in accordance with Appendix D.
The coating shall withstand a minimum impact of 5 J without resulting in a breakdown or loss of adhesion of
the coating.
13.1.7 Adhesion test
The adhesion test procedure shall be as specified in clauses E.5 and E.6 and the results assessed in accordance
with clause E.7.
13.1.8 Hardness and cure of coating
The hardness and degree of cure of the coating shall be determined and the Manufacturer shall specify the
hardness range to indicate the correct degree of cure of the coating.
13.2 Environmental test requirements
13.2.1 General
The Contractor shall ensure that the tests specified in 13.2.2, 13.2.3 and 13.2.4 are carried out in duplicate by
the Manufacturer in accordance with 14.4 and the results of the tests, demonstrating compliance, made
available.
The tests specified in 13.2.5 to 13.2.8 inclusive shall be carried out once to provide evidence of satisfactory
long term performance.
13.2.2 Cathodic disbondment test
Sample panels shall be tested by the procedure specified in Appendix F. The coating, when subjected to an
impressed current at a negative voltage of 1500 mV at 20
0
C, shall not disbond for greater than 5 mm radius
from the edge of the damaged coating after 28 days.
13.2.3 Strain/polarization cracking test
The sample panels shall be subjected to a bend strain at 20
0
C and then polarized and tested as specified in
Appendix G with the test area selected on the minimum radius of the bend, i.e. area of maximum strain.
13.2.4 Water immersion test
The sample panels shall be subjected to a water immersion test as specified in Appendix E. The test shall
show no loss of adhesion greater than 3 mm after 28 days.
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J229b ( Rev 08/98) - 11 -
13.2.5 Humidity resistance test
Coated steel test plates shall be exposed for 2000 h in accordance with BS 3900: Part F2. Coating shall not
lose adhesion and no underfilm corrosion or blistering of the film shall occur.
13.2.6 Salt spray resistance test
Coated steel test plates shall be exposed for 2000 h to continuous salt spray conditions in accordance with
BS 3900: Part F4. Coating shall not lose adhesion and no underfilm corrosion or blistering of the film shall
occur.
13.2.7 Artificial weathering test
Coated steel test plates shall be exposed for 2000 h to artificial weathering, in accordance with BS 3900:
Part F3, and shall show no signs of deterioration, apart from superficial chalking.
13.3 Thermal stability test
13.3.1 General
The Contractor shall ensure that the test specified in 13.3.2 is carried out in duplicate by the Manufacturer
and the results of the test, demonstrating compliance, made available.
13.3.2 Test conditions
Coated steel test plates shall be exposed to dry heat at 50
0
C for three months to determine thermal stability
and shall still meet the full requirements of this specification.
14. QUALITY CONTROL REQUIREMENTS
14.1 Before dispatch from the factory, the Manufacturer shall carry out sampling and testing of the
manufactured material covered by this specification in accordance with 14.2, 14.3 and 14.4.
14.2 During the production of each separate batch or twice every 8 h of continuous production
(whichever is the more frequent), the tests specified in 11.2, 11.3 and 11.4 shall be carried out. The
requirements of 11.5 to 11.8 inclusive shall also be met.
14.3 At least once every 8 h of continuous production, the tests specified in 13.1.2 to 13.1.7 inclusive
shall be carried out.
14.4 The tests specified in 12.2 to 12.7 inclusive and in 13.2.2, 13.2.3 and 13.2.4 (considered as type
tests) and the requirements of 11.8 shall be carried out once per year or at any time a production, source,
process or formulation change is made to the coating system.
15. COMPLIANCE
The coating material shall not be dispatched until it has been demonstrated that the Manufacturers inspection
and testing complies with the requirements of this specification.
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J229b ( Rev 08/98) - 13 -
APPENDIX A
METHODS FOR THE EVALUATION OF THE THERMAL CHARACTERISTICS OF POWDER AND
CURED COATING
A.1 INTRODUCTION
This appendix details methods by which the thermal characteristics of a powder (see clause A.2) and the
thermal characteristics of cured coating (see clause A.3) can be evaluated.
A.2 EVALUATION OF THERMAL CHARACTERISTICS OF POWDER
A.2.1 Principle
The method for the determination of powder reactivity and glass transition temperatures of powder consists of
heating the powder at a constant rate in a DSC. A first trace is made which records thermal changes in the
sample between ambient temperature and some point after full cure. When full cure is achieved, the sample is
cooled rapidly to ambient temperature and a second DSC run is carried out. Values for glass transition
temperature and heat of cure can be derived from the trace. Confirm the accuracy of both axes by calibration
before powder testing is carried out.
