Transcript Preparing a Coating Inspection Plan

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 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
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, 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)
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
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 Blotter test
cleanliness
Clean, dry air; no
evidence of water or oil
Verify installation of
protective coverings
Properly installed &
maintained
Visual
Inspection Plan Format
(complex)
Inspection
Item
Technique/
Instrument
Frequency
of Tests
Standard
Test Method
Reference
Spec.
Reference
Acceptance
Criteria
Verify preblast 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
Visual
Prior to
surface
preparation
and painting
NA
3.4.1
Properly
installed &
maintained
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
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
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
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 µg/cm2
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 µg/cm2
Verify correct
abrasive type
& cleanliness
Each lot
45-2.04
Expendable;
angular; no oil;
<1000 µMho/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 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
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 µg/cm2
Verify correct
abrasive type
& cleanliness
Each lot
45-2.04
Expendable;
angular; no oil;
<1000 µS/cm
Verify
compressed
air cleanliness
Once per
shift
45-2.04
No visible oil or
water on
collector
Verify postblast 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 mat’ls.
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:
40-100°F
RH: <85%
ST +5°F 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
Verify grease/
oil removal
Visual and/or
water break
Verify surface
chloride
removal
Acceptance
Criteria
100% of
surfaces,
prior to
surface prep.
SSPC-SP 1
45-2.03
No visible oil or
grease
contamination
Latex
patch/sleeve
Cl- strip/tube
Three tests
per 1000 sq.
ft.
SSPC Guide 15
45-2.03
< 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;
Verify
compressed
air cleanliness
Blotter test
Once per
shift
ASTM D 4285
45-2.04
No visible oil or
water on
collector
Verify postblast surface
cleanliness
SSPC VIS 1
100% of
surfaces,
prior to
primer appl.
SSPC-SP 10
45-2.04
Near-white
Blast
<1000 µS/cm
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection
Item
Technique/
Instrument
Frequency
of Tests
Standard
Test Method
Reference
Verify surface
profile depth
Visual
comparator
Depth micro.
Replica tape
Three tests
per area
cleaned, per
shift
ASTM D 4417
Verify surface
prep.-to-primer
interval
Visual
After final
surface prep.,
per area
Verify dust
removal
Visual/tactile
Verify correct
coating mat’ls.
Spec.
Reference
Acceptance
Criteria
45-2.04
1.5-3 mils
NA
45-2.04
Within same day
as blast cleaning
Prior to
primer appl.
NA
45-2.04
No visible dust
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
Methods
A, B, or C
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:
40-100°F
RH: <85%
ST +5°F 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