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Test Name: Concrete Coating Inspector Level 2 Theory Exam
Test Code: ConcreteCtgsIn2
Total Seat Time: 2 Hours (120 minutes)
Number of Questions: 100
Format: Computer-Based Testing (CBT)

1. Ambient Condition (5% - 10%)
2. Coating Application (5% - 10%)
3. Coating Defect (1% - 5%)
4. Coating Inspection (25% - 30%)
5. Coating Material (5% - 10%)
6. Concrete Construction (10% - 15%)
7. Concrete Failure (5% - 10%)
8. Health & Safety (1% - 5%)
9. Project Specification (10% - 15%)
10.Standards (10% - 15%)
11.Surface Preparation (5% - 10%)

1. Ambient Condition

- Relative humidity measurement and effects on coating application
- Dew point calculation and psychrometric charts
- Surface temperature vs. ambient temperature differentials
- Wind speed and its impact on application
- Environmental controls (dehumidification, heating, ventilation)
- Acceptable ranges per standards (e.g., minimum/maximum temperatures)
- Moisture in concrete substrate (vapor transmission, relative humidity in slab)

2. Coating Application

- Spray application techniques (airless, conventional, plural-component)
- Brush and roller application methods for concrete
- Thickness control (wet film thickness gauges, application rates)
- Plural-component spray systems for high-build coatings
- Curing mechanisms (air dry, chemical cure, moisture cure)
- Recoat windows and intercoat adhesion
- Application on vertical/overhead concrete surfaces
- Specialized techniques for thick-film linings and elastomeric coatings

3. Coating Defect

- Blistering (osmotic, solvent entrapment)
- Cracking (mud cracking, checking, alligatoring)
- Pinholes and holidays in thick coatings
- Sagging, runs, and curtain defects
- Delamination and intercoat disbondment
- Fisheyes and cratering from contamination
- Chalkings, fading, and discoloration
- Failure due to substrate moisture or pH issues

4. Coating Inspection

- Pre-application inspection (hold points)
- In-process monitoring of application
- Post-application testing (dry film thickness, adhesion, holiday detection)
- Visual inspection standards (e.g., gloss, color, uniformity)
- Documentation and reporting (daily logs, non-conformance reports)
- Inspection plan development and execution
- Use of destructive vs. non-destructive tests
- Quality control vs. quality assurance roles

5. Coating Material

- Generic coating types (epoxies, polyurethanes, polyureas, cementitious)
- Polymer linings (vinyl ester, novolac)
- Moisture-cure urethanes and penetrating sealers
- High-build and thick-film systems for immersion
- Primers, intermediates, and topcoats for concrete
- VOC-compliant and low-odor formulations
- Material storage, shelf life, and mixing ratios
- Safety data sheets (SDS) interpretation

6. Concrete Construction

- Concrete mix design and additives
- Formwork and placement techniques
- Curing methods (wet cure, membrane cure)
- Reinforcement (rebar placement, cover)
- Joints (construction, expansion, control)
- Common concrete elements (slabs, walls, beams, columns)
- Post-tensioning and prestressing basics
- Repair methods prior to coating

7. Concrete Failure

- Carbonation and chloride ingress
- Alkali-silica reaction (ASR)
- Freeze-thaw damage and scaling
- Sulfate attack and chemical degradation
- Cracking (plastic shrinkage, drying shrinkage, structural)
- Spalling and delamination
- Corrosion of embedded reinforcement
- Abrasion and impact damage

8. Health & Safety

- Personal protective equipment (PPE) for coating work
- Confined space entry procedures
- Hazardous materials handling (isocyanates, solvents)
- Ventilation requirements during application
- Fall protection and scaffolding safety
- Respiratory protection programs
- Hazard communication and SDS
- Emergency response and first aid

9. Project Specification

- Interpretation of coating specifications
- Hold point inspections and approvals
- Deviation requests and non-conformance handling
- Submittal review (product data, mock-ups)
- Contractual requirements and responsibilities
- Pre-job conference agendas
- Specification sections relevant to concrete coatings (e.g., 099600)
- Change orders and field modifications

10. Standards

- AMPP/NACE standards for concrete coatings
- SSPC-SP 13/NACE No. 6 Surface Preparation of Concrete
- ASTM standards (e.g., D4258 moisture testing, D7234 adhesion)
- ICRI Technical Guideline No. 310.2R Selecting and Specifying Concrete Surface Preparation
- ISO standards for coatings and inspection
- ACI standards for concrete repair and protection
- Holiday detection standards (NACE SP0188)
- Adhesion testing (ASTM D7234, D4541)

11. Surface Preparation

- Mechanical methods (abrasive blasting, scarification, grinding)
- Acid etching and neutralization
- Water jetting (hydroblasting) for concrete
- ICRI Concrete Surface Profile (CSP) chips and standards
- Removal of contaminants (oil, grease, laitance)
- Bug hole and void filling/repair
- Moisture testing (calcium chloride, RH probes)
- Cleanliness verification (dust, pH testing)