Transcript Preparing a Coating Inspection Plan

Inspection Planning
Keys to Successful
In-process QA/QC
Inspection During
Coating Operations
William D. Corbett
KTA-Tator, Inc.
Webinar Content
 Planning to perform inspection of coating
operations
 Comprehending project documents
 Gathering referenced standards
 Verifying correct type and functionality of inspection
instruments
 Verifying safety training and site-compatible PPE
 Understanding documentation procedures & formats
 Developing an Inspection Plan
 Purpose and benefits
 Common formats
 Preparation
Learning Outcomes
• Completion of this webinar will enable the participant
to:
Describe the value and importance of thorough planning
to perform inspection of coating operations
 Describe the purpose, benefits and common formats of
a written Inspection Plan
Prepare an inspection plan
INSPECT
PREPARE
PLAN
Comprehend Project Documents
• Obtain a copy of the
coating specification
(the key document!)
• Obtain copies of
manufacturer’s product
data sheets
• Read & comprehend all
• Watch for discrepancies
• Prepare a list of
questions
Gather Referenced Standards
• Review “referenced
standards” section of the
specification
• Obtain copies of industry
standards (watch version)
• E.g., ASTM, NACE,
SSPC, etc.
• Read and comprehend
• Standards change over
time
Verify Correct Type and Functionality
of Inspection Instruments
• Review specification for
required instruments &
visual guides
• Compatibility of probes
• Operation
• Currency of calibration
• Verification of accuracy
• Battery status
• Expendables
Verify Safety Training and SiteCompatible PPE
• Currency of general
safety training
• Site-specific safety
training
• Medical surveillance
• Site-specific PPE
• PPE compatible with
site conditions
Understand Documentation
Procedures & Formats
• Many types of forms
• Electronic or handwritten?
• Some forms are designed to
auto-populate directly from the
inspection gage
• Your forms?
• Someone else’s forms?
 Get clarification on entries
• Who needs to sign them
(besides you)?
• Distribution?
Prepare an Inspection Plan
• What is an Inspection Plan?
 A road map for QA and QC
inspection personnel
 Lists what to inspect, how to
inspect and what is acceptable
according to the project
specification
 Prevents missed inspection
check points/hold points
 Enables QA and QC personnel
to focus on inspection
requirements in a project
specification
Purpose of an Inspection Plan
• A systematic inspection
and testing plan that
covers all phases of work
in sequence
• A tool enabling QA/QC
inspectors to navigate
through and extract
inspection check points
from the specification
• May be a required
contract submittal
Benefits of a Coatings Inspection
Plan
 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
 Provides a key communication tool between QA
and QC inspection personnel
Required Items for
Developing an Inspection Plan
• Documents
Project specification
Referenced standards (SSPC, NACE, ASTM, etc.)
Product data sheets
SDS
• 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
Inspection Plan Format
(complex)
Inspection
Item
Technique/
Instrument
Frequency
of Tests
Standard
Test Method
Reference
Spec.
Reference
Acceptance
Criteria
Common Inspection Hold Points
• Pre-surface preparation
• Post-surface preparation
• Surface conditions for
coatings application
• Coating application
• Post-coating application
• Final inspection
Hold Point 1
Pre-Project & 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
 Dry film thickness (each
coat)
 Recoat window/free of
contamination (each coat)
 Coating application
defects (each coat)
 Pinhole / holiday
detection (buried/
immersion service)
Hold Point 6
Final Inspection
• Examples of inspection
check points
Repair and touch-up
Waste removal
Site restoration
Verification of
corrective action
implementation
Let’s Develop 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
Spec.
Reference
Acceptance
Criteria
Verify surface
profile depth
Depth
micrometer or
replica tape
Three tests
per area
cleaned, per
shift
ASTM D 4417;
SSPC-PA 17
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 mat’ls.
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
ASTM D7091;
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:
40-100°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 importance of thorough planning to
perform inspection of coating operations
 Described the purpose, benefits and common
formats of an Inspection Plan
Prepared an inspection plan based on a simulated
bridge coating project
Inspection Planning
Keys to Successful
In-process QA/QC
Inspection During
Coating Operations
Questions