A.2.2 Apparatus
The apparatus used shall be a DSC* with sufficient calorimetric sensitivity to respond to the glass transition
temperature of the powder (the thermal analysis curve shall be capable of displaying the heat flow rate at a
sensitivity of not less than cm / W 400 ). Additionally, the following accessories will be required:
*There are a number of DSC machines available and correlation shall be demonstrated.
a) Aluminium sample pans.
b) Quench cooling accessory.
c) Analytical balance capable of weighing to an accuracy of 0.1 mg.
d) Liquid nitrogen or other cooling fluid. Alternatively, a DSC with a built-in cooling device is
acceptable provided it can cool the sample rapidly at the rate required in the method.
A further device is required to measure the area under the cure exotherm (see A.2.5.6).
A.2.3 Calibration of the Differential Scanning Calorimeter
A.2.3.1 Temperature axis calibration
A method suitable for checking the temperature axis calibration is as follows:
a) Calibrate the upper temperature scale of the DSC using samples of pure indium, tin and lead
which have melting points of 156.6
0
C, 231.9
0
C and 327.4
0
C respectively.
b) Melt the metal samples in open pans in either static air or under inert gas purge, depending on
the test procedure being followed.
c) Take the melting point as the intersection of the leading edge of the fusion endotherm with the
projected baseline.
The results obtained are influenced by the scan rate, therefore adjust the instrument such that these values are
correct at the scanning rate employed in the test, i.e. 20
0
C/min.
CW6: Part 1
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In practice, melting points are usually within 2
0
C to 3
0
C of the accepted values when determined at
a 20
0
C/min scan rate and this is found to be adequate for Tg measurements of the coating film. If the
measured value differs from the true value by more than 2
0
C to 3
0
C, recalibrate the temperature axis.
A.2.3.2 Theory of calorimetric calibration
The mV signal which drives the pen in the Y direction is a measure of the rate of heat absorbed or evolved
and is derived from the following equation:
dt
dh
= K
1
Y
where Y = difference in Y-axis deflection between the sample and empty pan curves at the
temperature of interest, measured in units of length (centimetres, inches, etc.).
K
1
= proportionality constant, made up of:
a) The signal attenuation setting on the Y-axis, i.e. q
s
(Y axis range in mW or equivalent).
b) The cell calibration coefficient E (dimensionless).
The cell calibration coefficient E can be determined at any given temperature through the use of a material of
known specific heat (e.g. sapphire (
3 2
O 1 A )) using the following equation:
E =
Y q
m H C
s
r P

....................... (1)
where C
P
= specific heat of sample at the temperature of interest.
H
r
= heating rate.
m = sample mass.
Equation (1) is derived from another equation (2), which relates the heat release (or absorption) to the area of
the event on the thermogram, i.e.:
H =
M
A
(B E q
s
) ....................... (2)
where H = heat released.
A = area of the exotherm.
B = time base setting (see A.2.5.3 e)).
The heat release is a function of the specific heat of the test material and equal to:
H =
Y
1
AB H C
r P

....................... (3)
Therefore, if this is substituted in equation (2) and transposed, we arrive at the equation for E.
Alternatively, the cell constant may be determined by relating the latent heat fusion of the pure material
(e.g. iridium) to the area produced from the melting endotherm.
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J229b ( Rev 08/98) - 15 -
A.2.3.3 Method for determining the cell coefficient E
A.2.3.3.1 Place two empty pans in the DSC cell and run a temperature programme between ambient
temperature and 300
0
C. If the trace is not almost horizontal, the baseline slope control shall be adjusted until
the best line is achieved. A typical temperature calibration chart is shown in Figure A.1.
A.2.3.3.2 Load the sample pan with a weighed sapphire disc for a second run. Heat the pan up to the initial
ambient temperature and hold until equilibrium is obtained. This shall be achieved by setting the starting
temperature to ambient temperature and running in isothermal mode.
A.2.3.3.3 Run a second trace using the same final temperature as is used in A.2.3.3.1.
A.2.3.3.4 Measure several values for Y, the vertical difference between the traces, to calculate E values at
these points. The average of E over the range of interest shall be used.
A.2.4 Sampling
When it is necessary to sample large amounts of powder from the sample batch (e.g. several kilogram boxes),
take representative amounts (approximately 50 g) from each container, mix together and sample by coning
and quartering. Analyse different batches separately.
Take a final sample (approximately 250 g) and store it in an airtight container, at a temperature not higher
than 0
0
C, in case subsequent testing is required. When the cold sample is taken from cold storage, allow at
least 30 min in its closed container to reach ambient temperature. Take powder for DSC tests directly from the
250 g sample.
When amounts of powder less than 1 kg are involved, coning and quartering or riffle sampling is not
necessary.
Record the following information for each sample:
a) Date.
b) Time.
c) Powder lot number/batch number.
A.2.5 Test procedure
A.2.5.1 Instrument setting
The test procedure and instrument settings depend upon the design of equipment employed. However, there
are certain essential features in the test method which shall be followed if consistent and comparable results
are to be obtained.
