Alison B. Kaelin, ASQ-CQA KTA-Tator, Inc. Comparison of Documentation, Hold Point and Quality Control Training Requirements in SSPC Contractor QP1, QP3, QP6 and QP8 Standards This one-hour webinar reviews the requirements for training, hold point inspection and documentation in various SSPC QP Standards Alison B. Kaelin, ASQ-CQA KTA-Tator, Inc.

Introduction Webinar Content: General Overview of SSPC QP (PCCP) standards Overview of scope and content of QP1, QP3, QP6, QP8 Comparison of requirements for: Personnel Training Initial Refresher Summary of Required Programs, Technical Capabilities, Quality Control and Safety and Health Required QC Documentation

Learning Objectives/Outcomes Completion of this webinar will enable the participant to: Describe overall QP1, QP3, QP6, QP8 requirements Describe the training requirements for personnel for each standard Understand the minimum program requirements Understand minimum hold points and documentation requirements There are four learning outcomes or objectives for this webinar. Completing this webinar will enable you to: Describe overall QP1, QP3, QP6, QP8 requirements Describe the training requirements for QC and other personnel Understand the minimum required hold points identified in the procedures Document the minimum hold points identified in the procedures

SSPC Contractor Certification Program Based on consensus standards Only nationally recognized program for pre-qualification independent contractor evaluation Each program reviews the painting contractor's ability to provide quality work in compliance with applicable safety, health and environmental standards

Types of SSPC Contractor Certifications QP 1 evaluates contractors who perform surface preparation and industrial coating application on steel structures in the field (2008) QP 6 evaluates the qualifications of industrial thermal spray (metallizing) contractors in the field and shop (2010) QP 8 certification evaluates the qualifications of contractors installing coatings or surfacing on concrete (2003)

Types of SSPC Contractor Certifications QP 3 evaluates a contracting company's ability to perform surface preparation and protective coating application in a fixed shop facility (2010). This is a joint AISC/SSPC Standard Three categories of shop certification: Enclosed Shop Covered Shop Open (Exposed) Shop

Why Do we Need Certified Contractors? Contractor certification covers the entire organization not just specific individuals Contractor certification verifies: Has written program and procedures in place to achieve specified requirements Staff meets minimum requirements for competence, awareness and training Health, safety and environmental compliance Minimum documentation requirements

Management Procedures Each of the standards have requirements for “Management Procedures” Management Procedures include: Policy Commitment for written policies on quality, safety, health and environmental compliance Written procedures for disseminating information throughout the organization

Management Procedures (c0nt.) Organization and Personnel Organizational Chart Names, Titles, Duties and Job Descriptions Biographical Information (QP3 only)

Management Procedures (c0nt.) Administrative and Management Procedures Financial Recordkeeping Review of job specifications and bid documents Procedures for regulatory compliance Identify person responsible for tracking (QP1 only) Procedures of contract estimating, scheduling and cost accounting (QP6 and QP8 only) Procedures for evaluating each job function and required training (QP8 only)

Management Procedures (c0nt.) Administrative and Management Procedures QP1 Only Confirmation by CPA or equal of accounting practices Procedure for distribution of specifications to employees Information of business entity Documentation that subcontractors comply with QP1 requirements

Management Procedures (c0nt.) QP3 only Purchasing procedure and minimum data requirements Subcontractor evaluations Qualification and evaluation of vendors Minimum quality records established Material identification, storage and certification Non-conformances and corrective and preventive action

Technical Capabilities Each of the standards have requirements for “Technical Capabilities” that include: Technical Resources and Libraries Specific standards and resources are defined for each QP program Procedures Procedures for reviewing, logging and transmitting information related to the project to applicable personnel

Technical Capabilities (Cont.) Experience, Facilities and Equipment List of current and recently completed projects including product, scope, personnel, equipment, etc. Equipment maintenance and repair procedures and logs Specific process and inspection instrument equipment (QP3 only) Facility plan and equipment lists (QP3 only)

Technical Capabilities Technical capability requirements related to personnel qualifications vary dramatically between standards and are discussed in multiple sections of each standard Personnel Qualification requirements will be discussed by individual standards at the end of this webinar Make sure to mention WHY they differ. Different committees, different time frames, etc. QP3 is influenced also by AISC requirements and members.

