Activities
10.1 Defects and corrosion or rust
Tutor guidance notes
Aims and objectives
At the end of these activity sheets, learners should be able to:




know how to inspect an area and identify a range of surface defects
choose and use the correct filling agents to repair surface defects
identify areas of corrosion or rust
describe how to remove rust correctly by hand or using power tools.
These questions and activities are not intended as formal assessment. However,
the answers should be discussed with the learners as a group to ensure they
have full comprehension of the subject.
Individual teachers will use these questions and activities in different ways. They
could be used at the end of a session to recap; used individually during the
session as a ‘to-the-point’ learning tool; or used as homework. Whichever
teaching method is chosen, make sure that you set and agree upon a completion
date for each activity.
The answers given are not exhaustive and are to be used as a guide only.
Alternative, appropriate answers may be considered.
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Activities
Candidate name:
Date:
10.1 Defects and corrosion or rust
Chapter 10: Preparation of surfaces
Aims and objectives
At the end of these activity sheets, you should be able to:




1
know how to inspect an area and identify a range of surface defects
choose and use the correct filling agents to repair surface defects
identify areas of corrosion or rust
describe how to remove rust correctly by hand or using power tools.
State four surface defects that you might encounter.
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2
State and describe the two categories of filling agent.
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___________________________________________________________
3
State four tools or pieces of equipment that can be used to remove rust by
hand.
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___________________________________________________________
___________________________________________________________
___________________________________________________________
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Activities
4
What problem can be caused by overuse of a wire brush on rusted metal?
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5
These are the five steps in the procedure for removing rust by hand. What
order should the steps be in? Fill in the numbers 1–5.
Step
Step
Step
Step
Scrape off all loose rust, millscale and previous coatings.
Abrade with a rough aluminium oxide abrasive.
Use a wire brush to remove loose rust, but avoid burnishing.
Remove any traces of oil or grease to avoid spreading it around
the surface.
Step ___ Use a chipping hammer around rusted nails, bolts and rivets.
6
___
___
___
___
What are the advantages of removing rust using power tools, rather than
by hand?
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___________________________________________________________
7
State three power tools that can be used to remove rust, millscale and
existing coatings.
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___________________________________________________________
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8
Describe the procedure for removing rust with power tools.
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Activities
10.1 Defects and corrosion or rust
Chapter 10: Preparation of surfaces
Answers
1
State four surface defects that you might encounter.
holes
cracks
dents
pitting
2
State and describe the two categories of filling agent.
 filler – a smooth paste that is used to fill minor defects such as
shrinkage cracks and nail or screw holes
 stopper – a similar material to filler but better for use on large
holes and cracks
3
State four tools or pieces of equipment that can be used to remove rust by
hand.
scrapers
chipping hammers
wire brushes
abrasives
4
What problem can be caused by overuse of a wire brush on rusted metal?
It can serve to only polish the rust on the surface, which can affect
the ability of the primer to adhere to the surface.
5
These are the five steps in the procedure for removing rust by hand. What
order should the steps be in? Fill in the numbers 1–5.
Step 2 Scrape off all loose rust, millscale and previous coatings.
Step 5 Abrade with a rough aluminium oxide abrasive.
Step 4 Use a wire brush to remove loose rust, but avoid burnishing.
Step 1 Remove any traces of oil or grease to avoid spreading it around the
surface.
Step 3 Use a chipping hammer around rusted nails, bolts and rivets.
6
What are the advantages of removing rust using power tools, rather than
by hand?
quicker; more effective; and the life of the paint system will be
extended
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Activities
7
State three power tools that can be used to remove rust, millscale and
existing coatings.
rotary wire brushes
grinders
needle guns
8
Describe the procedure for removing rust with power tools.
 Remove any traces of oil or grease from the surface.
 Scrape off all loose rust, millscale and previous coatings.
 Use a needle gun to remove rust around corroded nuts, bolts,
rivets etc.
 Select and use the most effective method of removing rust to suit
the nature and condition of the surface (e.g. rotary wire brush,
disc sander or angle grinder).
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