Where applicable, select a baseline slope setting which gives a virtually horizontal line when the reference
and sample pans are loaded identically. This is normally carried out with empty pans.
A.2.5.2 Preparation of test samples
Weigh out accurately between 10 mg and 15 mg of powder into an aluminium sample pan. Heavier weights
(up to 25 mg) may be used, if needed, to give adequate sensitivity. The accuracy of weighing shall be
0.1 mg.
A.2.5.3 Standard air test
Carry out the standard air test under the following conditions:
a) Use open pans throughout.
b) Use an empty aluminium pan for the reference.
CW6: Part 1
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c) No purge gas is employed; carry out the test in static air at atmospheric pressure.
d) Appropriate experimental data recording conditions.
e) If exothermal areas are to be recorded accurately, it may be necessary with some instruments
to change from a temperature base on the abscissa to one of time before the onset of cure.
f) Heat the sample from ambient temperature to 280
0
C at a rate of 20
0
C/min and record the
trace. Rapidly cool the sample to ambient temperature. Repeat this procedure for the second
run, except that this run may be terminated at approximately 20
0
C in excess of the second run
glass transition temperature (Tg
2
).
The test temperature of 280
0
C may be subject to change depending on the type of coating material under test.
It should be advised by the powder manufacturer.
A.2.5.4 Inert gas test
Carry out the inert gas test as for the standard air test (see A.2.5.3), using an inert gas purge instead of static
air throughout the test. A flow rate of 40 ml/min shall be used.
A.2.5.5 Measuring the glass transition temperature
The glass transition temperature (Tg) is defined as that temperature (or temperature range) at which the
coating polymer is transformed from a hard and often brittle material (the glass) into a tough, rubber-like
material.
The glass transition temperature of the cured material is visible on the DSC trace as a baseline shift, resulting
from a marked step-like change in specific heat at Tg, the step usually covering several degrees. It is
conventional to take Tg as the point of intersection of the extrapolated baseline at the low temperature end and
the tangent of the curve at the inflection point (see Figure A.2). For raw powders, the Tg usually takes the
form of a baseline shift with a superimposed endothermic peak (see Figure A. 3).
A.2.5.6 Measuring the heat released during cure
It is necessary to measure the area under the curing exotherm either in the determination of thermal stability,
or when the quality of oversprayed powder is in question.
There are several ways of measuring the exothermal area which vary in their accuracy. These are:
a) Electronic integration using a computer or a dedicated integrator.
b) Planimeter.
c) Cut out the exothermal area marked on the chart paper, weigh it and compare it with the
weight of a known area of the same paper.
d) Count the squares within the exothermal area marked on the chart paper.
One of these, or a similar method, shall be selected for use with the DSC.
The points at which the cure exotherm commences and ends are used to calculate the heat release. They are
usually determined by drawing in the baseline to the exotherm using a rule. Care must be taken to distinguish
between the onset of cure (T
oc
) and the onset of flow (T
of
) and to commence the baseline at T
oc
(see Figure A. 3).
A.3 MEASUREMENT OF DEGREE OF CURE OF POWDER COATING
A.3.1 Principle
The method of assessment of the cure of the powder coating film cure by measurement of its glass transition
temperature consists of heating a ground coating sample at a constant rate in a DSC. A first trace is made
CW6: Part 1
J229b ( Rev 08/98) - 17 -
which records thermal changes in the sample between ambient temperature and some point after full cure as
defined by the powder manufacturer. The sample is cooled to ambient temperature and a second run carried
out. The glass transition temperatures before and after heating are determined and are used to assess the
degree of cure. It is essential that samples are initially pretreated in the calorimeter to remove moisture and to
confer a uniform thermal history.
A.3.2 Apparatus
The apparatus used shall be a DSC with sufficient calorimetric sensitivity to respond to the glass transition
temperature of the materials under test (the thermal analysis curve should display the heat flow rate at a
sensitivity of cm / W 400 minimum). Additionally, the following accessories will be required:
a) Aluminium sample pans.
b) Quench cooling accessory.
c) Analytical balance capable of weighing to an accuracy of 0.1 mg.
d) Liquid nitrogen or other cooling fluid. Alternatively, a DSC with a built-in cooling device is
acceptable provided it can cool the sample rapidly at the rate required in the method.
e) Hammer and cold chisel.
f) Microhammer mill or equivalent.
A.3.3 Temperature axis calibration
The method to be used for checking the temperature axis calibration is as follows:
a) Calibrate the upper temperature scale of the DSC using samples of pure indium, tin and lead
which have melting points of 156.6
0
C, 231.9
0
C and 327.4
0
C respectively.
b) Melt the samples in open pans in either static air or under an inert gas purge, depending on the
test procedure being followed.
c) Take the melting point as the intersection of the leading edge of the fusion endotherm with the
projected baseline.
