Preparing a Coating Inspection Plan

William D. Corbett KTA-Tator, Inc.

Preparing a Coating Inspection Plan

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

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

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

Benefits of a Coatings Inspection Plan

Coating specifications can be complex documents Specifications typically contain the quality requirements for a coatings project Good inspection doesnt 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

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 Guide for Planning Coating Inspection, cont.

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)

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

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.)

Inspection Plan Format (simple)

Inspection Item
Verify pre-blast surface cleanliness Verify correct type and cleanliness of abrasive media

Technique/Instrument
Visual

Acceptance Criteria
Removal of all visible grease, oil & debris

Visual & conductivity meter Expendable, angular slag, no visible oil; < 1,000 S/cm Clean, dry air; no evidence of water or oil Properly installed & maintained

Verify compressed air Blotter test cleanliness Verify installation of protective coverings Visual

Inspection Plan Format (complex)

Inspection Item Verify preblast surface cleanliness Verify correct type and cleanliness of abrasive media Verify compressed air cleanliness Verify installation of protective coverings Technique/ Instrument Visual Frequency of Tests 100% of surface Each lot of abrasive Standard Test Method Reference SSPC-SP 1 Spec. Reference 3.4.2 Acceptance Criteria Removal of all visible grease, oil & debris Expendable, angular slag, no visible oil; < 1,000 S/cm conductivity Clean, dry air; no evidence of water or oil Properly installed & maintained

Visual & conductivity meter

SSPC AB 1 ASTM D 7393 ASTM D 4940

2.3.1

Blotter test

Twice per work shift Prior to surface preparation and painting

ASTM D 4285

3.4.7

Visual

NA

3.4.1

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 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

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

Hold Point 3 Surface Conditions for Coatings Application

Examples of inspection check points
Surface cleanliness Ambient conditions Recoat windows

Performed for each coating 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

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

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)

Hold Point 7 Final Inspection

Examples of inspection check points
Repair and touch-up Waste removal Site restoration Verification of corrective action implementation

Guide to Inspection Instrumentation and Visual Guides

Instrument/Guide Name Sling psychrometer Surface temperature thermometer Psychrometric charts Electronic psychrometer Latex patch/sleeve & chloride indicator strips/tubes Conductivity Meter Comparator Discs Purpose Measurement of dry and wet bulb temperatures Measurement of surface temperatures Determining relative humidity (%) and dew point temperature Assessing ambient conditions and surface temperature Extracting and analyzing surface chloride concentrations Measuring the conductivity of abrasive or surface soluble salts Measurement of surface profile (ASTM D4417, method A)

Depth micrometer
Replica tape and spring micrometer Blotter paper Hypodermic needle pressure gage Blast nozzle orifice gage SSPC VIS 1 SSPC VIS 3 Wet film thickness gage Dry film thickness gage Paint thermometer Low voltage pinhole detector

Measurement of surface profile (ASTM D4417, method B)

Measurement of surface profile (ASTM D4417, method C) Assessing compressed air cleanliness Measuring blast nozzle pressure Measuring blast nozzle wear Assessing surface cleanliness after dry abrasive blast cleaning Assessing surface cleanliness after hand/power tool cleaning Measuring the applied wet thickness of paint Measuring the applied dry thickness of paint Measuring paint temperature Locating pinholes and holidays (misses) in coating systems

Developing an Inspection Plan

Example based on maintenance painting of a bridge structure First, populate from the specification:
Column 1: Column 3: Column 5: Column 6: Inspection check point column Frequency of test column Specification reference column Acceptance criteria column

Second, populate inspection method (Column 2) and standard test method (Column 4)

Inspection Plan for Maintenance Painting of a Bridge Structure

Inspection Item Verify grease/ oil removal Technique/ Instrument Frequency of Tests 100% of surfaces, prior to surface prep. Standard Test Method Reference Spec. Reference 45-2.03 Acceptance Criteria No visible oil or grease contamination

Inspection Plan for Maintenance Painting of a Bridge Structure

Inspection Item Verify grease/ oil removal Technique/ Instrument Frequency of Tests 100% of surfaces, prior to surface prep. Three tests per 1000 sq. ft. Standard Test Method Reference Spec. Reference 45-2.03 Acceptance Criteria No visible oil or grease contamination < 7 g/cm2