Quality Control – Inspection Procedures Each of the standards have requirements for written Inspection Procedures that include: Applicable standards and specifications System for maintaining records Job specific equipment and calibration requirements Inspection of each major operation or hold point

Quality Control – Inspection Procedures (Cont.) Managing, documenting and reporting Non conformances (QP1, QP3, and QP6 only) Adequate lighting (QP8 only) Concrete specific procedure requirements (QP8 only) QC Manual (QP8 only) Technical Requirements (ASTM D6237) and calibration standards Contract specific requirements Corrective action process (QP1 and QP3 only)

Safety, Health and Environmental Compliance Each of the standards (except QP3) have requirements for written Safety and Health Procedures or Program that include: Documentation of safety education meetings Process for conducting hazard assessments Process for formal management review of safety records and plans on annual basis Personal protection equipment Accident reporting

Safety, Health and Environmental Compliance (Cont.) Documentation of safety education meetings Process for conducting hazard assessments Process for formal management review of safety records and plans on annual basis Personal protective equipment Accident reporting Safety and loss control (QP6 and QP1 only) Provisions for first aid Safety procedures for equipment

Safety, Health and Environmental Compliance (Cont.) Environmental Compliance (QP1 and QP8 only) Procedures addressing: Disposal of hazardous waste Disposal of waste water (QP1 only) VOC compliant materials (QP1 only) Protection of air, soil and water (QP8 only) Note: control of hazardous paint and debris related to lead and other toxic metals is covered in SSPC QP2.

Personnel Qualifications QP1 – Quality Control Quality Control Supervisor Quality Control Inspector Experience 3 years protective coating industry experience 2 years field experience in protective coatings Training QCS course and SSPC Coating Inspection Training or equal Formal Training in the fundamentals of coating inspection including calibration verification and documentation

Personnel Qualifications QP1 – Craft Worker Training Current Standard requires implementation of formal written program addressing: Skills assessment Verification of qualifications Training as needed A revised standard is in the works and is expected in 2012 The PCCP Committee initiated a CAS QP 1 Execution Plan in March 2011

Personnel Qualifications CAS QP1 Execution Plan Applicable to project greater than $50,000 January 1 through December 1, 2012 Begin qualifying selected personnel within their organizations to become eligible to take the CAS Level II Interim Exam January 15, 2012 Have CAS Level II Interim staff OR Submit a “CAS Execution Plan” with application January 1, 2013 Have CAS Level II Interim staff

Proposed CAS Crew Definition for initial phase-in in 2013 One CAS for minimum 5 crew members holding the blast nozzle and spray gun If contract: exceeds $50,000 for painting Scope of work includes abrasive blast cleaning or spray application Industrial and Marine Steel/Metal Structures

Proposed CAS Crew Definition for initial phase-in in 2013 CAS requirement can be waived when: Owner-specifies craft worker certification (e.g. USN C-7; C-12, etc.) Owner exemption from craft-worker certification (e.g. MD SHA) Crews with less than five craft-workers holding the blast nozzle and spray gun

Personnel Qualifications CAS QP1 Execution Plan January 1, 2013 One (1) CAS Certified Level II-Interim craft-worker on each painting crew, regardless of crew size, during blast cleaning and spray application (Atmospheric and Immersion Service) January 1, 2014 One (1) CAS Certified Level II-Interim craft-worker to every three (3) non certified craft-workers (25%) on each painting crew

Personnel Qualifications CAS QP1 Execution Plan January 1, 2016 – 50% CAS Level II-Interim / crew January 1, 2018 – 75% CAS Level II-Interim / crew January 1, 2020 - – 75% CAS Level II-Full / crew

Personnel Qualifications CAS Interim Status Pre Requisite Item #1 Pre Requisite Item #2 Pre Requisite Item #3 Cert Exam Verifiable Work Experience Training Experience Process A Pass written exam with a 70% or greater and pass hands-on exam with a 90% or greater Minimum 2,000 hrs (equivalent to 2 years work experience) 150 CAS hours of accepted formal training Process B Minimum 3,000 hrs (equivalent to 3 years work experience) N/A