The results obtained are influenced by the scan rate, therefore adjust the instrument such that these values are
correct at the scanning rate employed in the test, i.e. 20
0
C/min.
In practice, melting points are usually within 2
0
C to 3
0
C of the true values when determined at a
20
0
C/min scan rate and this is found to be adequate for Tg measurements of the coating film. When the
temperature deviation is higher than this, it is necessary to adjust the sample thermocouple reference junction.
If adjustment has been necessary to bring within limits, carry out a further calibration to demonstrate that the
instrument is calibrated accurately.
A.3.4 Sampling
Remove coating film samples from the coated component using a hammer and cold chisel. This produces
furled coating flakes. Care should be taken to remove samples of full film thickness, but at the same time
avoid the inclusion of steel debris.
Sample a component at several points along its length and around its circumference. Take samples from test
panels in a similar manner.
Collect the coating flakes in a plastics bag and identify. Grind the flakes to pieces small enough to pass
through a 2.8 mm aperture sieve in a microhammer mill. Record the following information for each sample:
CW6: Part 1
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a) Date.
b) Time.
c) Component number.
d) Sequence number.
e) Powder lot number/batch number.
f) Location of sample on component.
A.3.5 Test procedure
A.3.5.1 Instrument setting
The test procedure and instrument settings used depends upon the design of equipment involved. However,
there are certain essential features in the test method which shall be followed if consistent and comparable
results are to be obtained.
Where applicable, select a baseline slope setting which gives a virtually horizontal line when the reference
and sample pans are loaded identically. This is normally carried out with empty pans.
A.3.5.2 Preparation of test samples
Weigh out accurately between 10 mg and 15 mg of ground coating into an aluminium sample pan. Heavier
weights (up to 25 mg) may be used, if needed, to give adequate sensitivity. The accuracy of weighing shall
be 0.1 mg.
A.3.5.3 Standard air test
Carry out the standard air test under the following conditions:
a) Use open pans to assist the release of moisture from the sample during pretreatment.
b) Use an empty aluminium pan for the reference.
c) No purge gas is employed; carry out the test in static air at atmospheric pressure.
d) Appropriate experimental data recording conditions.
e) It will normally be necessary to subject the coating sample to thermal pretreatment before
assessment of its degree of cure. Pretreatment is designed to remove any absorbed moisture
from the coating because moisture is known to influence glass transition temperature
measurements. Such pretreatment shall not significantly advance the cure of the coating
sample.
The powder Manufacturer should specify the thermal pretreatment required for the product.
This will typically require heating the sample in the DSC cell from ambient temperature
(i.e. 20
0
C to 25
0
C) to some defined temperature higher than 100
0
C, probably in the range
100
0
C to 150
0
C. This required temperature will typically be attained within 120 s and held
for a period up to 60 s. Immediately cool the sample to ambient temperature with liquid
nitrogen or a suitable cooling fluid; alternatively, a DSC with a built-in cooling device is
acceptable provided it can cool the sample rapidly at the rate required in the method.
Make a suitable record of the pretreatment run.
f) Heat the sample from ambient temperature to a temperature specified by the Manufacturer, at
a rate of 20
0
C/min, so that the sample achieves full cure, but avoids significant degradation.
Rapidly cool the sample to ambient temperature using liquid nitrogen or a suitable cooling
fluid. This establishes the first glass transition temperature (Tg
1
).
Repeat the procedure for the second run, except that this run may be terminated at
approximately 20
0
C higher than the second glass transition temperature (Tg
2
).
CW6: Part 1
J229b ( Rev 08/98) - 19 -
Make pen records of both (Tg
1
) and (Tg
2
) runs.
A.3.5.4 Inert gas test
Carry out the inert gas test as for the standard air test (see A.3.5.3), using an inert gas purge instead of static
air throughout the test. Use a flow rate of 40 ml/min throughout the test.
A.3.5.5 Measuring the glass transition temperature
The glass transition temperature (Tg) is defined as that temperature (or temperature range) at which the
coating polymer is transformed from a hard and brittle material (the glass) into a tough, rubber-like material.
The glass transition temperature is visible on the DSC trace as a baseline shift, resulting from a marked
step-like change in specific heat at Tg, the step usually covering several degrees. It is conventional to take Tg
as the point of intersection of the extrapolated baseline at the low temperature end and the tangent of the curve
at the inflection point (see Figure A.2).
