Preparing a Coating Inspection Plan

Preparing a Coating Inspection Plan
William D. Corbett KTA-Tator, Inc. This one-hour webinar is on Preparing an Inspection Plan, and will be conducted by Bill Corbett of KTA-Tator, Inc.

Webinar Content Purpose and benefits of developing an inspection plan Review the content of the SSPC Guide for Planning Coatings Inspection Common formats of inspection plans Common inspection check points that are transferred from the specification to the inspection plan Common inspection instruments, standards, guides and methods used to perform inspection that are listed on an inspection plan Listing the acceptance criteria from the specification onto the inspection plan The webinar will discuss a variety topics relating to preparation of inspection plans, including: The purpose and benefits of developing an inspection plan prior to production operations; A review of the Guide for Planning Coatings Inspection prepared by SSPC in 2008; A discussion on two different formats for inspection plans; A review of the more common inspection check points in coating specifications that ultimately become part of the inspection plan; A review of the more common instruments, industry standards, guides and test methods in coating specifications that ultimately become part of the inspection plan; and How to extract the acceptance criteria for each of the inspection check points referenced in the coating specification and populate the inspection plan.

Learning Outcomes Completion of this webinar will enable the participant to: Describe the purpose and importance of an inspection plan Explain the benefits of an inspection plan Recognize the SSPC Guide for Planning Coatings Inspection Describe the various formats of inspection plans Extract inspection check points from a specification Identify the instruments, guides and methods used to inspect Extract the acceptance criteria from a specification for each of the inspection check points Prepare an inspection plan There are eight learning outcomes for this webinar. Completing this webinar will enable you to: Describe the purpose and importance of preparing an inspection plan prior to production operations; Explain the benefits of establishing an inspection plan; Recognize that SSPC has developed a guide that describes the procedures associated with developing an inspection plan; Describe two basic formats for inspection plans; Identify and extract the inspection check points from a coating specification and populate them into an inspection plan; Identify the instrumentation and techniques, as well as the industry standards, guides and test methods used to inspect coating work; Identify and extract the acceptance criteria from the coating specification for each of the inspection check points and populate the criteria into an inspection plan; and Prepare an inspection plan.

Purpose of an Inspection Plan
Provides a systematic inspection and testing plan that covers all phases of work in sequence Provides a written document that lists what to inspect, how to inspect and the acceptance criteria Provides a tool enabling an inspector to navigate through and extract inspection check points from the specification May be a required contract submittal Why should a quality control or a quality assurance inspector prepare an inspection plan, when all of the inspection requirements and acceptance criteria are already described in the specification? A thorough, well-organized inspection plan provides an inspector with a systematic tool that covers each phase of work in the general sequence in which it will likely be performed. In general, an inspection plan is a written document that lists what must be inspected, how it is to be inspected and the acceptance criteria from the specification. Coating specifications are often complex documents and can describe both technical and legal or contractual requirements. The process of developing an inspection plan provides the inspector with an opportunity to carefully navigate through the contract, extract the inspection check points and transfer them to a separate chart that can be referenced throughout the project to clearly understand and communicate the quality requirements of the specification. Some specifications require the contractor to develop a Work Plan and a Process Control Plan or PCP. The inspection plan is a component to the process control plan. These items are considered “submittals” and oftentimes must be submitted and approved before production operations are allowed to begin.

Benefits of a Coatings Inspection Plan
Coating specifications can be complex documents Specifications typically contain the quality requirements for a coatings project Good inspection doesn’t happen by accident; it requires planning Inspection plans make specification enforcement more streamlined and complete Provide a key communication tool between QA and QC personnel Coating specifications can be very complex documents containing multiple parts, sections and items. The quality requirements for a coatings project are oftentimes contained in the Execution component of the specification, but may be scattered in other parts or sections as well. Proper quality assurance and quality control inspection doesn’t happen by accident. One of the many keys to quality inspection is careful planning, so that each check point is properly inspected using the techniques, instruments, standards, guides and test methods established by the industry to verify the adequacy of the work before proceeding to the next step. The development of a well-organized, thorough inspection plan prior to production activities commencing can help quality assurance and quality control inspection personnel verify that each of the specification requirements are being inspected. It is a key communication tool between contractor and inspector personnel that clarifies what will be inspected, how and when the inspection will take place and the quality requirements of the specification.

