Preparing a Coating Inspection Plan

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Preparing a Coating Inspection Plan

• William D. Corbett
• KTA-Tator, Inc.

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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

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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

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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

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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

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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

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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)

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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

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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.)

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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 lt 1,000 µS/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


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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 lt 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 Visual Prior to surface preparation and painting NA 3.4.1 Properly installed maintained
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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

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Hold Point 1Pre-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

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Hold Point 2Post-Surface Preparation

• Examples of inspection check points
• Ambient conditions
• Surface preparation media
• Removal of surface contamination
• Surface cleanliness
• Surface profile
• Surface imperfections
• Waste management

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Hold Point 3Surface Conditions for Coatings
Application

• Examples of inspection check points
• Surface cleanliness
• Ambient conditions
• Recoat windows
• Performed for each coating applied

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Hold Point 4Coating 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

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Hold Point 5Post-Coating Application

• Examples of inspection check points
• Coating thickness
• Ambient conditions
• Recoat window/free of contamination
• Performed for each coating applied

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Hold Point 6Post-Curing of Coating

• Examples of inspection check points
• Coating application defects (each coat)
• Dry film thickness (each coat)
• Pinhole/holiday detection (buried/immersion
  service)

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Hold Point 7Final Inspection

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

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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
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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)

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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
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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 lt 7 µg/cm2
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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 lt 7 µg/cm2
Verify correct abrasive type cleanliness Each lot 45-2.04 Expendable angular no oil lt1000 µMho/cm
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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 lt 7 µg/cm2
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
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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 lt 7 µg/cm2
Verify correct abrasive type cleanliness Each lot 45-2.04 Expendable angular no oil lt1000 µS/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
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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
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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 lt85 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
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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
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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
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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

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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 lt 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 45-2.04 Expendable angular no oil lt1000 µS/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
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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
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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 lt85 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
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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
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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
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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

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Preparing a Coating Inspection Plan

• THE END