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FIGURE A.1 - Typical temperature calibration
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J229b ( Rev 08/98) - 21 -
FIGURE A.2 - Typical DSC traces - Glass transition temperature
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FIGURE A.3 - Typical DSC traces - Enthalpy H
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J229b ( Rev 08/98) - 23 -
APPENDIX B
FLEXIBILITY TEST
B.1 LABORATORY PREPARED TEST PANELS
B. 1.1 Apply the coating to steel plates 50 mm x 300 mm x 6 mm thick and properly cure. Bend (at a
deflection rate of 25 mm/min) over appropriate sized mandrels (see B. 1.2) at two substrate test temperatures
(5
0
C and 20
0
C). After bending, the coating shall not crack, disbond or pinhole when holiday tested in
accordance with Appendix C. Inspect plates immediately after bending and again after 24 h at 20
0
C.
B.1.2 Select mandrel sizes according to the following formula:
D =
S
S t ) 1 (
where D = mandrel diameter, in mm (see Figure B.1).
t = plate thickness, in mm.
S = one of the values in clause B.3 depending on the intended coating application and
the temperature of the test.
The arc length of the mandrel shall be fixed at 225 25 mm.
B.1 .3 Set the panel support gap set according to the following formula:
Support gap = M + 2t + 4 mm
where M = chord length across the mandrel arc, in mm (see Figure B.1).
t = plate thickness, in mm.
Bend the panel until it makes contact with the entire surface area of the mandrel.
B.1 .4 During bending, peaking (point at which a gap occurs between the mandrel and the panel) may be
observed at the centre of the panel. In this case, the area of the panel where the gap exceeds 0.254 mm
(0.010 in.) shall be disregarded in evaluating the test results. This area shall not exceed 25% of the mandrel
surface area.
B.2 TESTS ON PIPE SPECIMENS
B.2.1 Cold cut test specimens 356 mm long x 50 mm wide from a pipe section with the long axis in the
circumferential direction. Where seamless pipe is being tested, select specimens which show a minimal
variation in pipe wall thickness, particularly within the test area (i.e. middle 75 mm to 100 mm of specimen).
Bend the test specimens over appropriate sized mandrels at two substrate test temperatures (5
0
C
and 20
0
C). After bending, the coating shall not exhibit visible signs of cracks, disbonding or pinholes and
shall pass a holiday detection test when tested in accordance with Appendix C. Inspect specimens immediately
after bending and again after 24 h at 20
0
C.
B.2.2 Select mandrel sizes according to the following formula:
D
1

= t
t D
1
t
S
1
o

+
CW6: Part 1
- 24 - J229b ( Rev 08/98)
where D
1
=

mandrel diameter, in mm.
D
o
=

original specified pipe outside diameter, in mm.
t = pipe wall nominal thickness, in mm.
S = one of the values specified in clause B.3 depending on the intended coating
application and the temperature of the test.
B.2.3 The arc length of the mandrel shall be fixed at 225 25 mm.
B.2.4 For specimens from pipes having an outside diameter in the range 406 mm to 1219 mm, set the
panel support gap according to the following formula:
Support gap = M + 2t + 4 mm
where M = chord length across the mandrel arc, in mm (see Figure B.1).
t = plate thickness, in mm.
Bend the specimen until contact is made with 75 10% of the mandrel area.
B.2.5 For specimens from pipes having an outside diameter in the range 305 mm to 405 mm, set the panel
support gap according to the following formula:
Support gap = M + 2t + 29mm
where M = chord length across the mandrel arc, in mm (see Figure B.1).
t = plate thickness, in mm.
Bend the specimen until it makes contact with the entire surface area of the mandrel.
Test specimens from pipes having an outside diameter below 305 mm by an appropriate method.
B.2.6 During bending, peaking (point at which a gap occurs between the mandrel and the panel) may be
observed at the centre of the panel. In this case, the area of the panel where the gap exceeds 0.254 mm
(0.010 in.) shall be disregarded in evaluating the test results. This area shall not exceed 25% of the mandrel
surface area.
B.3 S VALUES
B.3.1 For coatings intended for use on fittings, the following S values shall apply:
S = 0.005 at a temperature of 5
0
C.
S = 0.01 at a temperature of 20
0
C.
B.3.2 For coatings intended for use on line pipe, the following S values shall, apply:
S = 0.02 at a temperature of 5
0
C.
S = 0.03 at a temperature of 20
0
C.
B.4 TESTING AT 5 C
0
Testing at 5
0
C may be carried out by pre-cooling the panel in a refrigerator to a temperature slightly lower
than 5
0
C and carrying out the bending operation when the panel temperature reaches 5 2
0
C.
Alternatively, an environmental chamber which controls the temperature in the bending apparatus may be
used. The test specimens shall not be immersed in any liquefied coolant to achieve the test temperature.
CW6: Part 1
J229b ( Rev 08/98) - 25 -
FIGURE B.1 - Typical mandrel for flexibility tests
CW6: Part 1
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APPENDIX C
HOLIDAY DETECTION OF COATINGS
C.1 EQUIPMENT
Holiday detection shall be carried out using dc, non-pulsing holiday detection equipment on surfaces at
temperatures below 90
0
C and free from moisture.