SSPC Guide for Planning Coating Inspection
Introduction and Purpose of the Guide Key Terms Responsibilities for Project Quality Management Owner Contractor Coatings Inspector The need for an Inspection Plan SSPC’s Painting Contractor Certification Program or PCCP which oversees the various Qualification Procedures like QP1, QP3 and others requires the contractor to prepare a quality control plan, and many of SSPC’s coatings inspection training courses include the preparation of inspection plans in the curriculum. In order to provide guidance to those responsible for creating quality control plans and provide a training document to course participants, SSPC developed a Guide for Planning Coating Inspection in 2008. While there is not adequate time to review the entire content of the Guide during this webinar, I will briefly describe the general content. Copies of the Guide are available from SSPC. The Guide starts off by describing the importance of quality monitoring on a project to reduce the risk of coating failure, and describes the challenges associated with trying to assess quality after the project is complete. It also stresses the importance of planning the inspection to increase the likelihood that the inspections are performed and the results properly documented. The intended purpose of the guide is to assist coating inspectors, quality control personnel and owners with the development of a tool to help ensure the coating or lining installation is the best it can be. Keys terms defined in the Guide include: Owner, QA and QC Inspector, Corrective Action, Non-conformity, Latent Defect and Warranty. The facility owner’s, contractor’s and coating inspector’s responsibility for managing project quality is also described in the Guide. The owners responsibility includes developing the project specification and performing quality assurance inspection of the work. The contractor’s responsibility includes purchasing the coating materials and performing all surface preparation and coating installation work, as well as controlling the quality of the work, documenting and resolving non-conformities with the owner and preparing corrective action reports so that non-conformities do not reoccur. The quality assurance inspector’s responsibility is to observe the work performed, assess whether it meets the minimum requirements of the specification, document the results of the inspection and report to the owner. The Guide also conveys the need for the preparation and implementation of an inspection plan so that an inspector can perform their work both thoroughly and efficiently.

SSPC Guide for Planning Coating Inspection, con’t.
Developing an Inspection Plan Process Control Procedures (PCPs) Items Required for Inspection Plan Preparation Listing of Common Inspection Instruments & Guides Inspection Hold Points/Check Points Sample Coating Inspection Plans (steel & concrete) The Guide describes a typical scope of an inspection plan and recommends that the plan include a project schedule that matches the contractors Work Plan, in order to coordinate inspection and production activities without unduly interrupting production. The guide also describes a plan format, which will be illustrated later in this webinar. The Guide also describes the basic function and content of a Process Control Procedure or PCP, which includes an inspection plan. The documents typically required to develop an inspection plan, the equipment typically required to perform inspections, and a list of common inspection hold points and check points are described in the guide. We will look at each of these items in detail, since they are all vital to the preparation of a quality inspection plan. Finally, the Guide provides a sample coating inspection plan for an amine-cured epoxy coating or lining applied to a carbon steel structure, as well as an inspection plan for coating of concrete.

Required Items for Developing an Inspection Plan
Documents Project specification Referenced standards (SSPC, NACE, ASTM, etc.) Product data sheets MSDS Inspection Equipment and Guides The project specification and referenced standards will identify the appropriate test methods and equipment required There are four documents that will serve as references during the development of an inspection plan. They include a copy of the specification and any notes from the pre-construction conference that may become part of the specification; and all of the referenced standards from the specification, including those from SSPC, NACE International, ASTM International and others. Note that these are copyrighted documents and must by obtained by permission or even purchased. Current product data sheets, application instructions and material safety data sheets or MSDS from the coating manufacturer for each product to be applied are also acquired. Technical data sheets and MSDS should also be obtained from the abrasive supplier or any supplier of surface preparation-related products or chemicals. While MSDS have little to do with quality, they are required to be on-site, and read and understood by all personnel who will potentially come into contact with the product during its use. The project specification should be carefully read to identify each requirement and the owners expectation. It may be beneficial to highlight the inspection requirements as they are read. Recognize that the requirements may not be stated in the specification in the order that they will occur during execution of the work; for example, a specification may establish the surface preparation requirements, then requirements for containment of the structure, followed by requirements for a certified coatings inspector. The specification should establish each inspection test method to be used, the equipment necessary to perform each test, and the frequency at which each test should be performed. Referenced standards detail how to perform a specific test, but typically do not identify the frequency that a test should be performed. All inspection equipment necessary to complete a successful inspection should be verified for accuracy prior to beginning work and maintained in good working order throughout the project. The inspector should prepare and maintain a log of the inspection equipment used on each project.

