BRIDGE COATINGS INSPECTOR PROGRAM
CERTIFICATION EXAMINATION TEST 2026
◉ What info should be included when sending samples to a lab?
Answer: 1. Identity of materials 2. Properly packed/labeled samples
3. Chain of custody form 4. Type of analysis that is expected and the
concentrations of interest
◉ Specialized tests or equipment coating inspectors may encounter.
Answer: 1. AA/AE Atomic Absorption/Emission 2. ISP Induction
coupled plasma Spectrometer 3. GLC Gas liquid chromatographs 4.
IR, FTIR, FTIR-ATR INfrared spectrophotometers 5. DSC Differential
scanning calorimeters
◉ What is a cathodic dis-bondment test?. Answer: Procedure to
determine how easily a coating loosens from a substrate or develops
holidays as a result of normal soil potentials
◉ Individuals who perform surveys. Answer: 1. O-Cat or S-cat tech 2.
NACE coating specialist 3. NACE Level III 4. Coating Inspector
w/field experience 5. Coating manufacturer representative 6.
Maintenence engineer with specific plant knowledge.
◉ Coating survey steps. Answer: 1. Understand scope 2. Gather team
3. Develop survey plan 4. Review standards 5. Agree on format 6.
,Delegate various tasks 7. Eveluate existing coating 8. Delegate
various tasks 9. Evaluate existing coating 10. Gather additional info
11. Summarize data 12. Prepare maintenance plans 13. Prepare
reports/input data 14. Submit final survey reports.
◉ List some of the primary reasons surveys are performed. Answer:
1. Plan maintenance. 2. Prioritize work 3. Budgetary concerns 4.
Determine value of assets 5. Legal compliance
◉ Definition of a coating survey. Answer: Gather baseline info
needed to plan maintenance coating procedures
◉ What are faying surfaces and why not galvanize them?. Answer:
Surfaces that depend on friction to hold galvanizing it may/will
reduce friction if they are galvanized
◉ Common problems seen during the usual inspections of HD
galvanized items. Answer: 1. Cracking 2. Peeling 3. Bare spots 4.
Lumps 5. Blisters 6. Flux inclusions 7. Ash inclusions 8. Dross
inclusions
◉ Post galvanizing treatments and why. Answer: To Remove
Thickness: Roll, Wipe, Centrifuge/Air Blast
To change properties/To alloy: Annealing
,◉ Temperature range for galvanizing kettle. Answer: 820-850 F
◉ Purpose of pickling. Answer: Hydrochloric or sulfuric acid bath to
remove oxides and mill scale
◉ Purpose of caustic cleaning. Answer: Acid bath or caustic to
remove dirt, oil and grease
◉ Stages of hot dip process. Answer: 1. Surface prep. 2. Galvanizing
3. Post treatment 4. Inspection
◉ Hot dip galvanizing safety. Answer: 1. Can stay hot for some time
2. Molten metal splash 3. Nascent hydrogen above kettle
◉ Usual layers of galvanized coating consists of:. Answer: 1.
ETA=100% Zn 2. ZETA= 94% Zn 6%Fe 3. DELTA= 90% Zn 10 Fe 4.
GAMMA= 75% Zn 25% Fe
◉ What is hot dip galvanizing?. Answer: Coating iron or steel with
zinc at temperatures of 820-860 F
◉ If a maintenance coating to be applied is incompatible with the
existing coating system__________may occur. Answer: Curling
, ◉ ______________ is performed at the work area by working the edges
of the repaired area back to achieve a fairly smooth transition from
the repair area to sound coating.. Answer: Feathering
◉ With regards to maint. coating all parties should agree
on___________?. Answer: 1. Spot repair requirements 2. Feathering 3.
Appearance of repaired areas
◉ Maint. coating selection process should take the following into
consideration:. Answer: 1. Compatability with existing system 2.
Surface prep. 3. If abrasi ve blast is permitted and feasible
◉ When determining coating system life cycle the following should
be considered:. Answer: 1. Maint. costs 2. Length of coating life 3.
Initial and maint. material costs 4. Intial and maint. labor costs
◉ Life cycle of a coating system can be affected by:. Answer: 1.
Service environment 2. Maint. intervals 3. Coating system chosen 4.