C.2 OPERATING VOLTAGE
The operating voltage shall be 125 V per m 25 of coating thickness.
The rate of travel of the probe over the surface shall not exceed 300 mm/s.
C.3 ELECTRODE TYPE
For all coating systems the wire brush type of electrode shall be used, suitably curved to conform to the
contour of the coated surface of pipe. For fittings, a suitable procedure shall be agreed with the coating
applicator and shall normally be the one that is approved within the procedure qualification.
C.4 IDENTIFICATION METHOD
All holidays shall be identified with a waterproof marker.
C.5 EQUIPMENT CALIBRATION
All holiday detectors shall be calibrated at the beginning of every working day and, additionally, when
requested by Transco.
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J229b ( Rev 08/98) - 27 -
APPENDIX D
EVALUATION OF RESISTANCE TO IMPACT
D.1 GENERAL
The procedures specified in clauses D.2 to D.6 inclusive serve to assess the comparative resistance of
coatings to impact damage.
D.2 TEST EQUIPMENT
The following test equipment will be required:
a) A variable impact tester (ASTM G14-77, paragraph 4.2 or equivalent) with punch hammer
type indentor modified as shown in Figure D.1 to accommodate a 14.3 mm diameter ball
bearing and equipped with a minimum impact mass of 1 kg.
b) A sufficient supply of 14.3 mm diameter ball bearings manufactured from EN31 steel with a
Vickers hardness of 800 to 930.
c) A holiday detector (see Appendix C).
d) A thickness gauge.
e) Repair materials.
D.3 TEST PROCEDURE ON COMPONENTS
D.3.1 Check the test site to ensure that it is free from holidays with the holiday detector set at the required
voltage for the particular coating film (see clause C.2).
D.3.2 Position the impact tester on a holiday free site 300 50 mm from one end of the component.
D.3.3 Drop the impact weight from a height calculated to impart the specified impact energy to the
coating. The impact height may be calculated using the following formula:
H =
W 81 . 9
J
where H = impactor height, in m.
W = impactor mass, in kg.
J = impact energy, in joules.
D.3.4 Retest the impact area for holidays using the detector set at the required operating voltage
D.3.5. Repeat D.3.2, D.3.3 and D.3.4 at four more locations evenly spaced over the surface of the
component.
D.3.6 Rotate the ball bearing after each impact.
D.3.7 After every 20 impacts fit a new ball bearing.
D.3.8 If a holiday is caused by the impact test, check the coating thickness in the test area using a
thickness gauge.
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D.4 REPAIR PROCEDURE FOR COMPONENTS
Repair any holiday caused by impact testing using repair materials.
D.5 TEST PROCEDURE ON PANELS
D.5.1 Test sample panels (300 mm x 50 mm x 6 mm) and test panels (300 mm x 50 mm) cold cut from
component in the longitudinal direction according to the procedure detailed in ASTM G14-77, paragraphs
6 to 9, using the apparatus detailed in clause D.2 a). The additional modifications to the ASTM procedure
specified in D.5.2 to D.5.6 inclusive shall apply.
D.5.2 Test impact areas for failure using the holiday detector set at a voltage of 125 V per m 25 of
coating thickness (this relates to coating thickness before impact damage).
D.5.3 The minimum spacing between impacts along the centre line of the specimen shall be 25 mm.
D.5.4 Rotate the ball bearing after each impact.
D.5.5 After every 20 impacts fit a new ball bearing.
D.5.6 Increase the height by an increment of 10 mm between impacts.
D.5.7 There shall be no disbonding at the minimum impact energy. Verify this by testing in accordance
with clause E.6 and report in accordance with clause E.7.
D.6 REPORTING RESULTS
D.6. 1 If the coating withstands the specified impact energy without forming a holiday, the test shall be
recorded as a 'Pass'. If a holiday is formed at the specified impact energy, the test shall be reported as 'Fail at
thickness of...' and the measured coating thickness shall be recorded.
D.6.2 The impact strength shall be converted to impact energy in joules and this value shall be reported.
(A typical calculation is shown in Figure D.1).
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FIGURE D.1 - Impactor and typical calculation
CW6: Part 1
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APPENDIX E
EVALUATION OF RESISTANCE TO WATER IMMERSION
E.1 GENERAL
The equipment and procedure detailed in clauses E.2 to E.7 inclusive shall be used to assess the comparative
resistance of coatings applied to components (free of holidays) to loss of adhesion due to water absorption.