Inspection Plan Format
Variable, depending on contract documents and inspector preference Simple (three columns) Inspection Check Point Method of Inspection Acceptance Criteria Complex Simple format, plus three additional columns Testing Frequency Standard Test Method Reference Specification Reference (Part/Item No.) There is no standard format for inspection plans. The format may be dictated by the specification, or may be customized based on inspector preference. This webinar presents two formats: a simple 3-column format and a more complex 6-column format. The simple format contains 3 column headers including a column to list the inspection check points from the specification, a column to list the methods and instrumentation that will be used to perform the inspections and a third column to list the acceptance criteria corresponding to each inspection check point, which is provided in the specification. The more complex format contains these same 3 columns, but includes 3 additional columns where the testing frequency, the standard test method reference, and a reference to the specification part, section and item number are listed for each inspection checkpoint. The latter column is particularly useful when there is a need to go back into the specification for confirmation, clarifications, etc. It directs the user to the section where the inspection check point and the acceptance criteria are indicated.

Inspection Plan Format (simple)
Inspection Item Technique/Instrument Acceptance Criteria Verify pre-blast surface cleanliness Visual Removal of all visible grease, oil & debris Verify correct type and cleanliness of abrasive media Visual & conductivity meter Expendable, angular slag, no visible oil; < 1,000 µS/cm Verify compressed air cleanliness Blotter test Clean, dry air; no evidence of water or oil Verify installation of protective coverings Properly installed & maintained This slide illustrates a portion of an inspection plan using the simple, 3-column format. The first column lists examples of inspection actions, the second column indicates how the inspections will be conducted and the last column lists the acceptance criteria which has been extracted directly from the specification. However, this simple format does not indicate how often to perform a blotter test, or does not list the test method used to measure the conductivity of the abrasive.

Inspection Plan Format (complex)
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify pre-blast surface cleanliness Visual 100% of surface SSPC-SP 1 3.4.2 Removal of all visible grease, oil & debris Verify correct type and cleanliness of abrasive media Visual & conductivity meter Each lot of abrasive SSPC AB 1 ASTM D 7393 ASTM D 4940 2.3.1 Expendable, angular slag, no visible oil; < 1,000 µS/cm conductivity Verify compressed air cleanliness Blotter test Twice per work shift ASTM D 4285 3.4.7 Clean, dry air; no evidence of water or oil Verify installation of protective coverings Prior to surface preparation and painting NA 3.4.1 Properly installed & maintained This slide illustrates a portion of an inspection plan using the more complex 6-column format. Note that columns 1, 2 and 6 are identical to the earlier 3-column format, however the addition of three columns, which are highlighted in yellow provides additional information to the inspector, including the frequency in which the inspections are required to take place – column 3, the standard test method that describes how to perform the test – column 4, and the section of the specification where the details can be located, if required – column 5. This format is preferred since it provides inspection personnel with a more complete tool.

Typical Hold Points Pre-surface preparation Post-surface preparation
Surface condition for coatings application Coating application Post-coating application Post-curing of coating Final inspection Hold points are described as those points during surface preparation and coating application where production stops and the work performed is inspected for conformance. If an inspection does not occur at a hold point, it is possible that non-conforming work may be coated over, or the structure may be put into service with a compromised coating system, which may lead to failure. When inspections occur at hold points and non-conforming work is corrected before proceeding to the next step, the risk of coating failure is reduced. Common hold points include pre- and post-surface preparation; surface condition prior to coating; coating application; post-coating application; curing; and final inspection. Note that each of these hold points has multiple check points, each of which should be listed on the inspection plan. We’ll look at these next.

