Corbett Inspect Plan Web in Ar
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Transcript of Corbett Inspect Plan Web in Ar
Preparing a Coating Inspection Plan
William D. CorbettKTA-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 planDescribe the purpose and importance of an inspection plan Explain the benefits of an inspection planExplain the benefits of an inspection plan Recognize the SSPC Guide for Planning Coatings Recognize the SSPC Guide for Planning Coatings
InspectionInspection Describe the various formats of inspection plansDescribe the various formats of inspection plans Extract inspection check points from a specificationExtract inspection check points from a specification Identify the instruments, guides and methods used to Identify the instruments, guides and methods used to
inspectinspect Extract the acceptance criteria from a specification for Extract the acceptance criteria from a specification for
each of the inspection check pointseach of the inspection check points Prepare an inspection planPrepare 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
ManagementOwnerContractorCoatings 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 specificationReferenced standards (SSPC, NACE,
ASTM, etc.)Product data sheetsMSDS
• Inspection Equipment and GuidesThe 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 PointMethod of InspectionAcceptance Criteria
• ComplexSimple 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 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
Inspection Plan Format (simple)
Inspection Item
Technique/Instrumen
t
Frequency of Tests
Standard Test
Method Reference
Spec.Referenc
e
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 1ASTM D 7393ASTM 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
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 1Pre-Surface Preparation
• Examples of inspection check pointsContractor submittalsSurface preparation mediaCoatings materialsContainment and ventilationWaste managementSurface contamination
Oil, grease and debrisSoluble salts
Hold Point 2Post-Surface Preparation• Examples of inspection check points
Ambient conditionsSurface preparation mediaRemoval of surface contaminationSurface cleanlinessSurface profileSurface imperfectionsWaste management
Hold Point 3Surface Conditions for Coatings Application
• Examples of inspection check pointsSurface cleanlinessAmbient conditionsRecoat windows
• Performed for each coating applied
Hold Point 4Coating Application
• Examples of inspection check pointsCoatings materialsMixing, thinning and strainingAmbient conditionsWet film thicknessCoatings application defects
• Performed for each coating applied
Hold Point 5Post-Coating Application• Examples of inspection check points
Coating thicknessAmbient conditionsRecoat window/free of contamination
• Performed for each coating applied
Hold Point 6Post-Curing of Coating
• Examples of inspection check pointsCoating application defects (each coat)Dry film thickness (each coat)Pinhole/holiday detection
(buried/immersion service)
Hold Point 7Final Inspection
• Examples of inspection check pointsRepair and touch-upWaste removalSite restorationVerification 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 columnColumn 3: Frequency of test columnColumn 5: Specification reference columnColumn 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/Instrumen
t
Frequency of Tests
Standard Test
Method Reference
Spec.Referenc
e
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/Instrumen
t
Frequency of Tests
Standard Test
Method Reference
Spec.Referenc
e
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/Instrumen
t
Frequency of Tests
Standard Test
Method Reference
Spec.Referenc
e
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/Instrumen
t
Frequency of Tests
Standard Test
Method Reference
Spec.Referenc
e
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/Instrumen
t
Frequency of Tests
Standard Test
Method Reference
Spec.Referenc
e
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 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.Referenc
e
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 milsInterm: 5-7 milsFinish: 2-3 mils
Verify finish coat color
Prior to finish coat appl.
45-2.05 Fed. Std. 151BNo. 23456
Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item
Technique/
Instrument
Frequency of Tests
Standard Test
Method Reference
Spec.Referenc
e
Acceptance Criteria
Measure ambient conditions & surface temp.
Prior to coating mixing and 4 hr. intervals
45-2.06 Air & Surf. Temp: 40-100°FRH: <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/Instrumen
t
Frequency of Tests
Standard Test Method Reference
Spec.Referenc
e
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.Referenc
e
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 45-2.0445-2.05
Daylight hours only
Inspection Plan for Maintenance Painting of a Bridge Structure
• Complete the inspection plan by populating the remaining two columnsInspection instrument/techniqueStandard test method reference
Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item
Technique/Instrumen
t
Frequency of Tests
Standard Test Method Reference
Spec.Referenc
e
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/sleeveCl- 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 7237Conductivity:ASTM D 4940
45-2.04 Expendable; angular; no oil;
<1000 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
Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item
Technique/
Instrument
Frequency of Tests
Standard Test
Method Reference
Spec.Referenc
e
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 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
SSPC-PA 2 45-2.05 Primer: 3-5 milsInterm: 5-7 milsFinish: 2-3 mils
Verify finish coat color
Visual (check label)
Prior to finish coat appl.
NA 45-2.05 Fed. Std. 151BNo. 23456
Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item
Technique/Instrument
Frequency of Tests
Standard Test
Method Reference
Spec.Referenc
e
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°FRH: <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.Referenc
e
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.Referenc
e
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 45-2.0445-2.05
Daylight hours only
Summary
• During this webinar, we have:
Described the purpose and importance of an inspection Described the purpose and importance of an inspection planplan
Explained the benefits of an inspection planExplained the benefits of an inspection plan Reviewed the SSPC Guide for Planning Coatings InspectionReviewed the SSPC Guide for Planning Coatings Inspection Described two basic formats of inspection plansDescribed two basic formats of inspection plans Identified common inspection check points invoked by a Identified common inspection check points invoked by a
specificationspecification Listed common instruments, guides and methods used to Listed common instruments, guides and methods used to
inspectinspect Described how to extract the acceptance criteria invoked Described how to extract the acceptance criteria invoked
by a specification for each of the inspection check pointsby a specification for each of the inspection check points Prepared an inspection plan for recoating a bridgePrepared an inspection plan for recoating a bridge
Preparing a Coating Inspection Plan
THE ENDTHE END