E.2 EQUIPMENT
The following equipment will be required:
a) A water bath which shall be maintained at a temperature of 50 2
0
C.
b) A holiday detector.
c) Internal pipe coating material (complying with CM2).
d) 6 mm diameter twist drill.
e) Pointed sharp knife, e.g. Stanley type or similar.
f) 5 mm diameter steel rod 450 mm long.
g) Elastomeric adhesive for repairing test areas, e.g. Silastic silicone-rubber, grades RTV 738 or
RTV 732 or equivalent.
E.3 SAMPLE PREPARATION
E.3.1 Laboratory prepared specimens
Prepare 300 mm x 50 mm x 6 mm panels under conditions of application and cure similar to those for a
coated component.
E.3.2 Specimens taken from components
Cold cut 300 mm x 50 mm specimens from a sample pipe or, in the case of a fitting, from the pipe pup which
has been coated as a test piece.
E.4 PREPARATION OF TEST AREA
E.4.1 To ensure freedom from holidays, test the prepared panels for holidays with the holiday detector set
at the required voltage (see clause C.2).
E.4.2 Drill a 6 mm diameter hole through the test panel within 25 mm of one end.
E.4.3 Protect the bare metal of the panel with internal coating material (see clause E.2 c)).
E.5 INITIAL TEST PROCEDURE
E.5.1 Carry out an initial adhesion test as described in clause E.6.
E.5.2 Using the steel rod fitted through the 6 mm diameter hole, suspend the specimen panel in the water
bath immersing all but the top 50 mm of the panel.
E.5.3 At intervals of 24 h, remove the panel from the water bath and allow it to cool to ambient
temperature.
E.5.4 Test the coating adhesion as specified in clause E.6.
E.5.5 Repair the test area using elastomeric adhesive.
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E.5.6 Return the panel to the water bath immediately.
E.5.7 If, after seven days immersion, the coating is retested and is found to be satisfactory, return the
panel to the water bath and repeat the adhesion test at intervals of seven days up to a total immersion time of
28 days.
E.6 INVESTIGATION PROCEDURE
E.6.1 Use one or other of the following procedures (E.6.2, E.6.3) as appropriate.
E.6.2 For all coated components and coatings on panels equal to or less than m 600 thickness, use the
following procedure:
a) Using a sharp pointed knife (e.g. Stanley knife or similar), make two incisions approximately
13 mm long through to the metal surface to form a V with an angle of approximately 30
0
at
the intersection point.
b) Starting at the point of intersection force the coating from the steel substrate using the sharp
pointed knife. Take care to protect the eyes and hands when carrying out this operation.
E.6.3 For laboratory panels with coatings greater than m 600 thickness use the following procedure:
a) Using a small hacksaw blade (e.g. 'Junior' type or similar) make two incisions through to the
metal surface to form an X with an angle of approximately 30
0
at the point of intersection.
b) Draw a sharp knife along the cut lines to ensure that the hacksaw blade has reached the metal
surface.
c) Starting at the point of intersection, force the coating from the steel substrate using the sharp
pointed knife. Take care to protect the eyes and hands when carrying out this operation.
E.7 REPORTING RESULTS
Refusal of the coating to peel or a cohesive failure within the coating shall be recorded as a 'Pass'.
Cohesive failure, caused by voids leaving a honeycomb structure on the specimen surface, shall constitute a
'Fail' condition.
For the purpose of this test, cohesive failure will be recorded where some coating material remains on the
metal surface and where difficulty in coating removal has been experienced.
The extent of the adhesive failure between the coating and the metal substrate shall be recorded.
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APPENDIX F
EVALUATION OF RESISTANCE TO CATHODIC DISBONDING
F.1 GENERAL
The procedures detailed in clauses F.2 to F.8 inclusive serve to assess the comparative resistance of damaged
pipe coatings to disbonding when exposed to cathodic protection in potentially corrosive soils.
F.2 TEST REQUIREMENT
F.2.1 Apparatus
The following apparatus will be required:
a) A stabilized dc power unit having a voltage output of 12 V and a capability to supply 20 mA
simultaneously to each test area in circuit. A suitable circuit is shown in Figure F.1 a).
b) Digital voltmeter, range 1.999 V (3.5 digit), input impedance 10
3
M. Accuracy of 0.1% 1
digit at 20 1
0
C.
c) Variable resistor, range 1 k 10%, 1 W (one required for each specimen).
d) 75 mm length of 0.8 mm diameter platinum wire, or similar length of 6 mm wide, 1.5 mm thick
platinized titanium strip (one required for each test area).
e) Holiday detection equipment.
f) Reference electrode of the saturated calomel type, constructed from glass or plastics with
porous plug. The diameter should be not greater than 10 mm.
g) 6 mm diameter twist drill with included cutting angle of 160
0
.
h) Equipment for maintaining the temperature of the specimens and test area
at 20 2
0
C.
i) A length of rigid plastics pipe per test area to be used as a solution container (approximate
dimensions 60 mm long x 50 mm nominal bore).
j) Elastomeric adhesive for fixing the plastics pipe to the test surface, e.g. a silastic silicone
rubber grade RTV 738 or RTV 732 or equivalent material.
k) Fixed resistor, 1 2%, 1 W (one required for each test area).