Hold Point 1 Pre-Surface Preparation
Examples of inspection check points Contractor submittals Surface preparation media Coatings materials Containment and ventilation Waste management Surface contamination Oil, grease and debris Soluble salts This is a list of a few of the common items that are typically inspected or verified before the contractor begins surface preparation work. Many specifications require contractors to prepare a number of submittals for the owner prior to beginning work. These submittals often include detailed progress work schedules, worker safety plans, waste management plans, and other engineered drawings or plans. Prior to beginning surface preparation work, the inspector verifies that the contractor has acquired the appropriate surface preparation media and coatings materials based on the requirements of the specification. Containment materials, installation of the containment and ventilation system, required air and site monitoring, and waste management plans are verified for conformance to the specification requirements and submitted prior to beginning surface preparation work. In addition, the surface of the structure is examined to identify any areas of surface contamination; such as heavy deposits of oil, grease, debris, or soluble salts, as these areas often require pre-cleaning and inspection before mechanical surface preparation begins.

Hold Point 2 Post-Surface Preparation
Examples of inspection check points Ambient conditions Surface preparation media Removal of surface contamination Surface cleanliness Surface profile Surface imperfections Waste management Although hold point 2 is identified as post-surface preparation, some of the inspection check points such as ambient conditions, surface preparation media, and removal of surface contamination is verified or inspected prior to and throughout the surface preparation phase of work. Other check points include examining the cleanliness of the surface after mechanical methods of preparation are performed, as well as the surface profile yield if invoked by the contract documents. Surface imperfections observed during surface preparation, or caused by surface preparation operations are documented and addressed prior to coating system installation. Finally, the inspector may also be required to verify that the waste generated during surface preparation activities is properly stored and secured until it can be removed from the project site.

Hold Point 3 Surface Conditions for Coatings Application
Examples of inspection check points Surface cleanliness Ambient conditions Recoat windows Performed for each coating applied Conditions for coating installation includes inspection of prepared surfaces for dust or other debris that may inhibit surface wetting of the coating or adhesion; verification that the air and surface temperatures, as well as the relative humidity are within the allowable ranges, and that the surface temperature is warmer than the dew point temperature to preclude moisture formation on prepared surfaces. Once the coating is applied, the inspector verifies that the coating has cured for the minimum time, but has been overcoated before exceeding the maximum recoat time. These inspection check points are performed for each coating layer to be applied.

Hold Point 4 Coating Application
Examples of inspection check points Coatings materials Mixing, thinning and straining Ambient conditions Wet film thickness Coatings application defects Performed for each coating applied The coating application check points include verification that the coating materials on-site are the correct products that have a current shelf life, and that they are mixed, thinned and strained according to the manufacturers instructions. Again, the prevailing conditions of temperature and humidity are measured and recorded, and the applied wet film thickness may be measured and recorded, especially when dry film thickness measurements are not possible. The applied coating should also be inspected for visible defects that occurred during application, so that they can be repaired prior to application of the next coat. These inspection check points are performed for each coating layer to be applied.

Hold Point 5 Post-Coating Application
Examples of inspection check points Coating thickness Ambient conditions Recoat window/free of contamination Performed for each coating applied Monitoring and recording ambient conditions throughout the curing process of the coating, observing the minimum and maximum recoat windows and verifying cleanliness between coats can be significant factors in minimizing premature coatings failure, and are typically performed for each coating layer to be applied.

Hold Point 6 Post-Curing of Coating
Examples of inspection check points Coating application defects (each coat) Dry film thickness (each coat) Pinhole/holiday detection (buried/immersion service) Other post-curing check points include inspection for visible defects that occurred during application, measurement of dry film thickness of each applied coating, and pinhole and holiday detection when the coating or lining will be buried or subject to immersion.