Verify surface chloride removal

45-2.03

Inspection Plan for Maintenance Painting of a Bridge Structure

Inspection Item Verify grease/ oil removal Technique/ Instrument Frequency of Tests 100% of surfaces, prior to surface prep. Three tests per 1000 sq. ft. Each lot Standard Test Method Reference Spec. Reference 45-2.03 Acceptance Criteria No visible oil or grease contamination < 7 g/cm2

Verify surface chloride removal Verify correct abrasive type & cleanliness

45-2.03

45-2.04

Expendable; angular; no oil; <1000 Mho/cm

Inspection Plan for Maintenance Painting of a Bridge Structure

Inspection Item Verify grease/ oil removal Technique/ Instrument Frequency of Tests 100% of surfaces, prior to surface prep. Standard Test Method Reference Spec. Reference 45-2.03 Acceptance Criteria No visible oil or grease contamination

Verify surface chloride removal

Verify correct abrasive type Verify compressed air cleanliness

Three tests per 1000 sq. ft.

Each lot Once per shift

45-2.03

< 7 g/cm2

45-2.04 45-2.04

Expendable; Angular No visible oil or water on collector

Inspection Plan for Maintenance Painting of a Bridge Structure

Inspection Item Verify grease/ oil removal Technique/ Instrument Frequency of Tests 100% of surfaces, prior to surface prep. Three tests per 1000 sq. ft. Each lot Standard Test Method Reference Spec. Reference 45-2.03 Acceptance Criteria No visible oil or grease contamination < 7 g/cm2

Verify surface chloride removal Verify correct abrasive type & cleanliness Verify compressed air cleanliness Verify postblast surface cleanliness

45-2.03

45-2.04

Expendable; angular; no oil; <1000 S/cm No visible oil or water on collector SSPC-SP 10

Once per shift 100% of surfaces, prior to primer appl.

45-2.04

45-2.04

Inspection Plan for Maintenance Painting of a Bridge Structure

Inspection Item Verify surface profile depth Technique/ Instrument Frequency of Tests Three tests per area cleaned, per shift After final surface prep., per area Prior to primer appl. Prior to surface prep. Standard Test Method Reference Spec. Reference 45-2.04 Acceptance Criteria 1.5-3 mils

Verify surface prep.-to-primer interval Verify dust removal Verify correct coating matls.

45-2.04

Within same day as blast cleaning No visible dust OZ/EP/PU from 1 manufacturer

45-2.04 45-2.05

Coating thickness
Verify finish coat color

After each coat

Prior to finish coat appl.

45-2.05

Primer: 3-5 mils Interm: 5-7 mils Finish: 2-3 mils

Fed. Std. 151B No. 23456

45-2.05

Inspection Plan for Maintenance Painting of a Bridge Structure

Inspection Item Measure ambient conditions & surface temp. Verify proper mixing of coatings Verify straining of primer Verify proper thinning Technique/ Instrument Frequency of Tests Prior to coating mixing and 4 hr. intervals During mixing Standard Test Method Reference Spec. Reference 45-2.06 Acceptance Criteria Air & Surf. Temp: 40-100F RH: <85% ST +5F of DP Mechanical mixing blade Strained Type & amount per manuf. PDS

45-2.07

Prior to trsfr. to spray pot Prior to addition

45-2.07 45-2.07

Verify lighting
Verify lighting

Prior to production
Prior to inspection

45-2.07
45-2.07

Surf. prep & ctg appl: Min 20 fc

Minimum 50 fc

Inspection Plan for Maintenance Painting of a Bridge Structure

Inspection Item Verify spray pot agitation Technique/ Instrument Frequency of Tests During primer application Standard Test Method Reference Spec. Reference 45-2.07 Acceptance Criteria Constant agitation during appl. Stirrer w/i 2 from bottom Spray No moisture, dust, grease, etc. Minimum and maximum per PDS No runs, drips, sags or misses

Verify primer appl. by spray Verify intercoat cleanliness Verify recoat intervals Verify workmanship

Prior to primer appl. Prior to each successive coat Prior to each successive coat After appl. of each coat

45-2.08 45-2.08

45-2-08

45-2.08

Inspection Plan for Maintenance Painting of a Bridge Structure

Inspection Item Verify enclosure integrity Verify proper stenciling Verify time of operations Technique/ Instrument Frequency of Tests Daily Standard Test Method Reference Spec. Reference 45-2.09 Acceptance Criteria No damage to work, property or persons Proper location, size, content and color Daylight hours only

Prior to demobilization Daily

45-3

45-2.04 45-2.05

Inspection Plan for Maintenance Painting of a Bridge Structure

Complete the inspection plan by populating the remaining two columns
Inspection instrument/technique Standard test method reference