F.2.2 Reagent
An electrolyte comprising a sodium chloride (NaCl) solution, (3% W/V). 30 g of NaCl should be dissolved in
distilled water and made up to 1 litre.
F.3 PREPARATION OF TEST PANELS
F.3.1 Laboratory prepared specimens
Sample panels 300 mm x 50 mm x 6 mm shall be prepared simulating the conditions of application for a
factory coated pipe.
F.3.2 Specimens taken from components
Test panels 300 mm x 50 mm shall be cut from a sample production coated pipe.
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F.4 PREPARATION OF TEST AREAS
F.4.1 Test the prepared panels for holidays with the holiday detector set at the required voltage
(see clause C.2).
F.4.2 Fix two lengths of rigid plastics tube perpendicular to the coated surface using a suitable
elastomeric adhesive (see Figure F.1). Place them with their centres on the centre line of the panel width and
equidistant from the panel ends and each other and leave for a period of 12 h to allow the adhesive to fully
cure.
F.4.3 Drill a 6 mm diameter hole through the coating to the metal surface in the centre of each test area
using the drill specified in F.2.1 g).
F.5 INITIAL TEST PROCEDURE
F.5.1 Fill each plastics tube with NaCl electrolyte to a depth of approximately 50 mm (see F.2.2) with the
apparatus set up as shown in Figure F.1 a). Bring the temperature of the specimens and test area
to 20 2
0
C. Maintain this temperature throughout the test period.
F.5.2 Connect a voltmeter and reference electrode to each test rig in turn as shown in Figure F.1 b) With
the tip of the calomel reference electrode positioned approximately 10 mm from the centre of the hole, adjust
the voltmeter reading to read a negative voltage of 1500 mV with respect to the calomel electrode. Carry this
out using the variable resistance shown in Figure F.1 a).
F.5.3 Record, at intervals of 24 h, the voltmeter indication for each test area and adjust the variable
resistor to correct any drift from the negative voltage setting of 1500 mV. Also record, every 24 h, the current
flow by measuring the voltage drop across the 1 fixed resistor.
F.5.4 Every 24 h check the plastics tubes for loss of electrolyte and restore the level with distilled water
as necessary.
F.6 INVESTIGATION PROCEDURE
F.6.1 After seven days, remove the electrolyte and plastics tube from one test site and remove excess
moisture.
F.6.2 Use one or other of the following procedures (F.6.3, F.6.4) as appropriate:
F.6.3 For coatings up to and including m 600 use the following procedure:
a) Using a sharp-pointed knife (e.g. Stanley type or similar), make two incisions
approximately 13 mm long through to the metal surface extending radially from the 6 mm hole
and at an angle of approximately 30
0
to each other to form a truncated V.
b) Starting at the base of the truncated V, force the coating from the steel substrate using the
sharp pointed knife. Take care to protect the eyes and hands when carrying out this operation.
F.6.4 For all coatings in excess of m 600 thickness use the following method:
a) Using a small hacksaw blade (e.g. 'Junior' type or similar), make two cuts across the 6 mm
hole at an angle of approximately 30
0
to each other to form a truncated 'X'. Make the cuts
through to the metal surface and to extend radially from the 6 mm hole.
b) To ensure that the hacksaw blade has reached the metal surface, draw the point of the sharp
knife along the cut lines.
c) Starting at the base of the truncated V, force the coating from the steel substrate using the
sharp pointed knife. Take care to protect the eyes and hands when carrying out this operation.
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F.6.5 Repeat the investigation procedure at the second test site after 28 days.
F.7 REPORTING OF RESULTS
The amount of disbonding shall be quoted as the radial distance from the edge of the pre-damage to which the
coating peels easily from the metal surface.
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J229b ( Rev 08/98) - 35 -
a) Cathodic disbonding test rig
b) Voltage adjustment circuit
FIGURE F.1 - Cathodic disbonding test apparatus
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APPENDIX G
STRAIN/POLARIZATION TEST
G.1 Bend the test sections in accordance with the method detailed in Appendix B using a value
of S = 0.02 for line pipe powders and S = 0.005 for fitting powders at a temperature of 20 2
0
C.
G.2 Polarize the specimens, as detailed in Appendix F, with a single test site selected on the minimum
radius of the bend, i.e. area of maximum strain. After 28 days polarization, remove the electrolyte and plastics
tube and remove excess moisture.
G.3 The area of coating exposed to the electrolyte shall not exhibit signs of cracks, disbondment or
pinholes and shall pass a holiday detection test as detailed in Appendix C.