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 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 S/cm
Verify compressed air
cleanliness
Blotter test Clean, dry air; no
evidence of water or oil
Verify installation of
protective coverings
Visual Properly installed &
maintained
Inspection Plan Format
(simple)
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 S/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
Visual Prior to
surface
preparation
and painting
NA 3.4.1 Properly
installed &
maintained
Inspection Plan Format
(complex)
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
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
Guide to Inspection Instrumentation and Visual Guides



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)
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.
45-2.03 No visible oil or
grease
contamination
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.
45-2.03 No visible oil or
grease
contamination
Verify surface
chloride
removal
Three tests
per 1000 sq.
ft.
45-2.03 < 7 g/cm
2
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.
45-2.03 No visible oil or
grease
contamination
Verify surface
chloride
removal
Three tests
per 1000 sq.
ft.
45-2.03 < 7 g/cm
2
Verify correct
abrasive type
& cleanliness
Each lot 45-2.04 Expendable;
angular; no oil;
<1000 Mho/cm
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.
45-2.03 No visible oil or
grease
contamination
Verify surface
chloride
removal
Three tests
per 1000 sq.
ft.
45-2.03 < 7 g/cm
2
Verify correct
abrasive type
Each lot 45-2.04 Expendable;
Angular
Verify
compressed
air cleanliness
Once per
shift
45-2.04 No visible oil or
water on
collector
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.
45-2.03 No visible oil or
grease
contamination
Verify surface
chloride
removal
Three tests
per 1000 sq.
ft.
45-2.03 < 7 g/cm
2
Verify correct
abrasive type
& cleanliness
Each lot 45-2.04 Expendable;
angular; no oil;
<1000 S/cm
Verify
compressed
air cleanliness
Once per
shift
45-2.04 No visible oil or
water on
collector
Verify post-
blast surface
cleanliness
100% of
surfaces,
prior to
primer appl.
45-2.04 SSPC-SP 10
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 surface
profile depth
Three tests
per area
cleaned, per
shift
45-2.04 1.5-3 mils
Verify surface
prep.-to-primer
interval
After final
surface prep.,
per area
45-2.04 Within same day
as blast cleaning
Verify dust
removal
Prior to
primer appl.
45-2.04 No visible dust
Verify correct
coating matls.
Prior to
surface prep.
45-2.05 OZ/EP/PU from 1
manufacturer
Coating
thickness
After each
coat
45-2.05 Primer: 3-5 mils
Interm: 5-7 mils
Finish: 2-3 mils
Verify finish
coat color
Prior to finish
coat appl.
45-2.05 Fed. Std. 151B
No. 23456
Inspection Plan for Maintenance
Painting of a Bridge Structure
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
45-2.06 Air & Surf. Temp:
40-100F
RH: <85%
ST +5F of DP
Verify proper
mixing of
coatings
During mixing 45-2.07 Mechanical
mixing blade
Verify straining
of primer
Prior to trsfr.
to spray pot
45-2.07 Strained
Verify proper
thinning
Prior to
addition
45-2.07 Type & amount
per manuf. PDS
Verify lighting Prior to
production
45-2.07 Surf. prep & ctg
appl: Min 20 fc
Verify lighting Prior to
inspection
45-2.07 Minimum 50 fc
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 spray
pot agitation
During primer
application
45-2.07 Constant
agitation during
appl. Stirrer w/i
2 from bottom
Verify primer
appl. by spray
Prior to primer
appl.
45-2.08 Spray
Verify intercoat
cleanliness
Prior to each
successive
coat
45-2.08 No moisture,
dust, grease, etc.
Verify recoat
intervals
Prior to each
successive
coat
45-2-08 Minimum and
maximum per
PDS
Verify
workmanship
After appl. of
each coat
45-2.08 No runs, drips,
sags or misses
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
enclosure
integrity
Daily 45-2.09 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
Daily 45-2.04
45-2.05
Daylight hours
only
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
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 45-2.03 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 45-2.03 < 7 g/cm
2
Verify correct
abrasive type
& cleanliness
Visual;
Vial test (oil);
Conductivity
meter
Each lot 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
Blotter test Once per
shift
ASTM D 4285 45-2.04 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 45-2.04 Near-white
Blast
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 surface
profile depth
Visual
comparator
Depth micro.
Replica tape
Three tests
per area
cleaned, per
shift
ASTM D 4417

Methods
A, B, or C
45-2.04 1.5-3 mils
Verify surface
prep.-to-primer
interval
Visual After final
surface prep.,
per area
NA 45-2.04 Within same day
as blast cleaning
Verify dust
removal
Visual/tactile Prior to
primer appl.
NA 45-2.04 No visible dust
Verify correct
coating matls.
Visual Prior to
surface prep.
NA 45-2.05 OZ/EP/PU from 1
manufacturer
Coating
Thickness
Calib. dry film
thickness
gage
After each
coat
SSPC-PA 2 45-2.05 Primer: 3-5 mils
Interm: 5-7 mils
Finish: 2-3 mils
Verify finish
coat color
Visual (check
label)
Prior to finish
coat appl.
NA 45-2.05 Fed. Std. 151B
No. 23456
Inspection Plan for Maintenance
Painting of a Bridge Structure
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 45-2.06 Air & Surf. Temp:
40-100F
RH: <85%
ST +5F of DP
Verify proper
mixing of
coatings
Visual During
mixing
NA 45-2.07 Mechanical
mixing blade
Verify straining
of primer
Visual Prior to trsfr.
to spray pot
NA 45-2.07 Strained
Verify proper
thinning
Visual Prior to
addition
NA 45-2.07 Type & amount
per manuf. PDS
Verify lighting Light Meter Prior to
production
SSPC Guide 12 45-2.07 Surf. prep & ctg.
appl.: Min 20 fc
Verify lighting Light Meter

Prior to
inspection
SSPC Guide 12

45-2.07 Minimum 50 fc
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 spray
pot agitation
Visual During primer
application
NA 45-2.07 Constant
agitation during
appl. Stirrer w/i
2 of bottom
Verify primer
appl. by spray
Visual Prior to
primer appl.
NA 45-2.08 Spray
Verify intercoat
cleanliness
Visual/tactile Prior to each
successive
coat
NA 45-2.08 No moisture,
dust, grease, etc.
Verify recoat
intervals
Visual Prior to each
successive
coat
NA 45-2-08 Minimum and
maximum per
PDS
Verify
workmanship
Visual After appl. of
each coat
NA 45-2.08 No runs, drips,
sags or misses
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
enclosure
integrity
Visual Daily NA 45-2.09 No damage to
work, property or
persons
Verify proper
stenciling
Visual Prior to
demobilization
NA 45-3 Proper location,
size, content and
color
Verify time of
operations
Visual Daily NA 45-2.04
45-2.05
Daylight hours
only
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