Personnel Qualifications QP3 – Quality Control Top Individual Quality Control Inspector Experience Minimum 1 year experience in surface preparation and application of complex coating systems Inspection of complex coating systems; familiar and proficient with responsibilities and use of inspection equipment and procedures Qualification Not defined By training and experience as defined by Firm and competencies assessed and documented Training Documented formal training by qualified in-house or external sourcesbased on ASTM D 3276, Standard Guide for Painting Inspectors (Metal Substrates)

Personnel Qualifications QP3 – Production Formal written program addressing: Skills assessment Verification of qualifications Annual performance assessment Training as needed Meet contractual training requirements

Personnel Qualifications QP6 Job description and qualification requirements for personnel and Documentation of training experience and work history of thermal spray supervisor (TSS), thermal spray inspector (TSI) and thermal spray operators (TSO) Method for monitoring proficiency of workers and inspectors

Personnel Qualifications QP6 – Thermal Spray Supervisor Thermal Spray Supervisor (TSS) Steel Concrete Knowledge Thermal spraying per CS 23, QP1 and QP3 Thermal spraying of concrete per QP8 and AWS C2.20 Experience 2 years management of SP5 and SP10 jobs 1 year experience and C-7 Training 16 hours theory/quality per CS23 16 hours theory/quality per AWS C2.20 8 hours of documented theoretical, practical, and hands-on quality control instruments from TS supplier or equal Qualification (initial and every 2 years) under AWS C2.16 and C23 by SSPC or equal

Personnel Qualifications QP6 Thermal Spray Inspector (TSI) Thermal Spray Operator (TSO) Program for training, qualifying and certifying its thermal spray inspector *Definition implies training per CS23, and ASTM D 3276 Program for training, qualifying and certifying its thermal spray operator in accordance with AWS C2.16 *Definition states qualification is documented by signed and dated certificate indicating type of equipment, coating and application performed

Personnel Qualifications QP8 –Foreman and QC Job Crew Chief or Foreman Quality Control Manager Quality Control Inspector Experience 2 years experience in concrete coating or surfacing installation as installer, superintendant, project manager, owner or technical representative Not specified Training QC training (general) minimum 8 hours 2-day (16 hour) curriculum on concrete, masonry and cementitious surfaces 2-day (16-hour) ACI course on concrete fundamentals N/A

Personnel Qualifications QP8 – Quality Control Required Curriculum Basic Components , Characteristics, Surface Properties Reasons for Coating and Surfacing Precautions regarding adhesion Generic polymer coating and surfacing types Repair techniques Pre-preparation, surface preparation, application/installation, inspection and testing. Required safety, health, and environmental

Personnel Qualifications QP8 – Craftpersons Implement a program to ensure that qualified persons perform work If necessary, training must be available to workers, including training to meet regulatory requirements Have a method for monitoring proficiency of workers performing work Maintain documentation

Hold points and Documentation The standards vary greatly on the level of detail related to requirements for hold points or documentation of inspection QP1 , QP3 and QP6 are very broad and generally require that the contractor ensures that each major operation (e.g. surface, preparation, primer, intermediate and topcoat application) is properly performed and documented on a daily basis or in accordance with project documents QP8 requires documentation per the QC manual, contract and as deemed prudent by QC personnel

Hold points and Documentation Each of the standards audit checklists contain detailed lists of hold points and/or documentation required The initial application for each standard may have additional requirements (that are not in the standard) Certified contractors should review initial applications on an annual basis to stay informed of new requirements Several audit checklists and applications have been revised in 2011

Initial and Annual Evaluations SSPC reviews application and programs Schedules and performs office and field audit(s) Requires annual internal audit(s) by QP firms Performs annual scheduled field/office audits Performs random audits at any time If findings, contractors have to initiate Corrective Action Plan (CAPs) Major findings or regulatory citations may trigger Disciplinary Action Criteria (DAC)

Job Notifications (QP1 Only) QP1 requires that SSPC be notified of job in advance Notification required within 15 days of contract award There is an online system for notifications The online systems prompts contractors to provide Security arrangements PPE requirements Directions Contact Information

Summary During this webinar, we have: Reviewed the purpose of the contractor QP programs Described and contrasted the management procedures, technical capabilities, personnel qualifications required by each Described hold points and documentation requirements The SSPC website has a wealth of information that is updated frequently http://www.sspc.org/qp-programs/qp-for-contractors/ Check audit checklists and initial applications for new information and requirements

Thank you for attending! Any questions? THE END