Inspection Plan for Maintenance Painting of a Bridge Structure

Inspection Item Verify grease/ oil removal Technique/ Instrument Visual and/or water break Frequency of Tests 100% of surfaces, prior to surface prep. Three tests per 1000 sq. ft. Each lot Standard Test Method Reference SSPC-SP 1 Spec. Reference 45-2.03 Acceptance Criteria No visible oil or grease contamination < 7 g/cm2

Verify surface chloride removal Verify correct abrasive type & cleanliness

Latex patch/sleeve Cl- strip/tube Visual; Vial test (oil); Conductivity meter

SSPC Guide 15

45-2.03

SSPC AB 1; Oil: ASTM D 7237 Conductivity: ASTM D 4940

45-2.04

Expendable; angular; no oil; <1000 S/cm

Verify compressed air cleanliness

Verify postblast surface cleanliness

Blotter test

Once per shift

100% of surfaces, prior to primer appl.

ASTM D 4285

45-2.04

No visible oil or water on collector

Near-white Blast

SSPC VIS 1

SSPC-SP 10

45-2.04

Inspection Plan for Maintenance Painting of a Bridge Structure

Inspection Item Verify surface profile depth Technique/ Instrument Visual comparator Depth micro. Replica tape Visual Frequency of Tests Three tests per area cleaned, per shift After final surface prep., per area Prior to primer appl. Prior to surface prep. Standard Test Method Reference ASTM D 4417 Methods A, B, or C NA 45-2.04 Within same day as blast cleaning No visible dust OZ/EP/PU from 1 manufacturer Spec. Reference 45-2.04 Acceptance Criteria 1.5-3 mils

Verify surface prep.-to-primer interval Verify dust removal Verify correct coating matls.

Visual/tactile Visual

NA NA

45-2.04 45-2.05

Coating Thickness
Verify finish coat color

Calib. dry film thickness gage

Visual (check label)

After each coat

Prior to finish coat appl.

SSPC-PA 2

45-2.05

Primer: 3-5 mils Interm: 5-7 mils Finish: 2-3 mils

Fed. Std. 151B No. 23456

NA

45-2.05

Inspection Plan for Maintenance Painting of a Bridge Structure

Inspection Item Measure ambient conditions & surface temp. Verify proper mixing of coatings Verify straining of primer Verify proper thinning Verify lighting Verify lighting Technique/ Instrument Sling psychrometer; psychrometric charts; surf. thermometer Visual Frequency of Tests Prior to coating mixing and 4 hr. intervals During mixing Prior to trsfr. to spray pot Prior to addition Prior to production Prior to inspection Standard Test Method Reference ASTM E 337 Spec. Reference 45-2.06 Acceptance Criteria Air & Surf. Temp: 40-100F RH: <85% ST +5F of DP Mechanical mixing blade Strained Type & amount per manuf. PDS Surf. prep & ctg. appl.: Min 20 fc Minimum 50 fc

NA

45-2.07

Visual Visual Light Meter Light Meter

NA NA SSPC Guide 12 SSPC Guide 12

45-2.07 45-2.07 45-2.07 45-2.07

Inspection Plan for Maintenance Painting of a Bridge Structure

Inspection Item Verify spray pot agitation Technique/ Instrument Visual Frequency of Tests During primer application Standard Test Method Reference NA Spec. Reference 45-2.07 Acceptance Criteria Constant agitation during appl. Stirrer w/i 2 of bottom Spray No moisture, dust, grease, etc. Minimum and maximum per PDS No runs, drips, sags or misses

Verify primer appl. by spray Verify intercoat cleanliness Verify recoat intervals Verify workmanship

Visual Visual/tactile

Prior to primer appl. Prior to each successive coat Prior to each successive coat After appl. of each coat

NA NA

45-2.08 45-2.08

Visual

NA

45-2-08

Visual

NA

45-2.08

Inspection Plan for Maintenance Painting of a Bridge Structure

Inspection Item Verify enclosure integrity Verify proper stenciling Verify time of operations Technique/ Instrument Visual Frequency of Tests Daily Standard Test Method Reference NA Spec. Reference 45-2.09 Acceptance Criteria No damage to work, property or persons Proper location, size, content and color Daylight hours only

Visual

Prior to demobilization Daily

NA

45-3

Visual

NA

45-2.04 45-2.05

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

Preparing a Coating Inspection Plan

THE END