Sample PCS Examination Questions

The comprehensive certification examination and calculation questions consists of multiple choice, matching, essay, and material estimating questions. Questions are chosen primarily from the material covered in the C-1 and C-2 courses and from the suggested readings. Some of the questions can be answered from knowledge acquired by working in the coatings industry. Many of the questions require knowledge of several different subject areas.

Multiple Choice - give best answer

1. Which of the materials listed below is commonly used to make impressed current anodes for cathodic protection?
A. High-purity zinc
B. High-silicon cast iron
C. Electrolytic-grade magnesium
D. Titanium alloy

2. Which of the generic coating types listed below is recommended for service in sea water immersion?
A. Epoxy polyamide
B. Epoxy ester
C. Silicone alkyd
D. Acrylic emulsion

3. What is the upper limit for shadows, streaks, or stains allowed on steel abrasive blast cleaned to a near-white condition?
A. 0%
B. 5%
C. 33%
D. 50%

4. Which if the following spray painting methods listed below has the highest transfer efficiency?
A. Conventional air spray
B. Airless spray
C. High-volume low-pressure spray
D. Electrostatic spray

5. For what purpose is a plastic sheet test used?
A. To prevent early flash rusting
B. To test for coating cure
C. To determine if concrete is dry enough for coating
D. To detect efflorescence

6. Which of the following is NOT a type of payment for coating contracts?
A. Stage payment
B. Balloon payment
C. Incentive payment
D. Penalty payment

7. Who is normally responsible for preparation of a specification for a coating job?
A. An independent inspector
B. The general contractor
C. The owner
D. The coating contractor

8. Which of the following SSPC documents addresses maintenance painting?
A. PA 1
B. PA 3
C. PA 4
D. PA 5

9. Which of the following is a type of coating failure related to aging?
A. Blushing
B. Undercutting
C. Cratering
D. Wrinkling

10. How often are proposed regulations published in the Federal Register?
A. Daily
B. Weekly
C. Monthly
D. Annually

Match the structure with a likely coating or treatment:

1. Steel piping (atmospheric service)
2. Bridge in a severe environment
3. Lining for a chemical storage tank
4. Ships, to prevent fouling
5. New marine pilings

• A. Three coats epoxy-polyamide; two coats coal tar epoxy  
• B. FRP, vinyl ester; or epoxy resin, depending on specific product
• C. Petrolatum paste; microcrystalline wax, tape
• D. Organic zinc-rich primer; epoxy-polyamide midcoat; aliphatic polyurethane topcoat
• E. Copper oxide polymer

Essay:

1. Discuss the differences in surface profiles produced by round steel shot and steel grit.

2. Briefly describe the capabilities of at least two (2) laboratory instruments in conducting a coating failure analysis.

3. State in writing at least six (6) technical problems resulting from specification deficiencies that could adversely effect a coatings project.

4. Facility management has decided to repair damaged coatings on a power plant structure before damage to the substrate occurs. What are at least six (6) basic factors involved in deciding between spot repair and full overcoating?

5. Discuss the advantages and limitations of abrasive blast cleaning, high-pressure water jetting, and power tool cleaning in the removal of existing coatings containing hazardous metals such as lead or cadmium. For each of these three cleaning systems, discuss at least two (2) advantages and at least two (2) disadvantages.

Calculate:

1. A painter needs to apply a coating with 50% solids by volume at 4 mils dry-film-thickness. In order to do this, what should the wet-film-thickness measure be on his British wet-film-thickness gage? (answer in microns)

2. A manufacturer's data sheet indicates that when its coating is thinned by 10%, application at 5 mils WFT will result in 3.5 DFT. What is the % solids by volume of the coating?

3. A laboratory analysis of a new coating indicated that it had 75% total solids by weight and 35% pigment by weight. From these data, calculate the % of binder in the vehicle portion of the coating.

4. A painter is to coat the 20,000 square feet interior of a steel tank with a coating containing 80 % solids by volume at 4 mils dry film thickness. Assuming a 10% loss of coating during the work, how much coating would be required to complete the work?

5. A coating was found by laboratory analysis to contain 25% solvent by volume. What is its theoretical spreading rate at 4 mils DFT when thinned by 10%?

Answers

Multiple Choice: 1) B, 2) A, 3) B, 4) D, 5) C, 6) B, 7) C, 8) C and/or D, 9) B, 10) A

Matching: 1) C, 2) D, 3) B, 4) E, 5) A

Essay: There are multiple ways to answer the essay questions.Calculations: 1) 200 microns, 2) 77%, 3) 61.5%, 4) 69 gallons, 5) 273 per gallon