Surface condition
◉ Maint. coating operations are defined as:. Answer: Applying
coating over a substrate that has been installed in its final
environment and placed in service
CERTIFICATION EXAMINATION TEST 2026
◉ What info should be included when sending samples to a lab?
Answer: 1. Identity of materials 2. Properly packed/labeled samples
3. Chain of custody form 4. Type of analysis that is expected and the
concentrations of interest
◉ Specialized tests or equipment coating inspectors may encounter.
Answer: 1. AA/AE Atomic Absorption/Emission 2. ISP Induction
coupled plasma Spectrometer 3. GLC Gas liquid chromatographs 4.
IR, FTIR, FTIR-ATR INfrared spectrophotometers 5. DSC Differential
scanning calorimeters
◉ What is a cathodic dis-bondment test?. Answer: Procedure to
determine how easily a coating loosens from a substrate or develops
holidays as a result of normal soil potentials
◉ Individuals who perform surveys. Answer: 1. O-Cat or S-cat tech 2.
NACE coating specialist 3. NACE Level III 4. Coating Inspector
w/field experience 5. Coating manufacturer representative 6.
Maintenence engineer with specific plant knowledge.
◉ Coating survey steps. Answer: 1. Understand scope 2. Gather team
3. Develop survey plan 4. Review standards 5. Agree on format 6.
,Delegate various tasks 7. Eveluate existing coating 8. Delegate
various tasks 9. Evaluate existing coating 10. Gather additional info
11. Summarize data 12. Prepare maintenance plans 13. Prepare
reports/input data 14. Submit final survey reports.
◉ List some of the primary reasons surveys are performed. Answer:
1. Plan maintenance. 2. Prioritize work 3. Budgetary concerns 4.
Determine value of assets 5. Legal compliance
◉ Definition of a coating survey. Answer: Gather baseline info
needed to plan maintenance coating procedures
◉ What are faying surfaces and why not galvanize them?. Answer:
Surfaces that depend on friction to hold galvanizing it may/will
reduce friction if they are galvanized
◉ Common problems seen during the usual inspections of HD
galvanized items. Answer: 1. Cracking 2. Peeling 3. Bare spots 4.
Lumps 5. Blisters 6. Flux inclusions 7. Ash inclusions 8. Dross
inclusions
◉ Post galvanizing treatments and why. Answer: To Remove
Thickness: Roll, Wipe, Centrifuge/Air Blast
To change properties/To alloy: Annealing
,◉ Temperature range for galvanizing kettle. Answer: 820-850 F
◉ Purpose of pickling. Answer: Hydrochloric or sulfuric acid bath to
remove oxides and mill scale
◉ Purpose of caustic cleaning. Answer: Acid bath or caustic to
remove dirt, oil and grease
◉ Stages of hot dip process. Answer: 1. Surface prep. 2. Galvanizing
3. Post treatment 4. Inspection
◉ Hot dip galvanizing safety. Answer: 1. Can stay hot for some time
2. Molten metal splash 3. Nascent hydrogen above kettle
◉ Usual layers of galvanized coating consists of:. Answer: 1.
ETA=100% Zn 2. ZETA= 94% Zn 6%Fe 3. DELTA= 90% Zn 10 Fe 4.
GAMMA= 75% Zn 25% Fe
◉ What is hot dip galvanizing?. Answer: Coating iron or steel with
zinc at temperatures of 820-860 F
◉ If a maintenance coating to be applied is incompatible with the
existing coating system__________may occur. Answer: Curling
, ◉ ______________ is performed at the work area by working the edges
of the repaired area back to achieve a fairly smooth transition from
the repair area to sound coating.. Answer: Feathering
◉ With regards to maint. coating all parties should agree
on___________?. Answer: 1. Spot repair requirements 2. Feathering 3.
Appearance of repaired areas
◉ Maint. coating selection process should take the following into
consideration:. Answer: 1. Compatability with existing system 2.
Surface prep. 3. If abrasi ve blast is permitted and feasible
◉ When determining coating system life cycle the following should
be considered:. Answer: 1. Maint. costs 2. Length of coating life 3.
Initial and maint. material costs 4. Intial and maint. labor costs
◉ Life cycle of a coating system can be affected by:. Answer: 1.
Service environment 2. Maint. intervals 3. Coating system chosen 4.
Surface condition
◉ Maint. coating operations are defined as:. Answer: Applying
coating over a substrate that has been installed in its final
environment and placed in service