Hold Point 7 Final Inspection
Examples of inspection check points Repair and touch-up Waste removal Site restoration Verification of corrective action implementation Final inspection includes examination of repaired areas, as well as removal of waste by a licensed transporter, restoring the site to its original condition, and verification that corrective actions have been implemented by the contractor.

Instrument/Guide Name
Guide to Inspection Instrumentation and Visual Guides Instrument/Guide Name Purpose Sling psychrometer Measurement of dry and wet bulb temperatures Surface temperature thermometer Measurement of surface temperatures Psychrometric charts Determining relative humidity (%) and dew point temperature Electronic psychrometer Assessing ambient conditions and surface temperature Latex patch/sleeve & chloride indicator strips/tubes Extracting and analyzing surface chloride concentrations Conductivity Meter Measuring the conductivity of abrasive or surface soluble salts Comparator Discs Measurement of surface profile (ASTM D4417, method A) Depth micrometer Measurement of surface profile (ASTM D4417, method B) Replica tape and spring micrometer Measurement of surface profile (ASTM D4417, method C) Blotter paper Assessing compressed air cleanliness Hypodermic needle pressure gage Measuring blast nozzle pressure Blast nozzle orifice gage Measuring blast nozzle wear SSPC VIS 1 Assessing surface cleanliness after dry abrasive blast cleaning SSPC VIS 3 Assessing surface cleanliness after hand/power tool cleaning Wet film thickness gage Measuring the applied wet thickness of paint Dry film thickness gage Measuring the applied dry thickness of paint Paint thermometer Measuring paint temperature Low voltage pinhole detector Locating pinholes and holidays (misses) in coating systems Since we wont have time describe all of the instruments and guides that are used to perform the various inspection check points we just listed, the slide illustrates a chart which itemizes various instruments or guides and their purpose. This list is not comprehensive, but can be helpful when populating the Technique-Instrument column on the inspection plan.

Developing an Inspection Plan
Example based on maintenance painting of a bridge structure First, populate from the specification: Column 1: Inspection check point column Column 3: Frequency of test column Column 5: Specification reference column Column 6: Acceptance criteria column Second, populate inspection method (Column 2) and standard test method (Column 4) Now that we have described the purpose and benefits of an inspection plan, described two basic formats, and listed common inspection check points found in coating specifications, it is time to develop an inspection plan based on a simulated project entailing maintenance painting of a bridge structure. During this demonstration, we will be using the 6-column complex format. While it will not be possible to view the specification on the slides, the inspection plan will be populated based on a simulated specification for a simple grade separation bridge structure. The specification we will be working from was not designed to represent an actual contract and was simplified for use in this webinar. First, we will populate columns 1, 3, 5 and 6 directly from the specification, then back fill columns 2 and 4 based on the inspection method and industry standard referenced by the specification. At first, we will illustrate the development of the inspection plan row-by-row, as indicated by the yellow highlighted rows. After a few sample rows, we will illustrate several populated rows all at once.

Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify grease/ oil removal 100% of surfaces, prior to surface prep. No visible oil or grease contamination The first inspection check point addresses verification of grease and oil removal. Inspection of all surfaces is required and no visible oil or grease contamination is permitted. This detail is located in Section 45, Part 2.03 of the specification.

Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify grease/ oil removal 100% of surfaces, prior to surface prep. No visible oil or grease contamination Verify surface chloride removal Three tests per 1000 sq. ft. < 7 µg/cm2 The second inspection check point addresses verification of surface chloride removal. Three tests in each of 1000 square feet is required and surface concentrations must be maintained below 7 micrograms per square centimeter. This detail is also located in Section 45, Part 2.03 of the specification.

Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify grease/ oil removal 100% of surfaces, prior to surface prep. No visible oil or grease contamination Verify surface chloride removal Three tests per 1000 sq. ft. < 7 µg/cm2 Verify correct abrasive type & cleanliness Each lot Expendable; angular; no oil; <1000 µMho/cm The third inspection check point addresses verification that the correct abrasive has been brought on to the site and that it is clean. Each lot of abrasive must be tested, and the abrasive must be an expendable type that is angular in shape. The abrasive cannot contain any visible oil contamination and must have a conductivity of less than 1000 micro-mho per centimeter This detail is located in Section 45, Part 2.04 of the specification.

Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify grease/ oil removal 100% of surfaces, prior to surface prep. No visible oil or grease contamination Verify surface chloride removal Three tests per 1000 sq. ft. < 7 µg/cm2 Verify correct abrasive type Each lot Expendable; Angular Verify compressed air cleanliness Once per shift No visible oil or water on collector The fourth inspection check point addresses verification that the compressed air used for abrasive blast cleaning and blow down is clean and dry. The air must be tested a minimum of once per shift, and there can be no visible oil or water on the collector. This detail is located in Section 45, Part 2.04 of the specification.

Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify grease/ oil removal 100% of surfaces, prior to surface prep. No visible oil or grease contamination Verify surface chloride removal Three tests per 1000 sq. ft. < 7 µg/cm2 Verify correct abrasive type & cleanliness Each lot Expendable; angular; no oil; <1000 µS/cm Verify compressed air cleanliness Once per shift No visible oil or water on collector Verify post-blast surface cleanliness 100% of surfaces, prior to primer appl. SSPC-SP 10 The fifth inspection check point addresses surface cleanliness. Inspection of all surfaces is required and must meet the minimum requirements of SSPC-SP 10 Near-white Blast. This detail is also located in Section 45, Part 2.04 of the specification.

Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify surface profile depth Three tests per area cleaned, per shift 1.5-3 mils Verify surface prep.-to-primer interval After final surface prep., per area Within same day as blast cleaning Verify dust removal Prior to primer appl. No visible dust Verify correct coating mat’ls. Prior to surface prep. OZ/EP/PU from 1 manufacturer Coating thickness After each coat Primer: 3-5 mils Interm: 5-7 mils Finish: 2-3 mils Verify finish coat color Prior to finish coat appl. Fed. Std. 151B No The next six inspection check points include verification of surface profile depth, surface preparation-to-primer time interval, dust removal, correct coating materials, coating thickness and finish coat color. The testing frequency and acceptance criteria from the specification is shown for each, as is the specification reference section. The profile depth is measured in 3 locations for each area prepared during the shift and must be mils deep. Surfaces must be primed-in the same day they are prepared and there can be no visible dust on the surface prior to primer application. This detail is located in Section 45, Part 2.04 of the specification. The coatings consist of an organic zinc-rich primer, an epoxy midcoat and an acrylic polyurethane finish coat. The dry film thickness is 3-5 mils for the primer, 5-7 mils for the midcoat and 2-3 mils for the finish coat, which must be Federal Color No This detail is located in Section 45, Part 2.05 of the specification.

Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Measure ambient conditions & surface temp. Prior to coating mixing and 4 hr. intervals Air & Surf. Temp: 40-100°F RH: <85% ST +5°F of DP Verify proper mixing of coatings During mixing Mechanical mixing blade Verify straining of primer Prior to trsfr. to spray pot Strained Verify proper thinning Prior to addition Type & amount per manuf. PDS Verify lighting Prior to production Surf. prep & ctg appl: Min 20 fc Prior to inspection Minimum 50 fc The next six inspection check points include measurement of ambient conditions and surface temperature, verification of proper mixing, thinning and straining of the coating materials, and verification of minimum lighting for production and inspection operations. The testing frequency and acceptance criteria from the specification is shown for each, as is the specification reference section. Ambient conditions are measured prior to coating mixing and at 4 hour intervals thereafter, unless conditions appear to be changing. Air and surface temperatures must be maintained between 40 and 100 degrees F and the relative humidity cannot exceed 85%. The surface temperature must be a minimum of 5 degrees F higher than the dew point. Mixing must be performed using a mechanical mixing blade, and the primer must be strained before it is transferred to the spray pot. The thinner type and amount must conform to the manufacturer’s PDS, and lighting inside the containment area must provide a minimum of 20 foot candles for surface preparation and coating work, and a minimum of 50 foot-candles for inspection work. This detail is located in Section 45, Parts 2.06 and 2.07 of the specification.

Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify spray pot agitation During primer application Constant agitation during appl. Stirrer w/i 2” from bottom Verify primer appl. by spray Prior to primer appl. Spray Verify intercoat cleanliness Prior to each successive coat No moisture, dust, grease, etc. Verify recoat intervals Minimum and maximum per PDS Verify workmanship After appl. of each coat No runs, drips, sags or misses The next five inspection check points include verification of pot agitation, application method for the primer, intercoat cleanliness, recoat intervals and quality of workmanship. The testing frequency and acceptance criteria from the specification is shown for each, as is the specification reference section. The primer must be constantly agitated during application, and there is a requirement for the depth of the stirrer. The primer has to be spray-applied, and no moisture, dust or grease may be present on coated surfaces. The recoat intervals cannot be any less than the manufacturer’s stated minimum, nor any greater than the manufacturer’s maximum time period, and the applied coating cannot contain any runs, drips, sags or misses. This detail is located in Section 45, Parts 2.07 and 2.08 of the specification.

Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify enclosure integrity Daily No damage to work, property or persons Verify proper stenciling Prior to demobilization 45-3 Proper location, size, content and color Verify time of operations Daylight hours only The last three inspection check points include verification that the integrity of the containment remains intact throughout the project and that no damage to work, property or site personnel occurs. This information is located in section of the specification. Stenciling of the structure is required prior to demobilization, as described in section 45-3; and surface preparation and coating work can only occur during daylight hours, as noted in sections and 2.05 of the specification.

Complete the inspection plan by populating the remaining two columns Inspection instrument/technique Standard test method reference Now that we have populated the first 4 columns of the inspection plan, we can easily go back and populate the inspection method column and the standard test method column for each of the inspection check points previously listed.

Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify grease/ oil removal Visual and/or water break 100% of surfaces, prior to surface prep. SSPC-SP 1 No visible oil or grease contamination Verify surface chloride removal Latex patch/sleeve Cl- strip/tube Three tests per 1000 sq. ft. SSPC Guide 15 < 7 µg/cm2 Verify correct abrasive type & cleanliness Visual; Vial test (oil); Conductivity meter Each lot SSPC AB 1; Oil: ASTM D 7237 Conductivity: ASTM D 4940 Expendable; angular; no oil; <1000 µS/cm Verify compressed air cleanliness Blotter test Once per shift ASTM D 4285 No visible oil or water on collector Verify post-blast surface cleanliness SSPC VIS 1 100% of surfaces, prior to primer appl. SSPC-SP 10 Near-white Blast The two yellow highlighted columns list the technique or instrument used to perform the inspection and the standard test method reference, provided one exists. Note that in many cases the technique is visual and no instrumentation is required. To verify grease and oil removal, a visual inspection will be performed, and a water break test may be used on horizontal surfaces. The inspection will be performed as described in SSPC-SP 1 Solvent Cleaning. Surface extraction for chloride contamination will be performed using either the latex patch or latex sleeve methods and detection will be performed using either the chloride indicator strip or tube. Extraction and analysis will be performed according to SSPC Guide 15. The type and angularity of the abrasive will be inspected visually, and a vial test will be performed to verify abrasive cleanliness. A conductivity meter will be used to verify the abrasive does not contain excessive ionic contamination. The cleanliness of the abrasive is evaluated according to SSPC AB 1 for Mineral and Slag abrasives, since abrasive cleanliness is a referenced requirement of SSPC-SP 10, Near-white blast cleaning. The absence of oil contamination will be verified according to ASTM D 7237, and the conductivity of the abrasive will be measured according to the procedure described in ASTM D 4940. A blotter test will be performed according to ASTM D to verify compressed air cleanliness; and SSPC VIS 1 will be used to verify that surfaces have been abrasive blast cleaned to a near-white condition according to SSPC-SP 10.

Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify surface profile depth Visual comparator Depth micro. Replica tape Three tests per area cleaned, per shift ASTM D 4417 Methods A, B, or C 1.5-3 mils Verify surface prep.-to-primer interval Visual After final surface prep., per area NA Within same day as blast cleaning Verify dust removal Visual/tactile Prior to primer appl. No visible dust Verify correct coating mat’ls. Prior to surface prep. OZ/EP/PU from 1 manufacturer Coating Thickness Calib. dry film thickness gage After each coat SSPC-PA 2 Primer: 3-5 mils Interm: 5-7 mils Finish: 2-3 mils Verify finish coat color Visual (check label) Prior to finish coat appl. Fed. Std. 151B No Continuing with the two highlighted columns… The surface profile depth is measured according to ASTM D 4417 using either a visual comparator per method A, a depth micrometer per method B or replica tape according to method C. The surface preparation-to-primer interval, dust removal, verification of correct coating materials and finish coat color are each inspected for visually. Coating thickness is measured using a calibrated dry film thickness gage according to the requirements of SSPC PA 2.

Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Measure ambient conditions & surface temp. Sling psychrometer; psychrometric charts; surf. thermometer Prior to coating mixing and 4 hr. intervals ASTM E 337 Air & Surf. Temp: 40-100°F RH: <85% ST +5°F of DP Verify proper mixing of coatings Visual During mixing NA Mechanical mixing blade Verify straining of primer Prior to trsfr. to spray pot Strained Verify proper thinning Prior to addition Type & amount per manuf. PDS Verify lighting Light Meter Prior to production SSPC Guide 12 Surf. prep & ctg. appl.: Min 20 fc Prior to inspection Minimum 50 fc Again continuing with the two highlighted columns… Ambient conditions and surface temperature are measured using a sling psychrometer, psychrometric charts and a surface temperature thermometer according to ASTM E337; and mixing, thinning and straining are inspected visually. The adequacy of lighting is assessed using a light meter and the minimum and recommended illumination requirements for surface preparation and coating application work, as well as inspection activities are set forth in SSPC’s Guide 12.

Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify spray pot agitation Visual During primer application NA Constant agitation during appl. Stirrer w/i 2” of bottom Verify primer appl. by spray Prior to primer appl. Spray Verify intercoat cleanliness Visual/tactile Prior to each successive coat No moisture, dust, grease, etc. Verify recoat intervals Minimum and maximum per PDS Verify workmanship After appl. of each coat No runs, drips, sags or misses Continuing with the two highlighted columns… The spray pot agitation and spray application of the primer, recoat times and the quality of workmanship will all be verified visually; (next slide)

Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify enclosure integrity Visual Daily NA No damage to work, property or persons Verify proper stenciling Prior to demobilization 45-3 Proper location, size, content and color Verify time of operations Daylight hours only … as will the integrity of the enclosure, stenciling, and the time of surface preparation and coating application operations.

Summary During this webinar, we have:
Described the purpose and importance of an inspection plan Explained the benefits of an inspection plan Reviewed the SSPC Guide for Planning Coatings Inspection Described two basic formats of inspection plans Identified common inspection check points invoked by a specification Listed common instruments, guides and methods used to inspect Described how to extract the acceptance criteria invoked by a specification for each of the inspection check points Prepared an inspection plan for recoating a bridge In summary, we have described the purpose and benefits of an inspection plan and discussed it’s importance; and we have reviewed the basic content of SSPC’s guide for planning a coating inspection. We explored two formats for inspection plans, including both simple and complex formats, and listed the more common inspection check points for each of seven hold points. We also looked at a chart listing the various instruments and guides used to perform inspection, as well as what they are used for; and we described how to extract the acceptance criteria from the specification for each of the check points. Finally, we prepared an inspection plan for recoating a bridge based on a simulated specification.

THE END Thank you for attending his one-hour webinar on Preparing a Coating Inspection Plan

Preparing a Coating Inspection Plan

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Preparing a Coating Inspection Plan

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Presentation on theme: "Preparing a Coating Inspection Plan"— Presentation transcript:

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